Lincoln Electric Power Wave 355M Users Manual SVM181

405M to the manual 7f08111d-9dd6-4383-ba09-6ce994ed41b6

2015-02-09

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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •

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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

A
A T
PR VIS TEN
EC O D TIO
AU E N
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Safety Depends on You

POWER WAVE 355M/405M
For use with machine code numbers 11141, 11142

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January, 2008

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SVM181-A
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SERVICE MANUAL

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

SAFETY

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WARNING

CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.5. Do not work next to welding power source.

Mar ‘95

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SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

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3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.
4.a.

Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding
procedure
and
application
involved.
Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.

Aug ‘06

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iii

WELDING SPARKS can
cause fire or explosion.

SAFETY

6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

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6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

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6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.

CYLINDER may explode
if damaged.

iii

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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PRÉCAUTIONS DE SÛRETÉ

SAFETY

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Mar ‘93

SAFETY

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Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;

Return to Master TOC

e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093

3-1-96H

SAFETY

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Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions

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Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

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Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applications. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093

3-1-96H

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN
TO MAIN INDEX
RETURN TO MAIN MENU

Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-418 Series

POWER WAVE 355M/405M

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A-1

TABLE OF CONTENTS - INSTALLATION SECTION

A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications 355M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Technical Specifications 405M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Safety Precautions .....................................................................................................................................A-4
Stacking......................................................................................................................................................A-4

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Tilting ..........................................................................................................................................................A-4
Input Grounding Connections ....................................................................................................................A-4
Power Cord Connection.............................................................................................................................A-4
Output Cables, Connections and Limitations ............................................................................................A-5
Negative Electrode Polarity ........................................................................................................................A-5
Voltage Sensing..........................................................................................................................................A-5
Power Wave to Semi-Automatic Wire Feeder ...........................................................................................A-6
System Description ....................................................................................................................................A-7
System Set-up ...........................................................................................................................................A-8

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Multiple Group System...............................................................................................................................A-9
Single Group Multi-Head System ............................................................................................................A-10
Welding with Multiple Power Waves ........................................................................................................A-11
Control Cable Specifications....................................................................................................................A-11
I/0 Receptacle Specifications ..................................................................................................................A-13

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Dip Switch Settings and Locations..........................................................................................................A-13

POWER WAVE 355M/405M

INSTALLATION

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A-2

TECHNICAL SPECIFICATIONS - POWER WAVE 355

INPUT AC VOLTAGE & DC OUTPUT
Product Ordering
Input AC
Rated DC Output
Name Information Voltage Amps/Volts/Duty Cycle

Power
Wave
355

K2152-1

200-208
220-240
380-415
440-480
575

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Output
Range
(continuous)

350A / 34V / 60%
1 & 3 Phase

AMPS

Weight
with Cord

(81.5 lbs.)
(37.0 kg.)

5-425
300A / 32V / 100%
1 & 3 Phase

60/50 HZ

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A-2

Dimensions
HxWxD

14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm
*Includes
Handles

* Overall Length Including Handle, 21.6” (549mm) without handle.

POWER WAVE 355 INPUT CURRENT
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz
Output
Recommended
Notes
Voltage
Phases
300Amps @
350Amps @
Fuse size
Line Cord
32Volts(100%)
34Volts(60%)
AWG
Note 1
200
1
Not
Not
--Recommended Recommended
Note 2
208
1
76
94
125A
2
Note 2
230
1
69
85
125A
4
Note 1
380
1
Not
Not
--Recommended Recommended
Note 1
400
1
Not
Not
----Recommended Recommended
Note 2
415
1
41
64
80A
6
460
1
36
42
70A
8
575
1
31
37
50A
8
200
208
230
380
400
415
460
575

3
3
3
3
3
3
3
3

41
39
36
23
22
22
19
16

50
50
42
28
27
26
23
18

6
6
8
8
8
8
8
8

Note 2
Note 2

80A
80A
70A
50A
50A
50A
50A
35A

Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.
Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

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OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select The output cable size based upon the following chart.*
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
CURRENT
LENGTH UP 200FT.(61m)
100%
300
1/0
60%
350
1/0

*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
POWER WAVE 355M/405M

200-250 FT. (61-76m)
1/0
2/0

INSTALLATION

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A-3

TECHNICAL SPECIFICATIONS - POWER WAVE 405

INPUT AC VOLTAGE & DC OUTPUT
Product
Name

Power
Wave
405

Ordering Input AC
Rated DC Output
Information Voltage Amps/Volts/Duty Cycle

K 2152-2

200-208 /
220-240/
380-415/
3/50/60

350A / 34V / 60%
3 Phase
320A / 33V / 60%
1 Phase

Output
Range
(continuous)

Weight
with Cord

Dimensions
HxWxD

14.7”x12.5”x

AMPS
5-425

27.8”*
(373x318x
706*)mm

86.5lbs
(37.4 kg)

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60/50 Hz 275A / 31V /100%
1 Phase
300A / 32V / 100%
3 Phase

* Includes
handles

* Overall Length Including Handle, 21.6” (549mm) without handle.

POWER WAVE 405 INPUT CURRENT
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz
Output
Recommended
Voltage
Phases
300Amps@
350Amps@
Line Cord
Size Fuse Size
Notes
32Volts(100%)
34Volts(60%)
Size mm2
200
3
41
48
16
80A
Note 2
220
3
37
48
16
80A
Note 2
380
3
23
28
10
50A
400
3
22
27
10
50A
415
3
22
26
10
50A

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Voltage

Phases
275Amps@
320Amps@
Line Cord
Fuse Size
Notes
31Volts(100%)
33Volts(60%)
Size mm2
200
1
Not Recommended Not Recommended
------Note 1
220
1
64
82
20
125A
Note 2
380
1
44
55
16
80A
Note 2
400
1
40
50
10
80A
415
1
38
48
10
80A
1. Not rated is indicated by 4-x's in the box on the rating plate
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

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OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select the output cable size based upon the following chart.
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
CURRENT
LENGTH UP 61m (200 FT)
100%
275
1/0
60%
350
1/0

POWER WAVE 355M/405M

61-76m (200-250 FT)
1/0
2/0

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A-4

SAFETY PRECAUTIONS

INSTALLATION

WARNING
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DISCONNECT INPUT POWER LINES, OUTPUT
CABLES, OR CONTROL CABLES.
• Only qualified personnel should perform this
installation.
• Connect the green/yellow lead of the power cord
to ground per U.S.National Electrical Code.
----------------------------------------------------------------------

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back, out the sides and bottom will not be restricted.

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CAUTION

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Cord Length
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Machine
PW 355
PW 405

In order to assure long life and reliable operation,
the owner of this machine should follow these simple preventative measures:
NG

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RO
POWER

OFF

• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.

CAUTION
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POWER CORD CONNECTION
A power cord is provided and wired into the machine.
Follow the power cord connection instructions.

• Incorrect connection may result in equipment
damage.

• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.

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• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200230.
For higher voltages: Position the large switch to
380-575.
• Move the "A" lead to the appropriate terminal.

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SELECT SUITABLE LOCATION

A-4

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
STACKING
POWER WAVE 355M/405M cannot be stacked.
TILTING
Place the machine directly on a secure, level surface or
on a recommended undercarriage. The machine may
topple over if this procedure is not followed.
INPUT AND GROUNDING CONNECTIONS
• Only a qualified electrician should connect the
POWER WAVE 355M/405M. Installation should be
made in accordance with the appropriate National
Electrical Code, all local codes and the information
detailed below.
• When received directly from the factory, multiple voltage machines are internally connected for the highest
voltage. Always double-check connections before
powering up the machine.
• Initial 200VAC - 415VAC and 575VAC operation will
require an Input voltage panel setup.

Single Phase Input (PW 355M)
Connect green lead to ground per National Electrical
Code.
Connect black and white leads to power.
Wrap red lead with tape to provide 600V insulation.
Three Phase Input (PW 355M)
Connect green lead to ground per National Electric
Code.
Connect black, red and white leads to power.

