Manuale d’uso / di manutenzione del prodotto POWER WAVE SVM156-A del fabbricante Lincoln Electric
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SVM156-A October , 2001 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be in- creased by proper installation .
CALIFORNIA PROPOSITION 65 W ARNINGS i i SAFETY FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.
ii ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ARC RA YS can b urn. 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.
iii iii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn 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.
iv iv SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les .
v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - PO WER W A VE 455/R Page Safety .................................................................................................................................................i-iv Installation .....
Installation ................................................................................................................... ..........Section A T echnical Specifications ............................................................................
A-2 A-2 INST ALLA TION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHN.
A-3 A-3 INST ALLA TION PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/R (K1761-1), (K1761-2) (continued) PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 26.
SAFETY PRECA UTIONS Read this entire installation section before y ou start installation. ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • T urn the input power OFF at the dis- connect switch or fuse box before working on this equipment.
INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power W ave. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect/input access door of the machine.
A-6 A-6 INST ALLA TION PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return.
When these parameters are identical, the pulsing fre- quency 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 .
V OL T A GE SENSING The best arc performance occurs when the Power W ave has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the terminals of the welder .
WORK V OL T A GE SENSING The Power W ave is shipped from the factory with the work sense lead enabled. For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power W ave to the work. Attach the sense lead to the work as close to the weld as practical.
DIP SWITCH SETTINGS AND LOCA TIONS DIP switches on the PC boards allow for custom con- figuration of the Power W ave. Access the DIP switch- es as follows: ELECTRIC SHOCK CAN KILL. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing.
DEVICENET/GA TEW A Y BO ARD DIP SWITCH, B ANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 s witch 2 baud rate off of f ------- on off 125K off on 250K on on 500 S24958-6 and later software switch 1 s witch 2 baud rate off of f 125K off on 250K on off 500K on on 500K Programmable value.
A-12 A-12 NO TES PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
Operation ............................................................................................................................... Section B Safety Precautions ....................................................................................
SAFETY PRECA UTIONS Read this entire section of operating instructions before operating the mac hine . ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger , the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.
B-3 B-3 OPERA TION PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to .
GENERAL DESCRIPTION The Power W ave power source is designed to be a part of a modular , multi-process welding system. Depending on configuration, it can support constant current, constant voltage, Surface T ension Transfer and pulse welding modes.
RECOMMENDED PR OCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power W ave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs.
CASE FR ONT CONTROLS All operator controls and adjustments are located on the case front of the Power W ave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power W ave. 2. ST A TUS LIGHT : A two color light that indicates sys- tem errors.
WELDING MODE DESCRIPTIONS CONST ANT V OL T A GE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory . The preprogrammed voltage is the best average voltage for a given wire feed speed.
PULSE WELDING Pulse welding procedures are set by controlling an overall “ arc length ” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, background current, rise time, fall time and pulse frequency all affect the voltage.
STT WELDING The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intend- ed only for the purpose of showing how the variables affect the waveform. T rim in the STT mode adjusts the tailout and back- ground portion of the waveform.
B-10 B-10 NO TES PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
Accessories .................................................................................................................... ......Section C Optional Equipment .......................................................................................
OPTIONAL EQUIPMENT F ACT OR Y INST ALLED There are no factory installed options available for the Power W ave 455R. FIELD INST ALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an option- al accessory for the Power Feed Robotic wire drive unit.
Maintenance .................................................................................................................... ......Section D Safety Precautions .......................................................................................
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T urn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE 1.
D-3 D-3 MAINTENANCE PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 7 7 7 3 4 6 5 2 2 2 FIGURE D .1 – MAIN ASSEMBL Y (EXPLODED VIEW) 1.
D-4 D-4 NO TES PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
Theory of Operation ............................................................................................................ .Section E General Description ...........................................................................................
GENERAL DESCRIPTION The Power W ave 455/R power source is designed to be a part of a modular , multi-process welding system. It is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control.
INPUT V OL T A GE AND PRECHARGE The Power W ave 455/R can be connected for a variety of three-phase input voltages. Refer to Figure E.2. The initial input power is applied to the Power W ave 455/R through a line switch located on the front of the machine.
SWITCH BO ARDS AND MAIN TRANSFORMER There are two switch boards in the Power W ave 455/R machine. Each contains an input capacitor and insu- lated gate bipolar transistor (IGBT) switching circuitry .
DC BUS BO ARD , PO WER BO ARD , FEED HEAD BO ARD, GA TEW A Y BO ARD AND V OL T A GE SENSE BO ARD 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 Feed Head Board, the Power Board, and the wire feeder receptacle.
E-6 E-6 THEOR Y OF OPERA TION PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.
