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TROUBLESHOOTING AND REPAIR |
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.
PROBLEMS | POSSIBLE AREAS OF | RECOMMENDED | ||||
(SYMPTOMS) | MISADJUSTMENT(S) |
| COURSE OF ACTION | |||
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| WELDING PROBLEMS |
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For no apparent reason, the weld- | 1. | Check for proper wire feed | 1. If zero arc voltage is displayed | |||
ing characteristics have changed. |
| speed setting. In the MIG/MAG |
| on the Control Box while weld- | ||
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| and FCAW modes, check for |
| ing, the voltage sense leads | ||
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| proper voltage settings. | In the |
| may be broken. Check lead #67 | |
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| MIG/MAG pulse modes, check |
| at the wire drive. See wiring | ||
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| the arc length trim setting. |
| diagram. | Also check leads | |
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| These controls are on the |
| #202 (Neg. output terminal) and | ||
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| Control Box (user interface). |
| #206 (Pos. output terminal). | ||
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| See Power Wave 455 wiring | |
| 2. | Check for proper shielding gas |
| diagram. | If external voltage | |
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| and gas flow. |
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| sensing is utilized, check the | |
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| #21 lead between the | |
| 3. | Check for loose or faulty weld- |
| receptacle on the Power Wave | ||
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| ing cables and connections. |
| 455 and the workpeice. | ||
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| 2. Perform the Output Rectifier | ||
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| Test. |
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| 3. The control board may be faulty. | ||
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| 4. Perform the Current Trans- | ||
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| ducer Test. | |
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The machine often “noodle welds” | 1. | The machine may be trying to | 1. Perform the Current Trans- | |||
with a particular procedure. |
| deliver too much power. | When |
| ducer Test. | |
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| the average output current |
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| exceeds a maximum limit, the | 2. | The control board may be faulty. | ||
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| machine will “phase back” to |
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| protect itself. Adjust the proce- |
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| dure or reduce the load to lower |
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| the current draw from the Power |
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| Wave 455 machine. |
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| Power Wave 455 - When the |
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| average output current exceeds |
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| 570 amps, the output current is |
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| phased back to 100 amps. |
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The arc burns back to the tip. | 1. | The voltage settings may be too | 1. | Perform the Voltage Sense PC | ||
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| high for the procedure. |
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| Board Test. | |
| 2. | The voltage sensing lead or con- |
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| nection may be faulty. See the |
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| Power Feed 10 Wiring Diagram |
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call