Lead Color
Green
Black
White
Red

Single Phase

Three Phase

Connect to
Connect to
ground per NEC ground per NEC

Power Lead
Power Lead
Tape, provide
600V insulation

Power Lead
Power Lead
Power Lead

Single Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electrical Code.
Connect blue and brown leads to power.
Wrap black lead with tape to provide 600V insulation.
Three Phase Input (PW 405M)
Connect green/yellow lead to ground per National
Electric Code.
Connect black, blue and brown leads to power.

POWER WAVE 355M/405M

INSTALLATION

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UNDERCARRIAGE MOUNTINGS

CAUTION

NOTE: MOUNTING SCREWS CA N NOT PROTRUDE MORE THAN
0.5 INCHES INSIDE THE MACHINE.
3.50

1/4-20 NUT (4 PLACES)
5.50

11.84

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OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. Be sure the connection to the
work makes tight metal-to-metal electrical contact. To
avoid interference problems with other equipment and
to achieve the best possible operation, route all cables
directly to the work or wire feeder. Avoid excessive
lengths and do not coil excess cable.

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CAUTION

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Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
-----------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.

4/01

M19527

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A-5

MOUNTING HOLE LOCATIONS

10.00

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A-5

When using inverter type power sources like the
Power Waves, use the largest welding (electrode
and work) cables that are practical. At least 2/0
copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor welding characteristics, if undersized welding cables
are used.
-----------------------------------------------------------------------Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to
the specifications given in the output cable connections
section. Connect a work lead from the negative (-)
power source output Twist-Mate terminal to the work
piece. The work piece connection must be firm and
secure, especially if pulse welding is planned.

When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed instruction
manual for further details.

VOLTAGE SENSING
The best arc performance occurs when the
PowerWaves have accurate data about the arc conditions. Depending upon the process, inductance within
the electrode and work lead cables can influence the
voltage apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.

CAUTION
If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.
-----------------------------------------------------------------------The ELECTRODE sense lead (67) is built into the control cable, and is automatically enabled for all semiautomatic processes. The WORK sense lead (21) connects to the Power Wave at the four pin connector. By
default the WORK voltage is monitored at the output
stud in the POWER WAVE 355/405. For more information on the WORK sense lead (21), see"Work Voltage
Sensing” in the following paragraph.

For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the
Instruction Manuals.
POWER WAVE 355M/405M

INSTALLATION

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A-6

Enable the voltage sense leads as follows:
TABLE A.1
Process Electrode Voltage
Work Voltage
Sensing 67 lead *
Sensing 21 lead
GMAW 67 lead required
21 lead optional
GMAW-P 67 lead required
21 lead optional
FCAW 67 lead required
21 lead optional
GTAW Voltage sense at studs Voltage sense at studs
GMAW Voltage sense at studs Voltage sense at studs
SAW
67 lead required
21 lead optional
CAC-C Voltage sense at studs Voltage sense at studs

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* The electrode voltage 67 sense lead is integral to the
control cable to the wire feeder.
Work Voltage Sensing
The standard POWER WAVE 355M/405M default to
the work stud (work sense lead disabled)
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead (K940) from the
Power Wave work sense lead receptacle to the work
piece. Attach the sense lead to the work piece as close
to the weld as practical, but not in the return current
path. Enable the work voltage sensing in the Power
Wave as follows:

WARNING

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• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.

1. Turn off power to the power source at the disconnect
switch.
2. Remove the wrap around cover from the power
source.

5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
ELECTRODE VOLTAGE SENSING
Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire
feeder and always connected when a wire feeder is
present.
PF10M feeder has user preference features to select
voltage senses temporarily for testing sense leads.

CAUTION
Important: The electrode polarity must be configured at the feed head for all semi-automatic
processes. Failure to do so may result in extremely high welding outputs.
------------------------------------------------------------------------

POWER WAVE TO SEMI-AUTOMATIC POWERFEED WIRE FEEDER INTERCONNECTIONS
The POWER WAVE 355M/405M and semi-automatic
Power Feed family communicate via a 5 conductor
control cable (K1543). The control cable consists of two
power leads, one twisted pair for digital communication, and one lead for voltage sensing. The cables are
designed to be connected end to end for ease of extension. The output receptacle on the POWER WAVE
405M is on the case front. The input receptacle on the
Power Feed is typically located at the back of the feeder, or on the bottom of the user interface.
Due to the flexibility of the platform the configuration
may vary. The following is a general description of the
system. For specific configuration information, consult
the semi-automatic Power Feed instruction manual.

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3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.
4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.

O
N
1

A-6

POWER WAVE 355M/405M

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A-7

SYSTEM DESCRIPTION

INSTALLATION

The POWER WAVE 355M/405M and Power Feed
10/11 family of products utilize a digital communication
system called Arclink. Simply put, Arclink allows large
amounts of information to be passed at very high
speeds between components (nodes) in the system.
The system requires only two wires for communication,
and because of its bus-like structure, the components
may be connected to the network in any order, thus
simplifying the system set-up.
Each "system" must contain only one power source.
The power source may be connected to a maximum of
four feeder groups. Each group containing one user
interface (UI), and up to seven Feed Heads (FH). SEE
FIGURE A.1. The UI controls all of the FH’s of that
group. The UI’s and FH’s are assigned to groups by
setting a code on the DIP switches mounted on their
individual control boards. For example all of the FH’s to
be controlled by a given UI must have their "Group ID"
switches set to the same group number as the UI. In
addition, each FH must be assigned a separate FH
number within that group. See the system set-up section for further details.
System Model

From a network perspective, each component in the
system is considered a separate node, regardless of its
physical location. For example, even though a UI and
FH may be physically mounted together, they are still
viewed as separate pieces (nodes) by the network, and
can only communicate via Arclink. The connection is
generally made externally through the Linc-Net Control
Cable, but can also be made internally, as with the PF10 bench model feeder.
The most common Arclink configuration (called a simple system) consists of one power source, one user
interface and one feeder. Under these circumstances
the group and feed head ID DIP switches are ignored
and the system will function regardless of their position. The same is true for the minimum system consisting of a power source and one UI (Example: a stick
welding system).

FIGURE A.1

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Maximum
Configuration

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A-7

POWER WAVE 355M/405M

INSTALLATION

A-8

SYSTEM SET-UP

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A-8

Basic Rules
• Each group is required to have one user interface. No
group may have more than one user interface.
• Each group can have up to seven Feed Heads.
Exception: Group 3 is limited to a maximum of six
Feed Heads.
• Each system has only one power source. For network
purposes, the PS belongs to Group 3, which is why
group 3 is only allowed 6 feed heads in addition to it’s
user interface.

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• No two feed heads can have identical Group and
Feed Head numbers.
• Group and Feed Head ID numbers must be set on the
appropriate dip switches at each node. Consult the
PF-10/11 Instruction Manual for specific details
regarding dip switch settings.
• Feed head “0” not allowed. Exception: Simple system ignores all ID numbers, therefore “FH0” will function.

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• Each node must be connected to the Linc-Net communication network. The order of connection is not
important, as each node is identified by it’s unique
Group and Feed Head ID number as defined on it’s
dip switches. See Figures A.2 thru A.5.
Simple System

FIGURE A.2

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Group and Feed
Head ID numbers are
ignored in a simple
system.

POWER WAVE 355M/405M

A-9
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Multiple Group System

INSTALLATION
FIGURE A.3

A-9
No “FH0 Allowed!

Single Group Multi-Head System

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FIGURE A.4

No “FH0 Allowed!
The Dual Head option
allows the ability to
maintain 2 sets of
procedures. If more
then 2 heads are
used, odd #’s use
FH1 settings, even #’s
use FH2 settings.

POWER WAVE 355M/405M

INSTALLATION

A-10

FIGURE A.5

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No “FH0 Allowed!
When a standard
User Interface is used
in a group with multiple Feed Heads, all of
the Feed Heads use a
single set of procedures.