CONTR OL BO ARD The Control Board performs the primary interfacing functions to establish and maintain output control of the Power W ave 455R machine. The function generator and weld files exist within the Control Board hardware and software. Digital command signals and feedback information is received and processed at the Control Board.
OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BO ARD The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. The output choke is in series with the negative leg of the output rectifier and also in series with the welding load.
THERMAL PR O TECTION 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 output rectifier , one on the DC bus, and one on the output choke.
GENERAL DESCRIPTION OF THE STT (SURF A CE TENSION TRANSFER) PR OCESS The STT process cannot be classified as either a con- stant current (CC) or a constant voltage (CV) applica- tion. The STT function produces current of a desired waveform to reduce spatter and fumes.
INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow .
PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION (PWM) is used to describe how much time is devoted to conduc- tion in the positive and negative portions of the cycle.
T roubleshooting & Repair ...................................................................................................Section F How to Use T roubleshooting Guide ..............................................................................
This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “ PROBLEM ” (SYMP- TOMS).
ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING & REP AIR F-9 F-9 PO WER W A VE 455/R INPUT FIL TER CAP A CIT OR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-10 F-10 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BO ARD CAP ACITOR TERMINALS FIGURE F .
TROUBLESHOOTING & REP AIR F-11 F-11 PO WER W A VE 455/R SWITCH BO ARD TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-12 F-12 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 19C 19D RECONNECT SWITCHES FIGURE F .
TROUBLESHOOTING & REP AIR F-13 F-13 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BO ARD 1 1/12 OR 15/16 13/14 OR 17/18 -20 +19 FIGURE F .
TROUBLESHOOTING & REP AIR F-14 F-14 PO WER W A VE 455/R INPUT RECTIFIER TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-15 F-15 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NEG (-) POS (+) A B C INPUT RECTIFIER FIGURE F .
TROUBLESHOOTING & REP AIR F-16 F-16 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER TEST (CONTINUED) 6.
TROUBLESHOOTING & REP AIR F-17 F-17 PO WER W A VE 455/R INPUT CONT A CT OR TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-18 F-18 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONT ACTOR 601 X4 FIGURE F .
TROUBLESHOOTING & REP AIR F-19 F-19 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L3 L2 L1 T3 T2 T1 FIGURE F .
TROUBLESHOOTING & REP AIR F-20 F-20 PO WER W A VE 455/R DC BUS PO WER SUPPL Y PC BO ARD TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-21 F-21 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS PO WER SUPPL Y PC BO ARD CAP ACITOR C3 CA UTION! J47 J46 J46 J47 3 4 5 6 7 8 LED 1 2 3 4 1 2 FIGURE F .
TROUBLESHOOTING & REP AIR F-22 F-22 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DC BUS PO WER SUPPL Y PC BO ARD TEST (CONTINUED) 6.
TROUBLESHOOTING & REP AIR F-23 F-23 PO WER W A VE 455/R PO WER BO ARD TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-24 F-24 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC J42 J41 J43 4 5 6 3 4 7 8 9 10 1 1 12 J42 J41 J43 1 2 3 1 2 1 2 3 4 5 6 FIGURE F .
POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CO.
TROUBLESHOOTING & REP AIR F-26 F-26 PO WER W A VE 455/R INPUT BOARD TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-27 F-27 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONT A CTOR 601 X4 J60 J61 6 7 8 9 10 J61 1 2 3 4 5 6 7 8 1 2 3 4 5 J60 FIGURE F .
TROUBLESHOOTING & REP AIR F-28 F-28 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT BOARD TEST (CONTINUED) 6.
TROUBLESHOOTING & REP AIR F-29 F-29 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .
TROUBLESHOOTING & REP AIR F-30 F-30 PO WER W A VE 455/R STT CHOPPER BO ARD TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-31 F-31 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to .
TROUBLESHOOTING & REP AIR F-32 F-32 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC STT CHOPPER BO ARD TEST (CONTINUED) 4.
TROUBLESHOOTING & REP AIR F-33 F-33 PO WER W A VE 455/R PO WER W A VE CURRENT TRANSDUCER TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-34 F-34 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC J8 216 21 1 212 213 P91 CURRENT TRANSDUCER 1234 CONTROL BO ARD J8 5 6 7 8 1 2 3 4 FIGURE F .
TROUBLESHOOTING & REP AIR F-35 F-35 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .
TROUBLESHOOTING & REP AIR F-36 F-36 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .6 - CURRENT FEEDBA CK A T V ARIOUS OUTPUT LO ADS PO WER W A VE CURRENT TRANSDUCER TEST (CONTINUED) 8.
