Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM135-B service manual Power Wave 455/POWER Feed

Models: SVM135-B

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NOTES

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POWER WAVE 455/POWER FEED 10

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Lincoln Electric SVM135-B service manual Power Wave 455/POWER Feed

Contents

Power Wave 455/Power Feed Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Installation Table of Contents Installation Section Return to Section TOC Technical Specifications Power Wave Input AT Rated Output Three Phase only Safety Precautions Location and Mounting Control BOX Power Source Mounting Boom Mounting Electrical Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Grounding Flexible Connection Possibilities Cable ConnectionsControl Cable Connections Typical Bench Feeder Connection Electrode and Work Leads Electrode Positive Applications Control Cable SpecificationsCable Connections Available Cable Assemblies Electrode and Work Leads Electrode Negative Applications Wire Feeder SetupWire Drive Gear Ratio High or LOW Speed Voltage Sensing AT the WORK- Piece Ratio Change Procedure DIP Switch Setup Setting DIP Switches Control BOX Switch Off LSB Setting DIP Switches in the Wire Drive Figure A.4 See Gun Adapters in Accessories section GUN and Cable Assemblies Gmaw Shielding GAS CV/GOUGE Panel Standard Panel InstallationCONTROL/DISPLAY Panel Optional Panels for Control BOX Table of Contents Operation Section Operation System Description Safety InstructionsOperating Instructions Recommended Equipment Duty Cycle and Welding Capabilities Limitations Status Light 1 -STEP/ 4-STEP Switch Power Feed ControlsSTEP/4-STEP Switch Operation Cold FEED/GAS Purge Switch Amps Encoder Display Control PanelStatus Light Volts Blank Panel Trim Encoder Status Electrode Routing Weld Mode DescriptionsBoard Level Adjustments ARC Gouging Wire Spindle Placement Wire Reel Loading READI-REELS, Spools Or Coils KG Coil Using K1504-1 Coil Reel Figure B.5 Innershield Coils Figure B.4 Drive Roll Pressure Setting Feeding Electrode and Brake AdjustmentDrive Roll KIT Installation KP1505 Procedure for Setting Angle of Feedplate Wire Feed Overload Protection Accessories Table of Contents Accessories Section Table C.1 Power Feed 10 and Power Wave 455 Accessories General Accessories 3ACCESSORIESC-3Power Wave Options Wire Feeder Options and Accessories Cable Receptacles Control Box Cabinet ProcedureInput Cable Assemblies K1548-1 Receptacle KIT Input and Output Feed Head Enclosure Procedure Receptacle Input Reel Adapters Guns and GUN Adapters Conduit Adapters Dual Procedure Switch Options GAS and Water KitsChassis Options CC/STICK/GOUGE Mode Description and Installation of Optional Control BOX PanelsK1542-5 Dual Procedure Panel K1555-1 Insulated Lift Bail Descriptions Constant Voltage CV/MIG and CV/Flux Cored ProceduresK1542-7 MX Panel Large Panel Parameter Ranges Parameter Selection Mode SelectionParameter Adjustment K1542-8 MSP Panel Large Panel Gmaw Pulse Procedures K1542-9 Dual PROCEDURE/MEMORY Panel Small Panel Dual Procedure SelectionMemory Selection K1542-11 MX2 Panel K1542-12 MSP2 Panel Control BOX Panels -- SET UP Controls Description Control BOX -- PC Board Adjustments Control BOX -- Using Operating Limits Operation with Previous Software Version Maintenance Table of Contents Maintenance Section Routine Maintenance Periodic Maintenance Table of Contents Theory of Operation Section Theory of Operation Modular Inverter System Diagram aWire Drive Based Welding System System Diagram B System Diagram C Power Source General Description Input Voltage and Precharge Switch Boards and Main Transformer Operation Discussion and Diagrams in this section Control Board Figure E.6 Control Board Output Rectifier Choke Thermal Protection Over Current UNDER/OVER VoltageProtective Circuits Insulated Gate Bipolar Transistor Igbt Operation PassiveActive Pulse Width Modulation Minimum OutputMaximum Output See System Diagram a and System Control BOXUser Interface Step Power Feed Feed HeadLead #67 Step Power Wave 455/POWER Feed Troubleshooting and Repair Table of Contents Troubleshooting and Repair Section HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Troubleshooting and Repair Transformer Test Troubleshooting GuidePerform the Power Board Test Perform the Input Rectifier Perform the Main Contactor See