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Single Group Multi-Head System (Alternate Method)

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A-10

POWER WAVE 355M/405M

INSTALLATION

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A-11

WELDING WITH MULTIPLE POWER
WAVES
CAUTION

Special care must be taken when more than one
Power Wave is welding simultaneously on a single
part. Arc blow and arc interference may occur or be
magnified.
Each power source requires a work lead from the work
stud to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown below. Connect all of the work sense
leads from each power source to the work piece at the
end of the weld.

A-11

CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.

CAUTION
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communication problems such as: system shutdowns, poor
motor acceleration, poor arc starting) and low wire
driving force (wire feeding problems).
-----------------------------------------------------------------------The K1543 series of control cables can be connected
end to end for ease of extension. Do not exceed more
than 100 feet (30.5 m) total control cable length.

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the
arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.

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If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.6)

FIGURE A.6
POWER WA
WAVE 355/405

POWER WA
WAVE 355/405

TWO POWER WAVES

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Travel
Direction

Connect All Work
Sense Leads at the End
of the Joint

Connect All Welding
Work Leads at the
Beginning of the Joint

POWER WAVE 355M/405M

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A-12

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

INSTALLATION

POWER WAVE 355M/405M

A-12

INSTALLATION

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A-13

I / O RECEPTACLE SPECIFICATIONS
TABLE A.2
WIRE FEEDER RECEPTACLE
PIN
LEAD#
FUNCTION
A
53
Communication Bus L
B
54
Communication Bus H
C
67A
Electrode Voltage Sense
D
52
+40vdc
E
51
0vdc

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TABLE A.3
VOLTAGE SENSE RECEPTACLE
PIN
LEAD#
FUNCTION
3
21A
Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
LEAD#
FUNCTION
253
RS232 Receive
254
RS232 Transmit
#
Pin5
#
Pin4
##
Pin20
##
Pin6
251
RS232 Common

PIN
2
3
4
5
6
20
7

A-13

CONTROL BOARD DIP SWITCH:
switch
switch
switch
switch
switch
switch
switch
switch

1 = reserved for future
2 = reserved for future
3 = reserved for future
4 = reserved for future
5 = reserved for future
6 = reserved for future
7 = reserved for future
8* = work sense lead

switch 8*
off
on

use
use
use
use
use
use
use

work sense lead
work sense lead not connected
work sense lead connected

*Factory setting for Switch 8 is OFF.

FIGURE A.7
CONTROL BOARD (DIP Switch Location)

DIP SWITCH SETTINGS AND
LOCATIONS
DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches:

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WARNING
1. Turn off power to the power source at the disconnect switch.
-----------------------------------------------------------------------2. Remove the wrap around cover from the power
source.
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
look for switch 8 of the DIP switch.

NOTE: For PF10M Dual Boom Feeder set/up and operation. The Power Wave 355M/405M control
board dip switches must be set with 3, 4, 7 to
the “ON” position (Power Wave 355M/405M
input on/off switch must be cycled to enable
any change of dip switches).

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4. Using a pencil or other small object, slide the switch
to the OFF position if the work sense lead is NOT
connected. Conversely, slide the switch to the ON
position if the work sense lead is present.
5. Replace the wrap around and screws. The PC board
will “read” the switch at power up, and configure the
work voltage sense lead appropriately.
O
N
1

POWER WAVE 355M/405M

INSTALLATION

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A-14

CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING

For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 ft.(15.24m), traditional welding cables may be used without any effects
on welding performance. For the total welding loop
length greater than 50 ft.(15.24m)), the K1796 Coaxial
Welding Cables are recommended. The welding loop
length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.3).
FIGURE A.3

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POWER
WAVE

A
C

FIGURE A.4

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K1796 COAXIAL CABLE

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For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the
Instruction Manuals.

A
C

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Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and the positive
(+) output Twist-Mate terminal on the power source.
Connect the other end of the electrode cable to the
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to
the specifications given in the output cable connections section. Connect a work lead from the negative
(-) power source output Twist-Mate terminal to the
work piece. The work piece connection must be firm
and secure, especially if pulse welding is planned.

For long work piece lengths, a sliding ground should be
considered to keep the total welding loop length less
than 50 ft.(15.24m). (See Figure A.4.)

POWER
WAVE

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WORK

SLIDING WORK

A-14

C
B

MEASURE FROM END
OF OUTER JACKET OF
CABLE

POWER WAVE 355M/405M

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B-1

TABLE OF CONTENTS - OPERATION SECTION

B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions.......................................................................................................................................B-2
General Description .....................................................................................................................................B-2
Recommended Processes and Equipment .................................................................................................B-2
Required Equipment ....................................................................................................................................B-3

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Limitations....................................................................................................................................................B-3
Duty Cycle and Time Period........................................................................................................................B-3
Case Front Controls.....................................................................................................................................B-3
Making a Weld .............................................................................................................................................B-4
Welding Adjustments ...................................................................................................................................B-4
Constant Voltage Welding............................................................................................................................B-5
Tig (GTAW) ...................................................................................................................................................B-6
Special Welding Processes Available ..........................................................................................................B-6
Power Mode.................................................................................................................................................B-7

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Pulse Welding (GMAW-P) ............................................................................................................................B-8
Pulse-on-Pulse (GMAW-PP) ......................................................................................................................B-10
Benefits of Pulse-on-Pulse Welding ..........................................................................................................B-10

POWER WAVE 355M/405M

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B-2

SAFETY PRECAUTIONS

OPERATION

GENERAL DESCRIPTION

Read this entire section of operating instructions
before operating the machine.

WARNING
ELECTRIC SHOCK can kill.

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• Unless using cold feed feature, when
feeding with gun trigger, the electrode and drive mechanism are
always electrically energized and
could remain energized several seconds after the welding ceases.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-----------------------------------------------------------

FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from
breathing zone.

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-----------------------------------------------------------

WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
-----------------------------------------------------------

ARC RAYS can burn.
• Wear eye, ear, and body protection.

-----------------------------------------------------------

The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support
constant current, constant voltage, and pulse welding
modes.
The Power Wave power source is designed to be used
with the semi automatic family of Power Feed M wire
feeders, operating as a system. Each component in the
system has special circuitry to "talk with" the other system components, so each component (power source,
wire feeder, user interface) knows what the other is
doing at all times. These components communicate
with Arclink.
The POWER WAVE 355M/405M is a high performance, digitally controlled inverter welding power
source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW,
GMAW-P, FCAW, SMAW, GTAW, and CAC-A processes. It carries an output rating of 350 Amps, 34 Volts at
60% duty cycle and 300 Amps, 32 volts at 100% duty
cycle.

RECOMMENDED PROCESSES
AND EQUIPMENT
RECOMMENDED PROCESSES
The POWER WAVE 355M/405M can be set up in a
number of configurations, some requiring optional
equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures,
typically including GMAW, GMAW-P, FCAW, GTAW,
and CAC-A for a variety of materials, including mild
steel, stainless steel, cored wires, and aluminum.
The POWER WAVE 355M/405M is recommended for
semi-automatic welding, and may also be suitable for
basic hard automation applications.
• This Power Wave is not recommended for processes
other than those listed.

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Observe additional guidelines detailed in the
beginning of this manual.

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B-2

POWER WAVE 355M/405M

OPERATION

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B-3

POWER WAVE 355M/405M – Semi-Automatic
Operation

Semi Automatic Power Waves can only be used with
Arclink compatible Power Feed semi-automatic wire
feeders. In addition, the Power Feed semi-automatic
wire feeders may require optional equipment to access
certain weld modes in the Power Wave. Other models
of Lincoln feeders, or any models of non-Lincoln wire
feeders, cannot be used.
All welding programs and procedures are selected
through the Power Feed semi-automatic user interface

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REQUIRED EQUIPMENT

NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on. This
is a normal situation as the machine goes through a
self test at power up.
TABLE B.1
Meaning
Light
Condition
Steady Green System OK. Power source communicating
normally with wire feeder and its components
if other feeder & components show they are
powered up.
Blinking
Green

Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping
(identifying) each component in the system.
Normal for first 1-10 seconds after power is
turned on, or if the system configuration is
changed during operation

Alternating
Green and
Red

Non-recoverable system fault. If the PW
Status light is flashing any combination of red
and green, errors are present in the POWER
WAVE 355M/405M. Read the error code
before the machine is turned off.