TROUBLESHOOTING & REP AIR F-37 F-37 PO WER W A VE 455/R STT CURRENT TRANSDUCER TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-38 F-38 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC J8 81 1 813 CURRENT TRANSDUCER CONTROL BO ARD 816 812 P90 1234 J8 5 6 7 8 1 2 3 4 FIGURE F .
TROUBLESHOOTING & REP AIR F-39 F-39 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECEPT A CLE S7 STT POWER WAV E FIGURE F .
TROUBLESHOOTING & REP AIR F-40 F-40 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC STT CURRENT TRANSDUCER TEST (CONTINUED) 8.
TROUBLESHOOTING & REP AIR F-41 F-41 PO WER W A VE 455/R OUTPUT RECTIFIER TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-42 F-42 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC STT OUTPUT TERMINAL POSITIVE (+) OUTPUT TERMINAL NEGA TIVE (-) OUTPUT TERMINAL POWERW AVE 455/R I ON O OFF FIGURE F .
TROUBLESHOOTING & REP AIR F-43 F-43 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 1 TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-44 F-44 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONT ACTOR 601 X4 F AN MOTOR LEADS X3 X5 PO WER BO ARD RECTIFIER BRIDGE X1 X2 + - FIGURE F .
TROUBLESHOOTING & REP AIR F-45 F-45 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .7 – SECONDAR Y V OL T A GES A UXILIAR Y TRANSFORMER NO .
TROUBLESHOOTING & REP AIR F-46 F-46 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 2 TEST W ARNING 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 .
TROUBLESHOOTING & REP AIR F-47 F-47 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to .
TROUBLESHOOTING & REP AIR F-48 F-48 PO WER W A VE 455/R INPUT RECTIFIER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-49 F-49 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NEG (-) POS (+) A B C INPUT RECTIFIER FIGURE F .
TROUBLESHOOTING & REP AIR F-50 F-50 PO WER W A VE 455/R INPUT CONT A CT OR REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-51 F-51 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONT ACTOR 601 X4 FIGURE F .
TROUBLESHOOTING & REP AIR F-52 F-52 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 1 REMO V AL AND REPLA CEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-53 F-53 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to .
TROUBLESHOOTING & REP AIR F-54 F-54 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A UXILIAR Y TRANSFORMER NO .
TROUBLESHOOTING & REP AIR F-55 F-55 PO WER W A VE 455/R A UXILIAR Y TRANSFORMER NO . 2 REMO V AL AND REPLA CEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-56 F-56 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT CONT ACTOR 601 X4 CB4 CIRCUIT BREAKER & 1 15V RECEPT A CLE LEADS 33/32 P50 P52 FIGURE F .
TROUBLESHOOTING & REP AIR F-57 F-57 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A UXILIAR Y TRANSFORMER NO .
TROUBLESHOOTING & REP AIR F-58 F-58 PO WER W A VE 455/R CONTR OL, FEED HEAD, OR V OL T A GE SENSE PC BO ARD REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-59 F-59 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC COMP ARTMENT CO VER CONTROL BO ARD PO WER BO ARD FIGURE F .
TROUBLESHOOTING & REP AIR F-60 F-60 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTR OL, FEED HEAD, OR V OL T A GE SENSE PC BO ARD REMO V AL AND REPLA CEMENT (CONTINUED) 9.
TROUBLESHOOTING & REP AIR F-61 F-61 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Secure the rear of the control box in place using two screws and the 3/8 ” nut driver .
TROUBLESHOOTING & REP AIR F-62 F-62 PO WER W A VE 455/R GA TEW A Y PC BO ARD REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-63 F-63 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PHILLIPS SCREW DEVICENET/ GA TEW A Y BO ARD (LOCA TED BEHIND FRONT CO VER) FIGURE F .
TROUBLESHOOTING & REP AIR F-64 F-64 PO WER W A VE 455/R STT CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-65 F-65 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER P90 1234 RESISTOR ASSEMBL Y STT OUTPUT TERMINAL (TOP RIGHT) FIGURE F .
TROUBLESHOOTING & REP AIR F-66 F-66 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC STT CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT (CONTINUED) 6.
TROUBLESHOOTING & REP AIR F-67 F-67 PO WER W A VE 455/R PO WER W A VE CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-68 F-68 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER HEA VY LEAD BOL TED CONNECTION (BEHIND CASE FRONT) FIGURE F .
TROUBLESHOOTING & REP AIR F-69 F-69 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PO WER W A VE CURRENT TRANSDUCER REMO V AL AND REPLA CEMENT (CONTINUED) 9.
TROUBLESHOOTING & REP AIR F-70 F-70 PO WER W A VE 455/R OUTPUT RECTIFIER, STT CHOPPER BO ARD AND RECTIFIER MODULE REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-71 F-71 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to .
