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Lincoln Electric
SVM135-B
service manual
Power Wave 455/POWER Feed
Models:
SVM135-B
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Troubleshooting
Specs
Install
Error codes
System Diagram a
Wire Feeder Setup
Maintenance
Function Problems
3ACCESSORIESC-3
DIP Switch Setup
Page 142
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Return to Master TOC
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F-78
NOTES
F-78
POWER WAVE 455/POWER FEED 10
Page 141
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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 Considerations
Input Voltage Reconnect Procedure
Grounding
Flexible Connection Possibilities
Cable Connections
Control Cable Connections
Typical Bench Feeder Connection
Electrode and Work Leads Electrode Positive Applications
Control Cable Specifications
Cable Connections
Available Cable Assemblies
Electrode and Work Leads Electrode Negative Applications
Wire Feeder Setup
Wire 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 Installation
CONTROL/DISPLAY Panel
Optional Panels for Control BOX
Table of Contents Operation Section
Operation
System Description
Safety Instructions
Operating Instructions
Recommended Equipment
Duty Cycle and Welding Capabilities
Limitations
Status Light 1 -STEP/ 4-STEP Switch
Power Feed Controls
STEP/4-STEP Switch Operation
Cold FEED/GAS Purge Switch
Amps Encoder
Display Control Panel
Status Light
Volts Blank Panel Trim Encoder Status
Electrode Routing
Weld Mode Descriptions
Board 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 Adjustment
Drive 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-3
Power Wave Options
Wire Feeder Options and Accessories
Cable Receptacles
Control Box Cabinet Procedure
Input Cable Assemblies
K1548-1 Receptacle KIT Input and Output
Feed Head Enclosure Procedure
Receptacle Input
Reel Adapters
Guns and GUN Adapters
Conduit Adapters
GAS and Water Kits
Dual Procedure Switch Options
Chassis Options
CC/STICK/GOUGE Mode
Description and Installation of Optional Control BOX Panels
K1542-5 Dual Procedure Panel
K1555-1 Insulated Lift Bail
Descriptions
Constant Voltage CV/MIG and CV/Flux Cored Procedures
K1542-7 MX Panel Large Panel
Parameter Ranges
Parameter Selection
Mode Selection
Parameter Adjustment
K1542-8 MSP Panel Large Panel
Gmaw Pulse Procedures
Dual Procedure Selection
K1542-9 Dual PROCEDURE/MEMORY Panel Small Panel
Memory 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 a
Wire 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
UNDER/OVER Voltage
Thermal Protection Over Current
Protective Circuits
Passive
Insulated Gate Bipolar Transistor Igbt Operation
Active
Minimum Output
Pulse Width Modulation
Maximum Output
Control BOX
See System Diagram a and System
User Interface
Step
Power Feed Feed Head
Lead #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 Guide
Perform 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 Transfor
Mer 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 Faults
Status LED Error Code Table
Green, consult Status LED Error Code Table
Digital Communication Error Code LED Errors Sequence
Status LED Error Code Table
Welding 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 Drive
Perform 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 Procedures
Input 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-26
Reconnect Switches
19D 19C
11/12 15/16
27TROUBLESHOOTING and REPAIRF-27
20 +19 13/14 17/18
Power Wave 455/POWER Feed
Output Rectifier Test
Rectifier Module Replacement Procedure
30TROUBLESHOOTING and REPAIRF-30
Negative Output Terminal Positive +
Input Rectifier Test
Troubleshooting and Repair
Probe Acceptable Meter Readings
Input Contactor Test
Power Wave 455/POWER Feed
Input Contactor Test
X4/X4A 601/601A
36TROUBLESHOOTING and REPAIRF-36
Test Points
Auxiliary Transformer no Test
P81
38TROUBLESHOOTING and REPAIRF-38
High 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
Current Transducer
48TROUBLESHOOTING and REPAIRF-48
P90
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
GAS Solenoid Removal and Replacement
Component Replacement Procedures
Description
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
Replacement Procedures
To Remove the Wire Drive Assembly from the Gear BOX
To 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 Removal
11/12 15/16 19+
13/14 17/18
Replacement Procedure
Material Needed
Power Wave 455 / PF-10 Meter Accuracy Check
Procedure 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
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