Any Arclink compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF10M Series, Power Feed 15M and
Power Feed 25M).

LIMITATIONS
• Only Arclink compatible Power Feed semi-automatic
wire feeders and users interfaces may be used.
Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.

Error Code interpretation through the Status
light is detailed in the LED Status Chart.
Individual code digits are flashed in red with
a long pause between digits. If more than
one code is present, the codes will be separated by a green light.

• POWER WAVE 355M/405M Output Limitations
The POWER WAVE 355M/405M will support maximum average output current of 350 Amps @ 60%
duty cycle.

To clear the error, turn power source off, and
back on to reset.

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DUTY CYCLE AND TIME PERIOD
The duty cycle is based upon a ten minute period. A
60% duty cycle represents 6 minutes of welding and 4
minutes of idling in a ten minute period.

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Non recoverable hardware fault. Generally
indicates nothing is connected to the
POWER WAVE 355M/405M wire feeder
receptacle. See Trouble Shooting Section.

Blinking Red

Not applicable.

1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light.
Error conditions are indicated, per table B.1.

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Steady Red

CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)

B-3

3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled and the
fan continues to run, until the machine cools down.
When cool, the light goes out and output is enabled.
4. CB1 WIRE FEEDER CIRCUIT BREAKER: Protects
40 volt DC wire feeder power supply.

POWER WAVE 355M/405M

OPERATION

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B-4

FIGURE B.1
2

The steps for operating the Power Wave will vary
depending upon the options installed in the user interface (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.

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9
10

CASE FRONT LAYOUT
POWER WAVE 355M/405M
5. Internal POWER CIRCUIT BREAKER: Protects 115
volt AC circuit.
6. LEAD CONNECTOR (SENSE LEAD)
7. DIAGNOSTIC CONNECTOR (RS-232)
8. WIRE FEEDER RECEPTACLE (5-PIN)
9. NEGATIVE TWIST- MATE TERMINAL
10. POSITIVE TWIST- MATE TERMINAL

NOMINAL PROCEDURES

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The Power Wave is designed to operate with 3/4" electrode stick-out for CV and Pulse processes.

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B-4

FRINGE PROCEDURES
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.

First, consider the desired welding process and the
part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAW-P,
etc.)
Second, find the program in the welding software that
best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales representative.
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicated
digitally via the control cable.

WELDING ADJUSTMENTS
All adjustments are made on the system component
known as the User Interface (Control Box), which contains the switches, knobs, and digital displays necessary to control both the Power Wave and a Power Feed
wire feeder. Typically, the Control Box is supplied as
part of the wire feeder. It can be mounted directly on
the wire feeder itself, the front of the power source, or
mounted separately, as might be done in a welding
boom installation.

MAKING A WELD

WARNING
The serviceability of a product or structure utilizing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable for
all applications, and the build/user is and must be
solely responsible for welding program selection.
------------------------------------------------------------------------

Because the Control Box can be configured with many
different options, your system may not have all of the
following adjustments. Regardless of availability, all
controls are described below. For further information,
consult the Power Feed wire feeder instruction manual.
• WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW)
WFS (wire feed speed) is the dominant control parameter, controlling all other variables. The user adjusts
WFS according to factors such as weld size, penetration requirements, heat input, etc. The Power Wave
then uses the WFS setting to adjust its output characteristics (output voltage, output current) according to
pre-programmed settings contained in the Power
Wave.

POWER WAVE 355M/405M

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B-5

OPERATION

In non-synergic modes, the WFS control behaves more
like a conventional CV power source where WFS and
voltage are independent adjustments. Therefore to
maintain the arc characteristics, the operator must
adjust the voltage to compensate for any changes
made to the WFS.
In constant current modes (stick, TIG) this control
adjusts the output current, in amps.

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• VOLTS / TRIM:
In constant voltage modes (synergic CV, standard CV)
the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW only)
the user can change the Trim setting to adjust the arc
length. It is adjustable from 0.500 to 1.500. A Trim setting of 1.000 is a good starting point for most conditions.
• WELDING MODE
May be selected by name (CV/MIG, CC/Stick Crisp,
Gouge, etc.) or by a mode number (10, 24, 71, etc.)
depending on the Control Box options. Selecting a
welding mode determines the output characteristics of
the Power Wave power source. A more complete
description of all modes can be found in this section.

B-5

CONSTANT VOLTAGE WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The nominal preprogrammed voltage is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS
range.
Non Synergic CV:
This type of CV mode behaves more like a conventional CV power source. Voltage and WFS are independent
adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
All CV Modes:
Arc Control, often referred to as wave control, adjusts
the inductance of the wave shape. The wave control
adjustment is similar to the "pinch" function in that it is
inversely proportional to inductance. Therefore,
increasing wave control greater than 0.0 results in a
harsher, colder arc while decreasing the wave control
to less than 0.0 provides a softer, hotter arc.
(See Figure B.2)

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• ARC CONTROL
Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0 to
+10.0, with a nominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on some Power
Feed wire feeder control panels). See the Welding
Mode descriptions for a more detailed explanations of
how the Arc Control affects each mode.

FIGURE B.2

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CURRENT WAVE FORM (CV)

Current

POWER WAVE 355M/405M

OPERATION

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B-6

TIG GTAW

B-6

NOTE: Later versions of weld software
eliminated the Arc Control Function
in TIG mode and only allow for
“Touch Start” operation.

The TIG mode features continuous control from 5 to
425 amps. The TIG mode can be run in either the
Touch Start TIG or Scratch start mode.
The Arc Control level selects the starting mode.

SMAW
In SMAW (STICK mode), the arc control adjusts the
arc force. It can be set to the lower range (0 to -10) for
a soft and less penetrating arc characteristic or to the
higher range (0 to +10) for a crisp and more penetrating arc. Normally, when welding with cellulosic types of
electrodes (E6010, E7010, E6011), a higher energy
arc is required to maintain arc stability. This is usually
indicated when the electrode sticks to the work-piece
or when the arc pops-out during manipulative technique. For low hydrogen types of electrodes (E7018,
E8018, E9018, etc.) a softer arc is usually desirable
and the lower end of the Arc Control suits these types
of electrodes. In either case the arc control is available
to increase or decrease the energy level delivered to
the arc.

Between –10 and 0, the Touch Start TIG mode is
selected. The OCV is controlled below 10V and the
short circuit "TIG touch" current is maintained at
approximately 25 amps, independent of the preset
current. When the tungsten is lifted, an arc is initiated
and the output is regulated at the preset value. A setting of 0, results in the most positive arc initiation. A
setting of -10 reduces the start procedure to start the
weld, and from there, to ramp to the welding procedure over a specified amount of time.
A setting above 0 selects a Scratch Start. Full OCV is
available when the arc initiates the output is regulated
to the preset value
Typically starting procedure on a higher “+” setting is
known as a “Hot Start”. Setting a starting procedure
on a lower setting is known as a “Cold Start”.

Recommended Welding Procedures for Power Mode

Return to Master TOC

MATERIAL

Return to Master TOC

Return to Section TOC

Aluminum 4043 Aluminum 5356

Mild Steel

Stainless Steel Stainless Steel

WIRE

E4043

E5356

L56

E308L

WIRE SIZE

0.035

0.025

0.030

0.035

0.030

0.035

GAS

100% Agr.

100% CD2

75/25 Ar/CO2

Tri-mix

80 / 1.5

50 / 0.5

WFS / POWER MODE SETTING

MATERIAL THICKNESS

Return to Section TOC

TABLE B.2

75/25 Ar/CO2

100% CD2

75/25 Ar/CO2

22 ga.

Not
recommended

100 / 0.8

Not
recommended

90 / 1.0

20 ga.

120 / 1.0

100 / 0.7

100 / 1.0

18 ga.

140 / 1.7

140 / 1.5

110 / 1.5

100 / 2.5

110 / 2.0

16 ga.