TROUBLESHOOTING & REP AIR F-72 F-72 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER, STT CHOPPER BO ARD AND RECTIFIER MODULE REMO V AL AND REPLA CEMENT (CONTINUED) 7.
TROUBLESHOOTING & REP AIR F-73 F-73 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to .
TROUBLESHOOTING & REP AIR F-74 F-74 PO WER W A VE 455/R SWITCH BO ARD AND FIL TER CAP A CIT OR REMO V AL AND REPLA CEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-75 F-75 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 13/14 OR 17/18 NYLON SCREW (2X) 19+ 20- 1 1/12 OR 15/16 SWITCH BO ARD MOLEX PLUG MOUNTING SCREW (4X) FIGURE F .
TROUBLESHOOTING & REP AIR F-76 F-76 PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BO ARD AND FIL TER CAP A CIT OR REMO V AL AND REPLA CEMENT (CONTINUED) 7.
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.
F-78 F-78 NO TES PO WER W A VE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIA GRAMS SECTION - PO WER W A VE 455/R Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams ...................................................
ELECTRICAL DIAGRAMS G-2 POWER W A VE 455/R WIRING DIAGRAM - POWER W A VE 455/R CODE 10675 - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WIR E FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 .
ELECTRICAL DIAGRAMS G-3 POWER W AVE 455/R WIRING DIAGRAM- POWER W A VE 455/R CODE 10676 - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WIR E FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 C8.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 POW.
ELECTRICAL DIAGRAMS G-5 POWER W AVE 455/R SCHEMA TIC-COMPLETE MACHINE CODE 10676 MANUFAC TURING TOLE RANCE PER E2056 UNLESS OTHERW ISE SPECIFIED TOLERANCE SCALE: DO NOT SCALE THI S DRAWING ON 3 PLACE DECIMALS IS ± .
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 POWER W AVE 455/R SCHEMA TIC - CHOPPER PC BOARD 100V 100p C15 X3 9 8 10 100V 100p C16 475 R6 D7 50V 820p C17 301 R19 301 R17 4.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-7 POW.
ELECTRICAL DIAGRAMS G-8 POWER W AVE 455/R SCHEMA TIC-DEVICENET/GATEW A Y PC BOARD G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 POWER W AVE 455/R PC BOARD ASSEMBL Y-DEVICENET/GA TEW A Y .
ELECTRICAL DIAGRAMS G-10 POWER W AVE 455/R SCHEMA TIC - CONTROL PC BOARD SOLID EDGE MANUFACTURING TOLE RANCE PER E2056 UNLESS OTHERWIS E SPECIFIED TOL ER ANCE SC ALE: DO NOT SC ALE THI S D RAWING ON 3 PLACE DECIMALS IS ± .
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.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-12 POWER W AVE 455/R SCHEMA TIC - DIGITIAL POWER SUPPL Y PC BOARD .
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.
ELECTRICAL DIAGRAMS G-14 POWER W AVE 455/R SCHEMA TIC - FEEDHEAD PC BOARD #1 3823-1C1 /1 07/17/2000 LRW COMMON DIGI TAL CO NTROLS FEEDHEA D PC BOA RD SCHEMATI C 11 -3-2000A XA 1 OF 3 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-15 POWER W AVE 455/R SCHEMA TIC- FEEDHEAD PC BOARD #2 3823-1C1 /2 07/17/2000 LRW COMMON DIGITAL CONTROLS FEEDHEA D PC BOA RD SCHEMATI C 11-3-2000A XA TPD TPE 2 OF 3 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-16 POWER W AVE 455/R SCHEMA TIC- FEEDHEAD PC BOARD #3 3823-1C1 /3 07/17/2000 LRW COMMON DIGITAL CONTROLS FEEDHEA D PC BOA RD SCHEMATI C 11-3-2000A XA 3 OF 3 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
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.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-18 PO.
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.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-20 SCHEMA TIC -SWITCH PC BOARD G-20 NOTE: This diagram is for reference only .
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.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-22 POWER W AVE 455/R SCHEMA TIC - VOLT AGE SENSE PC BOARD G-22 NOTE: This diagram is for reference only .
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.
Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-24 POWER W AVE 455/R SCHEMA TIC - 40 VDC BUS PC BOARD G-24 NOTE: This diagram is for reference only .
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.
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Lincoln Electric POWER WAVE SVM156-A è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Lincoln Electric POWER WAVE SVM156-A - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Lincoln Electric POWER WAVE SVM156-A imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Lincoln Electric POWER WAVE SVM156-A ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Lincoln Electric POWER WAVE SVM156-A, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Lincoln Electric POWER WAVE SVM156-A.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Lincoln Electric POWER WAVE SVM156-A. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Lincoln Electric POWER WAVE SVM156-A insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
