Table of Contents Maintenance Section | Lincoln Electric 355M, 405M

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TABLE OF CONTENTS - MAINTENANCE SECTION

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions	D-2
Capacitor Discharge Procedure	D-2
Visual Inspection	D-2
Routine Maintenance	D-2
Periodic Maintenance	D-2
Major Component Locations	D-3

POWER WAVE 355M/405M

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Lincoln Electric 355M, 405M service manual Table of Contents Maintenance Section

Contents

Power Wave 355M/405M Califo Rnia Proposition 65 Warnings Safety 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 Technical Specifications Power Wave Installation Power Wave 405 Input Current Select Suitable Location Safety Precautions Voltage Sensing Negative Electrode Polarity Table A.1 Figure A.1 System Description Figure A.2 Figure A.3 Figure A.5 Waves Power Wave 355M/405M Control Board DIP Switch DIP Switch Settings Locations Return to Return to Section TOC Cable INDUCTANCE, and ITS Effects on Pulse Welding Table of Contents Operation Section Recommended Processes and Equipment Safety PrecautionsOperation General Description Case Front Controls Required EquipmentLimitations Duty Cycle and Time Period Making a Weld Welding AdjustmentsNominal Procedures Fringe Procedures Figure B.2 Current Wave Form CV Constant Voltage Welding Smaw TIG Gtaw ARC Gouging Power Mode Figure B.3 Pulse Welding GMAW-P Current Wave Form Pulse Pulse Welding Benefits of Pulse on Pulse from Lincoln Electric PULSE-ON-PULSE GMAW-PP Table of Contents Accessories Section Compatible Lincoln Equipment ACCESSORIESC-2Factory Installed Field Installed Table of Contents Maintenance Section Visual Inspection MaintenanceCapacitor Discharge Procedure Center Panel Power Wave 355M/405M 1TABLE of CONTENTS-THEORY of Operation Section E-1 TRANSFORMER, & Precharge Theory of OperationInput Line Voltage 115VAC Fan Supply Switch Board Main Transformer Control Board DC BUS BOARD, Power Board and Control Board DC BUS BoardPower Board Output Rectifier and Choke 5THEORY of Operation UNDER/OVER Voltage Protection Thermal ProtectionProtective Circuits Over Current Protection Figure E.6 Igbt Insulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2 PC Board Troubleshooting Procedures Troubleshooting and Repair Former Test Perform the Power Board TestPerform the Main Switch Board Auxiliary Trans Board Test Power BoardSee Fault Code Explanations Power Board Test Perform the T1 Auxiliary trans Removal Procedure will beFan Motor And Control Board Current WFS Transformer Test Light Condition Indication Using the Status LED toTroubleshoot System Problems Status LED Error Code Table Error Codes for the Power Wave Troubleshooting and Repair Power Wave 355M/405M Materials Needed 13TROUBLESHOOTING and REPAIRF-13Input Filter Capacitor Discharge Procedure Test Description Discharge Procedure Materials Needed 15TROUBLESHOOTING and REPAIRF-15 Test Procedure 16TROUBLESHOOTING and REPAIRF-16 Main Switch Board Removal and Replacement Power Wave 355M/405M Input Rectifier Test 19TROUBLESHOOTING and REPAIRF-19 #207 Test Point Terminals Analog Meter X10 Range Input Rectifier Bridge Removal & Replacement procedure Power Wave 355M/405M Power Board Test 23TROUBLESHOOTING and REPAIRF-23 J42 J41 J43 Test Procedure Power Board Test Power Wave 355M/405M DC BUS Board Test 27TROUBLESHOOTING and REPAIRF-27 J47 Table F.4 DC BUS Power Supply PC Board Voltage Table Power Wave 355M/405M Output Rectifier Modules Test 31TROUBLESHOOTING and REPAIRF-31 Output Rectifier Modules Test 32TROUBLESHOOTING and REPAIRF-32 Probe Diagram Left Side Auxiliary Transformer Test 35TROUBLESHOOTING and REPAIRF-35 Auxiliary Transformer Test To COM 1A quick connects Lead Identification Normal Expected Voltage Power Wave 355M/405M Current Transducer Test 39TROUBLESHOOTING and REPAIRF-39 Plug J8 Perform the Input Capacitor Discharge Procedure 300 250 200 150 100 Transducer Removal and Replacement Procedure Power Wave 355M/405M FAN Control and Motor Test 43TROUBLESHOOTING and REPAIRF-43 FAN Control and Motor Test Perform the Input Filter Capacitor Discharge Procedure Current Transducer Removal and Replacement Procedure FAN Control Test Procedure Power Wave 355M/405M Description 47TROUBLESHOOTING and REPAIRF-47Control Board Removal and Replacement Control Board Procedure J10B Mounting Main Switch Board Removal & Replacement 51TROUBLESHOOTING and REPAIRF-51 Troubleshooting Procedures at the beginning Main Switch Board Removal & Replacement + + 53TROUBLESHOOTING and REPAIRF-53 Power Wave 355M/405M Description 55TROUBLESHOOTING and REPAIRF-55Snubber Board Removal and Replacement Perform the Input Filter Capacitor Discharge Snubber Board Removal and Replacement Power Board Removal and Replacement 57TROUBLESHOOTING and REPAIRF-57 Left Side 58TROUBLESHOOTING and REPAIRF-58 J42 J41 J43 Power Wave 355M/405M DC BUS Board Removal and Replacement 61TROUBLESHOOTING and REPAIRF-61 DC BUS Board Removal and Replacement J46 63TROUBLESHOOTING and REPAIRF-63 Troubleshooting and Repair Input Rectifier Removal and Replacement 65TROUBLESHOOTING and REPAIRF-65 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 Current Transducer Removal and Replacement 74TROUBLESHOOTING and REPAIRF-74 #206 #202 #207A 75TROUBLESHOOTING and REPAIRF-75 Perform the Snubber Board Removal Procedure 76TROUBLESHOOTING and REPAIRF-76 Perform the Snubber Board Replacement Procedure 77TROUBLESHOOTING and REPAIRF-77 Maximum Output Voltages Input Idle Amps and Watts Table of Contents Diagram Section Wiring Diagram Powerwave 355/405 G4131 Electrical Diagrams Return to Section Schematic Complete Machine Schematic Digital Control PC Board #1 Schematic Digital Control PC Board #2 Schematic Digital Control PC Board #3 Schematic Digital Control PC Board #4 TOC Schematic Power Supply Printed Circuit Board Schematic Switch PC Board Return to Master PC Board Assembly Switch PC Board 2000 S24761 Schematic Snubber PC Board N.B PC Board Assembly Snubber PC Board Schematic 40 VDC Buss PC Board