190 / 2.0

125 / 2.0

125 / 3.0

140 / 2.5

130 / 2.7

260 / 3.0

160 / 2.3

160 / 3.8

160 / 3.5

210 / 3.0

190 / 3.5

330 / 5.0

330 / 4.5

230 / 3.5

200 / 5.0

200 / 4.5

270 / 5.0

230 / 6.0

240 / 6.5

240 / 7.0

325 / 6.5

300 / 7.0

14 ga.

400 / 2.0

400 / 2.5

12 ga.
10 ga.

500 / 7.0

300 / 6.0

3/16

570 / 90

600 / 7.8

400 / 7.5

400 / 7.0

1/4

700 / 9.1

700 / 8.5

COMMENTS

Not
Not
Recommended Recommended
below 400
below 400
WFS
WFS

POWER WAVE 355M/405M

OPERATION

Return to Master TOC

Return to Section TOC

B-7

ARC GOUGING

Gouging is basically removing metal to form a bevel or
groove in a piece of steel with controlled forced air and
a carbon rod.
The common procedures for Arc Gouging metal are:
• Removing poor welds from a weldment so that new
welds can be made.

Power Mode™ is a method of high speed regulation of
the output power whenever an arc is established. It
provides a fast response to changes in the arc. The
higher the Power Mode Setting, the longer the arc. If a
welding procedure is not established, the best way to
determine the Power Mode Setting is by experimentation until the desired output result is established.
In the Power Mode variables need to be set:

• Creating a welding groove or grooves in two pieces
of steel butted together. (See Example below)

Return to Master TOC

WELD GROOVES CREATED BY ARC GOUGING

Return to Section TOC

B-7

Setting up a Power Mode procedure is similar to setting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
STEEL BUTTED TOGTHER

• For steel, use 75/25 Ar/CO2 shield gas.
Mode 9 in the POWER WAVE 355M is specifically for
gouging. Gouging can also be done in the stick soft
and crisp modes. Setting the output of the Stick Soft
mode to 425 amps will enable the arc-gouging mode.
The actual output current will depend on the size of
carbon used. The recommended maximum size carbon
is 5/16".

Return to Section TOC

Return to Master TOC
Return to Master TOC

POWER MODE™

Return to Section TOC

• Wire Feed Speed
• Output
• Arc Control

The Power Mode™ process was developed by Lincoln
to maintain a stable and smooth arc at low procedure
settings which are needed to weld thin metal without
pop-outs or burning-through. For Aluminum welding, it
provides excellent control and the ability to maintain
constant arc length. This results in improved welding
performance in two primary types of applications.
• Short Arc MIG at low procedure settings.

• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
Start by setting the wire feed speed based upon material thickness and appropriate travel speed. Then
adjust the Output knob as follows:
• For steel, listen for the traditional “frying egg”
sound of a good short-arc MIG procedure to know
you have the process set correctly.
• For aluminum, simply adjust the Output knob until
the desired arc length is obtained.
Note the Volts display is simply a relative number and
DOES NOT correspond to voltage.
Some Power Mode procedure recommendations
appear in Table B.2.

• Aluminum MIG welding.

POWER WAVE 355M/405M

OPERATION

Return to Master TOC

Return to Section TOC

B-8

SPECIAL WELDING PROCESSES
AVAILABLE ON THIS MACHINE
PULSE WELDING (GMAW-P)

The pulsed-arc process is, by definition, a spray transfer process wherein spray transfer occurs in pulses at
regularly spaced intervals. In the time between pulses,
the welding current is reduced and no metal transfer
occurs.

Return to Master TOC

Return to Section TOC

Pulsed-arc transfer is obtained by operating a power
source between low and high current levels. The high
current level or “pulse” forces an electrode drop to the
workpiece. The low current level or “background” maintains the arc between pulses. (See Figure B.3).

B-8

Pulsed MIG is an advanced form of welding that takes
the best of all the other forms of transfer while minimizing or eliminating their disadvantages. Unlike short
circuit, pulsed MIG does not create spatter or run the
risk of cold lapping. The welding positions in pulsed
MIG are not limited as they are with globular or spray
and its wire use is definitely more efficient. Unlike the
spray arc process, pulsing offers controlled heat input
that allows better welding on thin materials. Pulsing
allows for lower wire feed speeds which leads to less
distortion and improved overall quality and appearance. This is especially important with stainless, nickel and other alloys that are sensitive to heat input.
In GMAW-P mode, arc control adjusts the background
current and frequency of the wave. When arc control
goes up, the frequency increases thus increasing the
droplet transfer.

EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
PEAK AMPS

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Return to Section TOC

FIGURE B.3

FREQUENCY

Return to Master TOC

Return to Section TOC

SPRAY TRANSITION
CURRENT

POWER WAVE 355M/405M

Return to Master TOC

Return to Section TOC

B-9

PULSE WELDING

OPERATION

Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting
"trim".

Return to Master TOC
Return to Master TOC
Return to Master TOC

Return to Section TOC
Return to Section TOC

FIGURE B.3

CURRENT WAVE FORM (PULSE)

Current

Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.

Return to Section TOC

B-9

All pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes "adaptive control" to compensate for changes in electrical stick out while welding.
(Contact to Work Distance is the distance from the
contact tip to the work piece.) The Power Wave wave
forms are optimized for a 0.75" (19mm) stick-out. The
adaptive behavior supports a range of stickouts from
0.50" (13mm) to 1.25" (32mm). At very low or high wire
feed speeds, the adaptive range may be less due to
reaching physical limitations of the welding process.
Arc Control, often referred to as wave control, in pulse
programs usually adjusts the focus or shape of the arc.
Wave control values greater than 0.0 increase the
pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed
sheet metal welding. Wave control values less than 0.0
decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-position welding.

POWER WAVE 355M/405M

Time

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Return to Master TOC

Return to Section TOC

B-10

PULSE-ON-PULSE™ (GMAW-PP)

OPERATION

B-10

When Arc Control is used in the Pulse on Pulse
modes, it does the same things it does in the other
pulsed modes: decreasing the Arc Control decreases
the droplet transfer and weld deposition rate.
Increasing the Arc Control increases the droplet transfer and weld deposition rate. Since Arc Control varies
weld droplet transfer rate, the Arc Control can be used
to vary the ripple spacing in the weld bead.

Pulse on Pulse™ is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum (See the table below). It gives
weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are
used, instead of the single pulse type normally used in
GMAW-P. A number of high energy pulses are used to
obtain spray transfer and transfer metal across the arc.
Such pulses are shown in the figure below. After a
number "N" of such pulses, depending on the wire feed
speed used, an identical number "N" of low energy
pulses are performed. These low energy pulses, shown
in the figure below, do not transfer any filler metal
across the arc and help to cool the arc and keep the
heat input low.

BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity

"N" PULSES

HIGH HEAT
PULSES

Table B.3 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position. The values in the table can be helpful as a starting point to
establish a welding procedure. From there, adjustments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).

LOW HEAT
PULSES

PEAK
AMPS

BACKGROUND
AMPS
TIME

The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down, the
major effect of the low energy pulses is that they form
a weld ripple. Since they occur at very regular time
intervals, the weld bead obtained is very uniform with a
very consistent ripple pattern. In fact, the bead has its
best appearance if no oscillation of the welding gun
("whipping") is used.(See the figure below)

The comments on the table below show values of WFS
below which it is not recommended to weld. The reason is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.

TABLE B.3
WELDING PROCEDURES FOR PULSE-ON-PULSE
MATERIAL

Aluminum 4043

Aluminum 5356

WIRE

E4043

E5356

WFS /
ARC CONTROL

WIRE SIZE

MATERIAL
THICKNESS

Return to Master TOC

Return to Section TOC

GAS

100% Ar.
0.035

100% Ar.
3/64

100% Ar.
0.035

100% Ar.
3/64

14 ga.

