ACCESSORIESC-2, Factory Installed | Lincoln Electric 405M, 355M

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C-2

ACCESSORIESC-2

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.

POWER WAVE 355M/405M

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Lincoln Electric 405M, 355M service manual ACCESSORIESC-2, Factory Installed, Field Installed, Compatible Lincoln Equipment

Contents

Power Wave 355M/405M Safety Califo Rnia Proposition 65 Warnings Fumes and Gases For Electrically LES Machines À Souder À Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Power Wave Power Wave 405 Input Current Safety Precautions Select Suitable Location Negative Electrode Polarity Voltage Sensing Table A.1 System Description Figure A.1 Figure A.2 Figure A.3 Figure A.5 Waves Power Wave 355M/405M DIP Switch Settings Locations Control Board DIP Switch Cable INDUCTANCE, and ITS Effects on Pulse Welding Return to Return to Section TOC Table of Contents Operation Section General Description Safety PrecautionsOperation Recommended Processes and Equipment Duty Cycle and Time Period Required EquipmentLimitations Case Front Controls Fringe Procedures Welding AdjustmentsNominal Procedures Making a Weld Constant Voltage Welding Figure B.2 Current Wave Form CV TIG Gtaw Smaw Power Mode ARC Gouging Pulse Welding GMAW-P Figure B.3 Pulse Welding Current Wave Form Pulse PULSE-ON-PULSE GMAW-PP Benefits of Pulse on Pulse from Lincoln Electric Table of Contents Accessories Section Field Installed ACCESSORIESC-2Factory Installed Compatible Lincoln Equipment Table of Contents Maintenance Section Capacitor Discharge Procedure MaintenanceVisual Inspection Center Panel Power Wave 355M/405M 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Line Voltage Theory of OperationTRANSFORMER, & Precharge Switch Board Main Transformer 115VAC Fan Supply Power Board DC BUS BOARD, Power Board and Control Board DC BUS BoardControl Board 5THEORY of Operation Output Rectifier and Choke Over Current Protection Thermal ProtectionProtective Circuits UNDER/OVER Voltage Protection Insulated Gate Bipolar Transistor Igbt Operation Figure E.6 Igbt Maximum Output Pulse Width ModulationMinimum Output 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting and Repair PC Board Troubleshooting Procedures Auxiliary Trans Perform the Power Board TestPerform the Main Switch Board Former Test Power Board Test Power BoardSee Fault Code Explanations Board Test Board Removal Procedure will beFan Motor And Control Perform the T1 Auxiliary trans Current Transformer Test WFS Troubleshoot System Problems Using the Status LED toLight Condition Indication Error Codes for the Power Wave Status LED Error Code Table Troubleshooting and Repair Power Wave 355M/405M Test Description 13TROUBLESHOOTING and REPAIRF-13Input Filter Capacitor Discharge Procedure Materials Needed Discharge Procedure 15TROUBLESHOOTING and REPAIRF-15 Materials Needed 16TROUBLESHOOTING and REPAIRF-16 Test Procedure Main Switch Board Removal and Replacement Power Wave 355M/405M 19TROUBLESHOOTING and REPAIRF-19 Input Rectifier Test #207 Input Rectifier Bridge Removal & Replacement procedure Test Point Terminals Analog Meter X10 Range Power Wave 355M/405M 23TROUBLESHOOTING and REPAIRF-23 Power Board Test Test Procedure J42 J41 J43 Power Board Test Power Wave 355M/405M 27TROUBLESHOOTING and REPAIRF-27 DC BUS Board Test J47 Table F.4 DC BUS Power Supply PC Board Voltage Table Power Wave 355M/405M 31TROUBLESHOOTING and REPAIRF-31 Output Rectifier Modules Test 32TROUBLESHOOTING and REPAIRF-32 Output Rectifier Modules Test Diagram Probe Left Side 35TROUBLESHOOTING and REPAIRF-35 Auxiliary Transformer Test Auxiliary Transformer Test Lead Identification Normal Expected Voltage To COM 1A quick connects Power Wave 355M/405M 39TROUBLESHOOTING and REPAIRF-39 Current Transducer Test Perform the Input Capacitor Discharge Procedure Plug J8 Transducer Removal and Replacement Procedure 300 250 200 150 100 Power Wave 355M/405M 43TROUBLESHOOTING and REPAIRF-43 FAN Control and Motor Test Perform the Input Filter Capacitor Discharge Procedure FAN Control and Motor Test FAN Control Test Procedure Current Transducer Removal and Replacement Procedure Power Wave 355M/405M Control Board Removal and Replacement 47TROUBLESHOOTING and REPAIRF-47Description Procedure Control Board J10B Mounting 51TROUBLESHOOTING and REPAIRF-51 Main Switch Board Removal & Replacement Main Switch Board Removal & Replacement Troubleshooting Procedures at the beginning 53TROUBLESHOOTING and REPAIRF-53 + + Power Wave 355M/405M Snubber Board Removal and Replacement 55TROUBLESHOOTING and REPAIRF-55Description Snubber Board Removal and Replacement Perform the Input Filter Capacitor Discharge 57TROUBLESHOOTING and REPAIRF-57 Power Board Removal and Replacement 58TROUBLESHOOTING and REPAIRF-58 Left Side J42 J41 J43 Power Wave 355M/405M 61TROUBLESHOOTING and REPAIRF-61 DC BUS Board Removal and Replacement DC BUS Board Removal and Replacement 63TROUBLESHOOTING and REPAIRF-63 J46 Troubleshooting and Repair 65TROUBLESHOOTING and REPAIRF-65 Input Rectifier Removal and Replacement Input Rectifier Removal and Replacement #207A Power Wave 355M/405M Output Rectifier Modules Removal and Replacement Output Rectifier Modules Removal and Replacement con’t Mounting Bolts Allen Power Wave 355M/405M Current Transducer Removal and Replacement 74TROUBLESHOOTING and REPAIRF-74 Current Transducer Removal and Replacement 75TROUBLESHOOTING and REPAIRF-75 #206 #202 #207A 76TROUBLESHOOTING and REPAIRF-76 Perform the Snubber Board Removal Procedure 77TROUBLESHOOTING and REPAIRF-77 Perform the Snubber Board Replacement Procedure Input Idle Amps and Watts Maximum Output Voltages Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Powerwave 355/405 G4131 Schematic Complete Machine Return to Section Schematic Digital Control PC Board #1 Schematic Digital Control PC Board #2 Schematic Digital Control PC Board #3 Schematic Digital Control PC Board #4 Schematic Power Supply Printed Circuit Board TOC Schematic Switch PC Board PC Board Assembly Switch PC Board Return to Master Schematic Snubber PC Board 2000 S24761 PC Board Assembly Snubber PC Board N.B Schematic 40 VDC Buss PC Board