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Lincoln Electric SVM159-A service manual Table of Contents Accessories Section

Models: SVM159-A

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C-1C-1

TABLE OF CONTENTS

- ACCESSORIES SECTION -

Accessories	Section C
Optional Equipment	C-2
Field Installed	C-2
Compatible Lincoln Equipment	C-2

POWER WAVE 355/405

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Lincoln Electric SVM159-A service manual Table of Contents Accessories Section

Contents

Power Wave 355/405 Safety Electric Shock can kill Welding Sparks can cause fire or explosion Safety Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Electromagnetic Compatibility EMC Installation Installation 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 Output CABLES, Connections and LimitationsNegative Electrode Polarity Table A.1 Figure A.1 System Description Figure A.2 System SET-UP Figure A.3 Figure A.5 TWO Power Waves Welding with Multiple Power WavesControl Cable Specifications Control Board DIP Switch Receptacle SpecificationsDIP Switch Settings and Locations Table of Contents Operation Section Operation Safety Precuations General Description Limitations Required EquipmentDuty Cycle and Time Period Case Front Controls Nominal Procedures Welding AdjustmentsFringe Procedures Making a Weld Current Wave Form CV Constant Voltage Welding TIG Gtaw Power ModeSpecial Welding Processes Available on this Machine Figure B.3 Pulse Welding GMAW-P PULSE-ON-PULSE GMAW-PP Welding Procedures for PULSE-ON-PULSE Table of Contents Accessories Section Factory Installed AccessoriesField Installed Optional Equipment Maintenance Table of Contents Routine Maintenance Capacitor Discharge ProcedurePeriodic Maintenance Visual Inspection 355 Power Wave 355/405 Table of Contents Theory of Operation Section Input Line VOLTAGE, Auxiliary TRANSFORMER, & Precharge Theory of OperationGeneral Description 42VAC Switch Board Main Transformer Control Board DC BUS BOARD, Power Board and Control Board DC BUS BoardPower Board Figure E.5 Output Rectifier and Choke Output Rectifier and Choke Protective Circuits Thermal ProtectionOver Current Protection UNDER/OVER Voltage Protection Figure E.6 Igbt Insulated Gate Bipolar Transistor Igbt Operation Minimum Output Maximum Output Pulse Width Modulation Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair PC board can be damaged by static electricity PC Board Troubleshooting Procedures Perform the Main Switch Board Perform the Power Board TestAuxiliary Transformer Test See Fault Code Explanations Power BoardBoard Test Perform the Output Rectifier Fan Motor And Control Removal Procedure will beBoard Perform the T1 Auxiliary trans Current Current Calibration Procedure Light Condition Indication Using the Status LED to Troubleshoot System Problems Status LED Error Code Table Troubleshooting & Repair Power Wave 355/405 Description Input Filter Capacitor Discharge Procedure Discharge Procedure Input Filter Capacitor Discharge Procedure Main Switch Board Test Main Switch Board Test Main Switch Board Removal and Replacement Power Wave 355/405 Input Rectifier Test #207 #207A #209 Probe Input Rectifier Bridge Removal & Replacement procedure+ Probe Power Wave 355/405 Power Board Test J42 J41 J43 Test Procedure Table F.3 Power Board Voltage Checks Check Point Power Wave 355/405 Materials Needed DC BUS Board TestTest Description J47 Table F.4 DC BUS Power Supply PC Board Voltage Table Power Wave 355/405 Output Diode Modules Test Output Diode Modules Test Figure F.8 Terminal Probes Diagram Left Side Auxiliary Transformer Test Plug P52 Normal Expected Voltage Auxiliary Transformer NO.1 Test Power Wave 355/405 Current Transducer Test Troubleshooting and Repair Plug J8 Output Load Current Transducer Removal and Replacement Procedure Power Wave 355/405 FAN Control and Motor Test FAN Control and Motor Test Perform the Input Filter Capacitor Discharge Procedure Current Transducer Removal and Replacement Procedure FAN Control Test Procedure Power Wave 355/405 Control Board Removal and Replacement Control Board J10A Mounting Main Switch Board Removal and Replacement Troubleshooting Procedures at the beginning Main Switch Board Removal & Replacement Allen Bolts Power Wave 355/405 Snubber Board Removal and Replacement Perform the Input Filter Capacitor Discharge Snubber Board Removal and Replacement Power Board Removal and Replacement Left Side J42 J41 J43 Power Wave DC BUS Board Removal and Replacement DC BUS Board Removal and Replacement J47 Troubleshooting & Repair Input Rectifier Removal and Replacement Input Rectifier Removal and Replacement #207 #207A #209 Power Wave 355/405 Output Rectifier Modules Removal Replacement Output Rectifier Modules Removal and Replacement Mounting Bolts Allen Power Wave 355/405 Current Transducer Removal and Replacement Rear Nut Return to Section Section TOC Perform the Snubber Board Removal Procedure Perform the Snubber Board Replacement Procedure Maximum Output Voltages Retest After RepairInput Idle Amps and Watts Table of Contents Electrical Diagrams Section Electrical Diagrams Wiring Diagram Powerwave 355/405 G4131 Wiring Diagram Power Wave 355/405 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 ‡‚ÁËÌ‰ü¬ÓÌÛÒÓÎüœÓˆ‰ÒüÙÔÔÎ¯ Schematic Power Supply Printed Circuit Board Schematic Switch PC Board Return to Section PC Board Assembly Switch PC Board 2000 S24761 Schematic Snubber PC Board Reqd Description PC Board Assembly Snubber PC Board Schematic 40 VDC Buss PC Board SVM Error Reporting Form