250 / 0

200 / 0

230 / 0

225 / 0

3/16

550 / 0

340 / 0

670 / 0

500 / 0

10 ga.
1/4

COMMENTS

400 / 0

600 / 0
Not Recommended
below 200 WFS

280 / 0

400 / 0
Not Recommended
below 100 WFS

425 / 0

700 / 0
Not Recommended
below 200 WFS

POWER WAVE 355M/405M

400 / 0

550 / 0
Not Recommended
below 200 WFS

Return to Master TOC

C-1

TABLE OF CONTENTS - ACCESSORIES SECTION

C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Optional Equipment ....................................................................................................................................C-2
Field Installed .................................................................................................................................C-2

Return to Master TOC

Compatible Lincoln Equipment......................................................................................................C-2

POWER WAVE 355M/405M

Return to Master TOC
Return to Master TOC

Return to Section TOC

C-2

ACCESSORIES

OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.

FIELD INSTALLED
K940-Work Voltage Sense Lead Kit
K1764-1-Undercarriage*
K1838-1-Valet Style Undercarriage
K1796-Coaxial Welding Cable-(Requires Adapter K2176-1)
K2176-1 Twist-mate to Lug Adapters
* Dual Cylinder Kit for K1764-1 is K1702-1
K2436-1 Ethernet/Devicenet Communication Interface
Welding Cable Connectors:
K852-70 1/0-2/0 CABLE
K852-95 2/0-3/0 CABLE

COMPATIBLE LINCOLN EQUIPMENT
Any ARC Link compatible wire feeding equipment
PF10M, PF15M, PF25M series.

Return to Section TOC

Return to Master TOC

Return to Section TOC

Return to Master TOC

NOTE: No Linc-Net semi-automatic wire feeding equipment is compatible. Specifically, the semi-automatic
Power Feed family (PF-10, PF-10X2, PF-11) will not
work with a PW355M/405M.

POWER WAVE 355M/405M

C-2

Return to Master TOC

D-1

TABLE OF CONTENTS - MAINTENANCE SECTION

D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions.......................................................................................................................................D-2
Capacitor Discharge Procedure ..................................................................................................................D-2
Visual Inspection..........................................................................................................................................D-2
Routine Maintenance...................................................................................................................................D-2

Major Component Locations .......................................................................................................................D-3

Return to Master TOC

Periodic Maintenance ..................................................................................................................................D-2

POWER WAVE 355M/405M

MAINTENANCE

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Return to Section TOC

D-2

VISUAL INSPECTION

WARNING
Have qualified personnel do the maintenance
work. Always use the greatest care when
working near moving parts.
Do not put your hands near the cooling blower
fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------

EXPLODING PARTS can cause
injury.

• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves
when servicing.
------------------------------------------------------------------------

See additional warning information
throughout this Manual.

Clean interior of machine with a low pressure air
stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.

ROUTINE MAINTENANCE
1. Every 6 months or so the machine should be
cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these
areas:
•
•
•
•
•
•
•

All printed circuit boards
Power switch
Main transformer
Input rectifier
Auxiliary Transformer
Reconnect Switch Area
Fan (Blow air through the rear louvers)

2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good
condition to insure that high voltage parts are protected
and correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.

------------------------------------------------------------------------

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PERIODIC MAINTENANCE
CAPACITOR DISCHARGE PROCEDURE
1. Obtain a power resistor (25 ohms, 25 watts).
2. Hold resistor body with electrically insulated glove.
DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two studs in the position
shown. Hold in each position for 1 second. Repeat
for all four capacitors.

Calibration is accomplished with our Diagnostic Utility
software found on the Lincoln Electric Service
Navigator CD or on our web site at www.lincolnelectric.com.
If a welder has difficulty in being calibrated some things
to look for proper configuration of the sense leads.
Make sure your meter is measuring at the same point
as the power source - local (studs) or remote (feeder).

Return to Master TOC

Return to Section TOC

RESISTOR

Calibration of the POWER WAVE 355M/405M is critical
to its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the calibration of output Voltage and Current should be
checked yearly.

CAPACITOR
TERMINALS
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capacitors.

All meters used for calibration checks must be calibrated and traceable to National Standards. Some digital
meters may not function properly with inverter supplies. Try an analog type meter and calibrate around
300 amps @ 30V loading in all cases.

POWER WAVE 355M/405M

Return to Master TOC

R
WE

1
ST
AT

MAL
TH
ER

LIN

C
ELOLN
EC
TR

Return to Section TOC

Return to Master TOC

POWER WAVE 355M/405M

Return to Section TOC

Return to Master TOC

VE
WA
ER
OW

Return to Section TOC

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Use parts page exploded views to also help isolate and identify smaller parts. Parts page numbers can be found on the Master Table of
Contents in the front of this manual.

FIGURE D.1 – MAJOR COMPONENT LOCATIONS
Return to Section TOC

Return to Master TOC

1. Center Panel
2. Case Back
3. Case Front
4. Base Assembly
5. Case Wraparound

D-3

MAINTENANCE
D-3

9
20

7
20

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Return to Master TOC

Return to Section TOC

Return to Master TOC

Return to Section TOC
Return to Master TOC

Return to Section TOC

D-4

NOTES

POWER WAVE 355M/405M

D-4

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Return to Master TOC

E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description ...................................................................................................................................E-2
Input Line Voltage, Auxiliary Transformer and Precharge..........................................................................E-2
Switch Board and Main Transformer .........................................................................................................E-3
DC Bus Board, Power board and Control Board ......................................................................................E-4
Output Rectifier and Choke .......................................................................................................................E-5
Thermal Protection ...................................................................................................................................E-6
Protective Circuits......................................................................................................................................E-6

Return to Master TOC

Over current Protection .......................................................................................................................E-6
Under/Over Voltage Protection ...........................................................................................................E-6
Insulated Gate Bipolar Transistor (IGBT) Operation ..................................................................................E-7
Pulse Width Modulation.............................................................................................................................E-8
Minimum/Maximum Output ................................................................................................................E-8
FIGURE E.1 BLOCK LOGIC DIAGRAM
To Control
Board

Main Switch Board

Current
Feedback

Return to Master TOC

Input switch

Primary
Current
Sensor

Choke

Primary
Current
Sensor

Fan

4
0
5
o
n
l
y

Power
Board

Soft Start Control
V/F Capacitor Feedback (2)

Machine Control Supply
+15VDC, -15VDC, +5VDC

Control Board

Status
Red/Green
LED

Can Supply +5VDC

DC
Bus
Board

Arc
Link

40VDC

Negative
Output
Terminal

Yellow
Thermal
LED

RS232 Supply +5VDC

42VAC

220
Receptacle

Fan Control

{

40VDC

65VAC

W
a
v
e

220 VAC

Auxiliary
Transformer

Input Relay Control

IGBT Drive Signal

Primary Current Feedback(2)

115VAC Fan Supply

Positive
Output
Terminal

Output Voltage Sense

Reconnect
Switch

P
o
w
e
r

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Input
Rectifier

Electrode
Sense

Wire
Feeder
Recp.

To
Feeder

POWER WAVE 355M/405M

21 Lead
Voltage
Sense
Recp.

Thermostats
2

R232
Connector

THEORY OF OPERATION

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FIGURE E.2 - GENERAL DISCRIPTION
Main Switch Board

E-2
To Control
Board

Current
Feedback

Input
Rectifier

Input switch

Primary
Current
Sensor

Choke
Reconnect
Switch

Primary
Current
Sensor

Fan

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4
0
5
o
n
l
y

40VDC
Power
Board

Machine Control Supply
+15VDC, -15VDC, +5VDC

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Control Board

Status
Red/Green
LED

Can Supply +5VDC

DC
Bus
Board

Arc
Link

40VDC

Negative
Output
Terminal

Yellow
Thermal
LED

RS232 Supply +5VDC

42VAC

220
Receptacle

Fan Control

{

Auxiliary
Transformer

Electrode
Sense

Wire
Feeder
Recp.

21 Lead
Voltage
Sense
Recp.

R232
Connector

Thermostats
2

GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process
welding system. Depending on configuration, it can
support constant current, constant voltage, and pulse
welding modes.

