Safety Depends on You | Lincoln Electric SVM135-B instruction

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RETURN TO MAIN INDEX	SVM135-B
	SVM135-B
	July,2001

Power Wave 455/Power Feed 10

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Lincoln Electric SVM135-B service manual Power Wave 455/Power Feed, Safety Depends on You

Contents

Safety Depends on You Power Wave 455/Power Feed California Proposition 65 Warnings Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Return to Section TOC Input AT Rated Output Three Phase only Technical Specifications Power Wave Location and Mounting Safety Precautions Boom Mounting Control BOX Power Source Mounting Input Voltage Reconnect Procedure Input Fuse and Supply Wire ConsiderationsElectrical Connections Grounding Control Cable Connections Cable ConnectionsFlexible Connection Possibilities Typical Bench Feeder Connection Cable Connections Control Cable SpecificationsElectrode and Work Leads Electrode Positive Applications Available Cable Assemblies Wire Drive Gear Ratio High or LOW Speed Wire Feeder SetupElectrode and Work Leads Electrode Negative Applications Voltage Sensing AT the WORK- Piece Ratio Change Procedure Setting DIP Switches Control BOX DIP Switch Setup Switch Off LSB Figure A.4 Setting DIP Switches in the Wire Drive GUN and Cable Assemblies Gmaw Shielding GAS See Gun Adapters in Accessories section CONTROL/DISPLAY Panel Standard Panel InstallationCV/GOUGE Panel Optional Panels for Control BOX Operation Table of Contents Operation Section Operating Instructions Safety InstructionsSystem Description Recommended Equipment Limitations Duty Cycle and Welding Capabilities STEP/4-STEP Switch Operation Power Feed ControlsStatus Light 1 -STEP/ 4-STEP Switch Cold FEED/GAS Purge Switch Status Light Display Control PanelAmps Encoder Volts Blank Panel Trim Encoder Status Board Level Adjustments Weld Mode DescriptionsElectrode Routing ARC Gouging Wire Reel Loading READI-REELS, Spools Or Coils Wire Spindle Placement Innershield Coils Figure B.4 KG Coil Using K1504-1 Coil Reel Figure B.5 Drive Roll KIT Installation KP1505 Feeding Electrode and Brake AdjustmentDrive Roll Pressure Setting Procedure for Setting Angle of Feedplate Wire Feed Overload Protection Table of Contents Accessories Section Accessories General Table C.1 Power Feed 10 and Power Wave 455 Accessories Power Wave Options 3ACCESSORIESC-3Accessories Wire Feeder Options and Accessories Input Cable Assemblies Control Box Cabinet ProcedureCable Receptacles K1548-1 Receptacle KIT Input and Output Receptacle Input Feed Head Enclosure Procedure Guns and GUN Adapters Reel Adapters Conduit Adapters GAS and Water Kits Dual Procedure Switch OptionsChassis Options K1542-5 Dual Procedure Panel Description and Installation of Optional Control BOX PanelsCC/STICK/GOUGE Mode K1555-1 Insulated Lift Bail K1542-7 MX Panel Large Panel Constant Voltage CV/MIG and CV/Flux Cored ProceduresDescriptions Parameter Ranges Parameter Adjustment Mode SelectionParameter Selection K1542-8 MSP Panel Large Panel Gmaw Pulse Procedures Dual Procedure Selection K1542-9 Dual PROCEDURE/MEMORY Panel Small PanelMemory Selection K1542-12 MSP2 Panel K1542-11 MX2 Panel Control BOX -- PC Board Adjustments Control BOX Panels -- SET UP Controls Description Operation with Previous Software Version Control BOX -- Using Operating Limits Table of Contents Maintenance Section Maintenance Periodic Maintenance Routine Maintenance Theory of Operation Table of Contents Theory of Operation Section Wire Drive System Diagram aModular Inverter Based Welding System System Diagram B System Diagram C Input Voltage and Precharge Power Source General Description Operation Discussion and Diagrams in this section Switch Boards and Main Transformer Figure E.6 Control Board Control Board Choke Output Rectifier UNDER/OVER Voltage Thermal Protection Over CurrentProtective Circuits Passive Insulated Gate Bipolar Transistor Igbt OperationActive Minimum Output Pulse Width ModulationMaximum Output Control BOX See System Diagram a and SystemUser Interface Lead #67 Power Feed Feed HeadStep Step Power Wave 455/POWER Feed Table of Contents Troubleshooting and Repair Section Troubleshooting and Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Troubleshooting and Repair Perform the Power Board Test Troubleshooting GuideTransformer Test Perform the Input Rectifier See LED Code Table Perform the Input Rectifier Perform the Main Contactor Mer T2 Test Perform the Auxiliary TransforPerform the Output Rectifier Ducer Test Board Test Perform the Voltage Sense PC Wire Drive/Control Box Troubleshooting Function Problems Status LED Error Code Table Power Wave 455 Status LED Chart Condition Possible FaultsTroubleshooting Guide Thermal LED