LED Code Table Perform the Input Rectifier Perform the Output Rectifier Perform the Auxiliary TransforMer T2 Test Ducer Test Perform the Voltage Sense PC Board Test Function Problems Wire Drive/Control Box Troubleshooting Troubleshooting Guide Thermal LED is lit Power Wave 455 Status LED Chart Condition Possible FaultsStatus LED Error Code Table Green, consult Status LED Error Code Table Status LED Error Code Table Digital Communication Error Code LED Errors SequenceWelding File Errors Error Code LED Sequence Power Source Error Code Errors LED Sequence Power Feed Setting DIP Switches Wire Drive in the Installation Rectly. See Figure A.2. Switches in the Wire DrivePerform the Encoder PC Board Auxiliary Troubleshooting and Repair Troubleshooting and Repair Weld Welding Problems Control BOX/WIRE Drive Error Code Chart Power Feed Error Code Chart Control BOX/WIRE Drive Error Code Chart LED Color and Number Circuit Indicators PW 455 Control Board LED Definitions Test Description Test ProceduresInput Filter Capacitor Discharge Procedure Materials Needed Test Procedure Never USE a Shorting Strap for this Procedure Switch Board Test Perform the Capacitor Discharge Procedure 26TROUBLESHOOTING and REPAIRF-26Reconnect Switches 19D 19C 27TROUBLESHOOTING and REPAIRF-27 11/12 15/1620 +19 13/14 17/18 Power Wave 455/POWER Feed Output Rectifier Test 30TROUBLESHOOTING and REPAIRF-30 Rectifier Module Replacement ProcedureNegative Output Terminal Positive + Input Rectifier Test Troubleshooting and Repair Probe Acceptable Meter Readings Input Contactor Test Power Wave 455/POWER Feed Input Contactor Test 36TROUBLESHOOTING and REPAIRF-36 X4/X4A 601/601ATest Points Auxiliary Transformer no Test 38TROUBLESHOOTING and REPAIRF-38 P81High 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 3 4 J32 J31 91011 Power PC Check 65 VDC Power Wave 455/POWER Feed Current Transducer Test 48TROUBLESHOOTING and REPAIRF-48 Current TransducerP90 500 450 400 350 300 250 200 150 100 Power Wave 455/POWER Feed Drive Motor Test Black Box and Drive Motor Removal and Replacement#551 #550 #551 + Tach Feedback Test Black RED Blue Wire Feed Control Board #3 #1 Voltage Sense PC Board Test 56TROUBLESHOOTING and REPAIRF-56 J1 4 5 Dual Encoder PC Board Test Dual Encoder PC Board Test Control Cable Continuity Test Control Cable Continuity Test Component Replacement Procedures GAS Solenoid Removal and ReplacementDescription 62TROUBLESHOOTING and REPAIRF-62 Installation Wire Feeder Control Board Removal Replacement Wire Feeder Control Board Removal and Replacement Tach Hall Effect Assembly Removal Replacement Removal Procedure Replacement Procedure Gear BOX and Drive Motor Removal Replacement Drive Motor Gear BOX #551#550 To Remove the Wire Drive Assembly from the Gear BOX Replacement ProceduresTo Remove the Drive Motor from the Gear BOX Power Wave 455/POWER Feed Switch Board and Filter Capacitor Removal Replacement Nylon Screw Switch Board and Filter Capacitor Removal11/12 15/16 19+ 13/14 17/18 Replacement Procedure Material Needed Power Wave 455 / PF-10 Meter Accuracy CheckProcedure to Repair if Meters are OUT of Range 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 Replacement Procedure Auxiliary Transformer no Removal 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 Figure F.25 Input Rectifier Removal and Replacement NEG Output Rectifier and Module Removal Replacement Rectifier Assembly Removal Procedure Return to Power Wave 455/POWER Feed Power Source Error Interpretation Guide Flowchart Power Source Error Interpretation Guide Performance Troubleshooting Guide Flowchart Performance Troubleshooting Guide Functional Troubleshooting Guide Flowchart Functional Troubleshooting Guide Electrical Diagrams Table of Contents Electrical Diagrams Section 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 Power Feed 10 Machine Schematic Master Power Wave 455 Machine Schematic Code To Section 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 Power Wave 455 Power PC Board Schematic ComF Power Wave 455 Input PC Board Schematic 17921 M Power Wave 455 Switch PC Board Schematic Code 10372 V450 Power Wave 455 Switch PC Board Schematic Code 221K Power Feed 10 Mother Control PC Board Schematic Encoder Supply Power Feed 10 Control PC Board Schematic To Master Power Feed 10 Display PC Board Schematic 14X-5 Power Feed 10 Encoder PC Board Schematic 22920 Power Feed 10 Voltage Sense PC Board Schematic 23918