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Lincoln Electric SVM159-A service manual Table of Contents, Maintenance

Models: SVM159-A

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Section D-1Section D-1

	TABLE OF CONTENTS
	-MAINTENANCE-
Maintenance	Section D
Capacitor Discharge Procedure	D-2
Visual Inspection	D-2
Routine Maintenance	D-2
Periodic Maintenance	D-2
Major Component Locations	D-3

POWER WAVE 355/405

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Lincoln Electric SVM159-A service manual Table of Contents, Maintenance

Contents

Power Wave 355/405 Safety Electric Shock can kill Welding Sparks can cause fire or explosion SafetySûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC InstallationInstallation Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power Wave InstallationPower Wave 405 Input Current Select Suitable Location Safety PrecautionsNegative Electrode Polarity Output CABLES, Connections and LimitationsVoltage Sensing Table A.1 Figure A.1 System DescriptionFigure A.2 System SET-UPFigure A.3 Figure A.5 Control Cable Specifications Welding with Multiple Power WavesTWO Power Waves DIP Switch Settings and Locations Receptacle SpecificationsControl Board DIP Switch Table of Contents Operation Section Operation Safety Precuations General DescriptionCase Front Controls Required EquipmentLimitations Duty Cycle and Time PeriodMaking a Weld Welding AdjustmentsNominal Procedures Fringe ProceduresCurrent Wave Form CV Constant Voltage WeldingSpecial Welding Processes Available on this Machine Power ModeTIG Gtaw Figure B.3 Pulse Welding GMAW-PPULSE-ON-PULSE GMAW-PP Welding Procedures for PULSE-ON-PULSETable of Contents Accessories Section Optional Equipment AccessoriesFactory Installed Field InstalledMaintenance Table of ContentsVisual Inspection Capacitor Discharge ProcedureRoutine Maintenance Periodic Maintenance355 Power Wave 355/405 Table of Contents Theory of Operation Section General Description Theory of OperationInput Line VOLTAGE, Auxiliary TRANSFORMER, & Precharge 42VAC Switch Board Main TransformerPower Board DC BUS BOARD, Power Board and Control Board DC BUS BoardControl Board Figure E.5 Output Rectifier and Choke Output Rectifier and ChokeUNDER/OVER Voltage Protection Thermal ProtectionProtective Circuits Over Current ProtectionFigure E.6 Igbt Insulated Gate Bipolar Transistor Igbt OperationMinimum Output Maximum Output Pulse Width ModulationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC board can be damaged by static electricity PC Board Troubleshooting ProceduresTransformer Test Perform the Power Board TestPerform the Main Switch Board AuxiliaryPerform the Output Rectifier Power BoardSee Fault Code Explanations Board TestPerform the T1 Auxiliary trans Removal Procedure will beFan Motor And Control BoardCurrent Current Calibration ProcedureLight Condition Indication Using the Status LED to Troubleshoot System ProblemsStatus LED Error Code Table Troubleshooting & Repair Power Wave 355/405 Description Input Filter Capacitor Discharge ProcedureDischarge Procedure Input Filter Capacitor Discharge ProcedureMain 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 procedureProbe Power Wave 355/405 Power Board Test J42 J41 J43 Test ProcedureTable F.3 Power Board Voltage Checks Check Point Power Wave 355/405 Test Description DC BUS Board TestMaterials Needed 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 DiagramLeft Side Auxiliary Transformer Test Plug P52 Normal Expected Voltage Auxiliary Transformer NO.1 TestPower Wave 355/405 Current Transducer Test Troubleshooting and RepairPlug J8 Output Load Current Transducer Removal and Replacement ProcedurePower Wave 355/405 FAN Control and Motor Test FAN Control and Motor Test Perform the Input Filter Capacitor Discharge ProcedureCurrent Transducer Removal and Replacement Procedure FAN Control Test ProcedurePower 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 & ReplacementAllen Bolts Power Wave 355/405 Snubber Board Removal and Replacement Perform the Input Filter Capacitor Discharge Snubber Board Removal and ReplacementPower 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 ReplacementMounting Bolts Allen Power Wave 355/405 Current Transducer Removal and Replacement Rear Nut Return to Section Section TOC Perform the Snubber Board Removal ProcedurePerform the Snubber Board Replacement Procedure Input Idle Amps and Watts Retest After RepairMaximum Output Voltages Table of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram Powerwave 355/405 G4131 Wiring Diagram Power Wave 355/405To Section Schematic Complete MachineSchematic 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 BoardSchematic Switch PC Board Return to Section PC Board Assembly Switch PC Board2000 S24761 Schematic Snubber PC BoardReqd Description PC Board Assembly Snubber PC BoardSchematic 40 VDC Buss PC Board SVM Error Reporting Form