is lit Green, consult Status LED Error Code Table Digital Communication Error Code LED Errors Sequence Status LED Error Code TableWelding File Errors Error Code LED Sequence Power Source Error Code Errors LED Sequence Power Feed Wire Drive in the Installation Setting DIP Switches Perform the Encoder PC Board Switches in the Wire DriveRectly. See Figure A.2. Auxiliary Troubleshooting and Repair Troubleshooting and Repair Weld Welding Problems Control BOX/WIRE Drive Error Code Chart Control BOX/WIRE Drive Error Code Chart Power Feed Error Code Chart PW 455 Control Board LED Definitions LED Color and Number Circuit Indicators Input Filter Capacitor Discharge Procedure Test ProceduresTest Description Materials Needed Never USE a Shorting Strap for this Procedure Test Procedure Switch Board Test Reconnect Switches 26TROUBLESHOOTING and REPAIRF-26Perform the Capacitor Discharge Procedure 19D 19C 11/12 15/16 27TROUBLESHOOTING and REPAIRF-2720 +19 13/14 17/18 Power Wave 455/POWER Feed Output Rectifier Test Rectifier Module Replacement Procedure 30TROUBLESHOOTING and REPAIRF-30Negative Output Terminal Positive + Input Rectifier Test Troubleshooting and Repair Input Contactor Test Probe Acceptable Meter Readings Power Wave 455/POWER Feed Input Contactor Test X4/X4A 601/601A 36TROUBLESHOOTING and REPAIRF-36Test Points Auxiliary Transformer no Test P81 38TROUBLESHOOTING and REPAIRF-38High voltage is present at plug P80 Troubleshooting and Repair FAN Motor Leads High voltage is present at primary of Auxiliary Transformer Power Wave 455/POWER Feed Power Board Test J32 J31 91011 3 4 Power PC Check 65 VDC Power Wave 455/POWER Feed Current Transducer Test Current Transducer 48TROUBLESHOOTING and REPAIRF-48P90 500 450 400 350 300 250 200 150 100 Power Wave 455/POWER Feed Drive Motor Test #551 #550 Box and Drive Motor Removal and ReplacementBlack #551 + Tach Feedback Test #3 #1 Black RED Blue Wire Feed Control Board Voltage Sense PC Board Test J1 4 5 56TROUBLESHOOTING and REPAIRF-56 Dual Encoder PC Board Test Dual Encoder PC Board Test Control Cable Continuity Test Control Cable Continuity Test GAS Solenoid Removal and Replacement Component Replacement ProceduresDescription Installation 62TROUBLESHOOTING and REPAIRF-62 Wire Feeder Control Board Removal Replacement Wire Feeder Control Board Removal and Replacement Tach Hall Effect Assembly Removal Replacement Replacement Procedure Removal Procedure Gear BOX and Drive Motor Removal Replacement #551#550 Drive Motor Gear BOX Replacement Procedures To Remove the Wire Drive Assembly from the Gear BOXTo Remove the Drive Motor from the Gear BOX Power Wave 455/POWER Feed Switch Board and Filter Capacitor Removal Replacement 11/12 15/16 19+ Switch Board and Filter Capacitor RemovalNylon Screw 13/14 17/18 Replacement Procedure Procedure to Repair if Meters are OUT of Range Power Wave 455 / PF-10 Meter Accuracy CheckMaterial Needed Meter Accuracy Check Control or Power Board Removal and Replacement Control or Power Board Removal and Replacement Installation Procedure Power Wave 455/POWER Feed Auxiliary Transformer no Removal Replacement Procedure Auxiliary Transformer no Removal Replacement Procedure TOC Power Wave 455/POWER Feed Main Input Contactor Removal and Replacement X4/X4A Replacement Procedure Power Wave 455/POWER Feed Input Rectifier Removal and Replacement NEG Figure F.25 Input Rectifier Removal and Replacement Output Rectifier and Module Removal Replacement Rectifier Assembly Removal Procedure Return to Power Wave 455/POWER Feed Flowchart Power Source Error Interpretation Guide Power Source Error Interpretation Guide Flowchart Performance Troubleshooting Guide Performance Troubleshooting Guide Flowchart Functional Troubleshooting Guide Functional Troubleshooting Guide Table of Contents Electrical Diagrams Section Electrical Diagrams Return to Section TOC Power Wave 455 Wiring Diagram Code Rear Reconnect Panel Sense Power Feed 10 Control Box Wiring Diagram Power Feed 10 Wire Drive Wiring Diagram Master Power Feed 10 Machine Schematic To Section Power Wave 455 Machine Schematic Code Switch Board #1 Left Return to Section Return to Section TOC To Section TOC Power Wave 455 Control PC Board Schematic 1 Power Wave 455 Control PC Board Schematic 2 Power Wave 455 Control PC Board Schematic 3 ComF Power Wave 455 Power PC Board Schematic 17921 M Power Wave 455 Input PC Board Schematic V450 Power Wave 455 Switch PC Board Schematic Code 10372 221K Power Wave 455 Switch PC Board Schematic Code Encoder Supply Power Feed 10 Mother Control PC Board Schematic To Master Power Feed 10 Control PC Board Schematic 14X-5 Power Feed 10 Display PC Board Schematic 22920 Power Feed 10 Encoder PC Board Schematic 23918 Power Feed 10 Voltage Sense PC Board Schematic