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W
a
v
e

220 VAC

65VAC

P
o
w
e
r

Primary Current Feedback(2)

Input Relay Control
Soft Start Control
V/F Capacitor Feedback (2)

IGBT Drive Signal

115VAC Fan Supply

Positive
Output
Terminal

Output Voltage Sense

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E-2

The Power Wave power source is designed to be used
with the semi-automatic family of power feed wire
feeders, operating as a system. Each component in
the system has special circuitry to “talk with” the other
system components, so each component (power
source, wire feeder, user interface) knows what the
other is doing at all times. These components communicate with Arc Link (a digital communications system).
The POWER WAVE 355M/405M is a high performance,
digitally controlled inverter welding power source
capable of complex, high speed waveform control.
Properly equipped, it can support the GMAW, GMAWP, FCAW, SMAW, GTAW, and CAC-A processes. It carries an output rating of 350 Amps, 34 Volts at 60%
duty cycle and 300 Amps, 32 volts at 100% duty cycle.

INPUT LINE VOLTAGE, AUXILIARY
TRANSFORMER, & PRECHARGE
The POWER WAVE 355M/405M can be connected for
a variety of three-phase or single-phase input voltages. The initial power is applied to the 355M/405M
through a line switch located on the front of the
machine. Two phases of the input voltage are applied
to the auxiliary transformer. The auxiliary transformer

develops
The
Feeder three different secondary voltages.
115VAC is applied, via the main switch board, to the
fan motor. The 42VAC is rectified and filtered. The
65VDC produced by the Bus board rectifier is used by
the Bus board to provide 40VDC to the power board.
40VDC is also applied to the wire feeder receptacle.
PW405 models have an additional 220VAC winding
that is connected to a 220 AC receptacle.
The input voltage is rectified by the input rectifier and
the resultant DC voltage is applied to the switch board
through the reconnect switch assembly located at the
rear of the machine. The reconnect switch connects
the two pairs of input capacitors either in a parallel
(lower voltage) or series (higher voltage) configuration
to accommodate the applied input voltage.
During the precharge time the DC input voltage is
applied to the input capacitors through a current limiting circuit. The input capacitors are charged slowly
and current limited. A voltage to frequency converter
circuit located on the switch board monitors the
capacitor voltages. This signal is coupled to the control board. When the input capacitors have charged
to an acceptable level, the control board energizes the
input relays, that are located on the switch board,
making all of the input power, without current limiting,
available to the input capacitors. If the capacitors
become under or over voltage the control board will
de-energize the input relays and the 355M/405M output will be disabled. Other possible faults may also
cause the input relays to drop out.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion

POWER WAVE 355M/405M

THEORY OF OPERATION

E-3

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FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER
To Control
Board

Main Switch Board

Current
Feedback

Input
Rectifier

Input switch

Primary
Current
Sensor

Choke
Reconnect
Switch

Primary
Current
Sensor

Fan

W
a
v
e
4
0
5
o
n
l
y

Auxiliary
Transformer

40VDC
Power
Board

Soft Start Control
V/F Capacitor Feedback (2)

Machine Control Supply
+15VDC, -15VDC, +5VDC

Control Board

Status
Red/Green
LED

Can Supply +5VDC

DC
Bus
Board

Arc
Link

40VDC

Negative
Output
Terminal

Yellow
Thermal
LED

RS232 Supply +5VDC

42VAC

220
Receptacle

Fan Control

{

220 VAC

65VAC

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P
o
w
e
r

Primary Current Feedback(2)

Input Relay Control

IGBT Drive Signal

115VAC Fan Supply

Positive
Output
Terminal

Output Voltage Sense

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E-3

Electrode
Sense

Wire
Feeder
Recp.

21 Lead
Voltage
Sense
Recp.

R232
Connector

Thermostats
2

To
Feeder

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SWITCH BOARD &
MAIN TRANSFORMER
There is one switch board in the POWER WAVE
355M/405M. This board incorporates two pairs of
input capacitors, two insulated gate bipolar transistor
(IGBT) switching circuits, a fan motor drive circuit, and
a voltage/frequency capacitor feedback circuit. The
two capacitors in a pair are always in series with each
other. When the reconnect switch is in the lower voltage position the capacitor pairs are in parallel - that is,
two series capacitors in parallel with two series capacitors. When the reconnect switch is in the high voltage
position the two capacitor pairs are in series or, four
capacitors in series. This is required to accommodate
the higher input voltages.
When the input capacitors are fully charged they act
as power supplies for the IGBT switching circuits.
When welding output is required the Insulated Gate
Bipolar Transistors switch the DC power from the input
capacitors, "on and off" thus supplying a pulsed DC
current to the main transformer primary windings. See
IGBT Operation Discussion and Diagrams in this
section. Each IGBT switching circuit feeds current to
a separate, oppositely wound primary winding in the
main transformer. The reverse directions of current
flow through the main transformer primaries and the
offset timing of the IGBT switching circuits induce an

AC square wave output signal at the secondary of the
main transformer. The two current transformers (CT)
located on the switch board monitor these primary
currents. If the primary currents become abnormally
high the control board will shut off the IGBTs, thus disabling the machine output. The DC current flow
through each primary winding is clamped back to
each respective input capacitor when the IGBTs are
turned off. This is needed due to the inductance of the
transformer primary winding. The firing of the two
switch boards occurs during halves of a 50 microsecond interval, creating a constant 20 KHZ output. In
some low open circuit Tig modes the firing frequency
is reduced to 5KHZ.
The POWER WAVE 355M/405M has a F.A.N. (fan as
needed) circuit. The fan operates when the welding
output terminals are energized or when a thermal over
temperature condition exists. Once the fan is activated it will remain on for a minimum of five minutes. The
fan driver circuit is housed on the switch board but it
is activated by a signal from the control board.

NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion

POWER WAVE 355M/405M

THEORY OF OPERATION

E-4

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FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS

To Control
Board

Main Switch Board

Current
Feedback

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E-4

Input
Rectifier

Input switch

Primary
Current
Sensor

Choke

Primary
Current
Sensor

W
a
v
e
4
0
5
o
n
l
y

Auxiliary
Transformer

40VDC
Power
Board

Soft Start Control
V/F Capacitor Feedback (2)

Machine Control Supply
+15VDC, -15VDC, +5VDC

Yellow
Thermal
LED

Control Board

RS232 Supply +5VDC

42VAC

220
Receptacle

Fan Control

{

220 VAC

Status
Red/Green
LED

Can Supply +5VDC

65VAC

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P
o
w
e
r

Primary Current Feedback(2)

Input Relay Control

IGBT Drive Signal

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Fan
115VAC Fan Supply

DC
Bus
Board

Arc
Link

40VDC

Negative
Output
Terminal

Output Voltage Sense

Reconnect
Switch

Positive
Output
Terminal

Electrode
Sense

Wire
Feeder
Recp.

21 Lead
Voltage
Sense
Recp.

R232
Connector

Thermostats
2

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To
Feeder

DC BUS BOARD, POWER BOARD
AND CONTROL BOARD
DC BUS BOARD
The DC Bus Board receives approximately 65VDC
from the bus board rectifier. The DC Bus Board regulates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Power Board and the wire
feed receptacles.

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POWER BOARD
The power board, utilizing a switching power supply,
processes the 40VDC input and develops several regulated positive and negative DC supplies. Three DC
supplies are fed to the control board for machine control supplies. A +5VDC is used for the RS232 connection supply. Another +5VDC supply is utilized by the
CAN digital communication circuitry. An over or under
input voltage detection and shutdown circuit is also
part of the power board’s circuitry.

CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of
the POWER WAVE 355M/405M. The function generator and weld files exist within the Control Board hardware and software. Digital command signals received
from the user interface/feed head and feedback information received from the current sensor and output
voltage sensing leads, are processed at the control
board. Software within the control board processes
the command and feedback information and sends the
appropriate pulse width modulation (PWM) signals
(See PULSE WIDTH MODULATION in this section) to
the switch board IGBT’s. In this manner, the digitally
controlled high speed welding waveform is created.
In addition, the Control Board monitors the thermostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine’s output.

NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M

THEORY OF OPERATION

E-5

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FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE

To Control
Board

Main Switch Board

Current
Feedback

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E-5

Input
Rectifier

Input switch

Primary
Current
Sensor

Choke

Primary
Current
Sensor

W
a
v
e
4
0
5
o
n
l
y

Auxiliary
Transformer

40VDC
Power
Board

Soft Start Control
V/F Capacitor Feedback (2)

Machine Control Supply
+15VDC, -15VDC, +5VDC

Yellow
Thermal
LED

Control Board

RS232 Supply +5VDC

42VAC

220
Receptacle

Fan Control

{

220 VAC

DC
Bus
Board

Arc
Link

40VDC

Electrode
Sense

Wire
Feeder
Recp.

21 Lead
Voltage
Sense
Recp.

Thermostats
2

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To
Feeder

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Status
Red/Green
LED

Can Supply +5VDC

65VAC

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P
o
w
e
r

Primary Current Feedback(2)

Input Relay Control

IGBT Drive Signal

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Fan
115VAC Fan Supply

Negative
Output
Terminal

Output Voltage Sense

Reconnect
Switch

Positive
Output
Terminal

OUTPUT RECTIFIER AND CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. Since the output choke is in series with
the negative leg of the output rectifier and also in
series with the welding load, a filtered DC output is
applied to the machine’s output terminals.

NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE 355M/405M

R232
Connector

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E-6

THEORY OF OPERATION

THERMAL PROTECTION

OVER CURRENT PROTECTION

Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are connected to the control board. One of the thermostats is
located on the heat sink of the switch board, one is
located on the output choke and the third thermostat
is located on the DC Bus Board. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur,
the thermostats will prevent output from the machine.
The yellow thermal light, located on the front of the
machine, will be illuminated. The thermostats are selfresetting once the machine cools sufficiently. If the
thermostat shutdown was caused by excessive output
or duty cycle and the fan is operating normally, the
power switch may be left on and the reset should
occur within a 15-minute period. If the fan is not turning or the air intake louvers are obstructed, then the
power must be removed from the machine, and the
fan problem or air obstruction corrected.

If the average current exceeds 450 amps for one second, then the output will be limited to 100 amps until
the load is removed. If the peak current exceeds 600
amps for 150 ms, the output will be limited to 100
amps until the load is removed.

PROTECTIVE CIRCUITS

UNDER/OVER VOLTAGE PROTECTION
Protective circuits are included on the switch and control boards to monitor the voltage across the input
capacitors. In the event that a capacitor pair voltage
is too high, or too low, the machine output will be disabled. The protection circuits will prevent output if any
of the following conditions exist.
1. Voltage across a capacitor pair exceeds 467
volts. (High line surges or improper input voltage
connections.)
2. Voltage across a capacitor pair is under 190 volts.
(Due to improper input voltage connections.)
3. Any major internal component damage.

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Protective circuits are designed into the POWER
WAVE 355M/405M to sense trouble and shut down
the machine before damage occurs to the machine's
internal components.

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E-6

POWER WAVE 355M/405M

THEORY OF OPERATION

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E-7

INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION

An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high
current applications.

E-7

capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to the circuit components
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar to
turning ON a light switch.

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Example A in Figure E.6 shows an IGBT in passive
mode. There is no gate signal, zero volts relative to the
source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not
supply current to components connected to the
source. The circuit is turned OFF like a light switch.
Example B shows the IGBT in an active mode. When
the gate signal , a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is

FIGURE E.6 – IGBT
POSITIVE
VOLTAGE
APPLIED
GATE

GATE
SOURCE

SOURCE

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BODY REGION

DRAIN DRIFT REGION

BUFFER LAYER

INJECTING LAYER

DRAIN

B. ACTIVE

A. PASSIVE

POWER WAVE 355M/405M

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E-8

THEORY OF OPERATION

FIGURE E.7 — TYPICAL IGBT OUTPUTS.

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PULSE WIDTH
MODULATION

MAXIMUM OUTPUT

The term Pulse Width Modulation is used to describe
how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the
pulse width is known as modulation. Pulse Width
Modulation (PWM) is the varying of the pulse width
over the allowed range of a cycle to affect the output
of the machine.

By holding the gate signal on for 24 microseconds
each, and allowing only two microseconds of dwell
time (off time) during the 50-microsecond cycle, the
output is maximized. The darkened area under the top
curve can be compared to the area under the bottom
curve. The more dark area that is under the curve indicates that more power is present.
1An IGBT group consists of two IGBT modules feeding one transformer primary winding.

MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during the
cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 50-microsecond
time period.

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The positive portion of the signal represents one IGBT
group1 conducting for one microsecond. The negative
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E-8

portion is the other IGBT group1. The dwell time (off
time) is 48 microseconds (both IGBT groups off). Since
only two microseconds of the 50-microsecond time
period is devoted to conducting, the output power is
minimized.

POWER WAVE 355M/405M

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F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide..........................................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.......................................................................F-3
Troubleshooting Guide .............................................................................................................................F-4
Test Procedures

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Input Filter Capacitor Discharge Procedure .....................................................................................F-13
Main Switch Board Test....................................................................................................................F-15
Input Rectifier Test............................................................................................................................F-19
Power Board Test .............................................................................................................................F-23
DC Bus Board Test ...........................................................................................................................F-27
Output Rectifier Modules Test ..........................................................................................................F-31
Auxiliary Transformer Test.................................................................................................................F-35
Current Transducer Test ...................................................................................................................F-39
Fan Control and Motor Test..............................................................................................................F-43

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Replacement Procedures
Control Board Removal and Replacement.......................................................................................F-47
Main Switch Board Removal and Replacement...............................................................................F-51
Snubber Board Removal and Replacement.....................................................................................F-55
Power Board Removal and Replacement ........................................................................................F-57
DC Bus Board Removal and Replacement ......................................................................................F-61
Input Rectifier Removal and Replacement.......................................................................................F-65
Output Rectifier Modules Removal and Replacement.....................................................................F-69
Current Transducer Removal and Replacement ..............................................................................F-73
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F-1

Retest after Repair............................................................................................................................F-78

POWER WAVE 355M/405M

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F-2

TROUBLESHOOTING AND REPAIR

HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------

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This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
All of the referenced test procedures referred
to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

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 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------

POWER WAVE 355M/405M

F-2

TROUBLESHOOTING AND REPAIR

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F-3

PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.

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CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

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3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

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F-3

PC board can be damaged by static electricity.

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
6. Always indicate that this procedure was
followed when warranty repor ts are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

F-4
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PROBLEMS
(SYMPTOMS)

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RECOMMENDED
COURSE OF ACTION

Major physical or electrical damage
is evident when the sheet metal
cover is removed.

1. Contact the Lincoln Electric
Service Department,
1-888-935-3877.

The machine is dead—no output—
no LED’s.

1. Make sure the input line switch is
in the ON position.

1. Perform the Auxiliary Transformer Test.

2. Check the main input line fuses.
If open , replace.

2. Perform the DC Bus Board Test.

3. Check the 15 amp circuit breaker (CB1). Reset if tripped. Also
check CB3.
4. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.

2. Perform the Power Board Test.
3. The Bus Board rectifier and or
associated filter capacitor (C5)
may be faulty.
Check and
replace as necessary.
4. The Control Board may be faulty.

5. If the machine is being operated
with single phase input voltage
make sure the correct lead is not
connected. See the Installation
Section.

The main input fuses (or breaker)
repeatedly fail.

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POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.

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Observe Safety Guidelines detailed in the beginning of this manual.

F-4

1. Make certain the fuses or breakers are sized properly.
2. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and /or reduce the duty
cycle.

1. Check the reconnect switches
and associated wiring. See the
Wiring Diagram.
2. Perform the Input Rectifier
Test.
3. Perform the Main Switch Board
Test.
4. Perform the
Module Test.

Output

Diode

5. The Input Filter Capacitors may
be faulty. Check, and if any are
faulty replace all four.

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 1-888-935-3877.
POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

F-5
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PROBLEMS
(SYMPTOMS)

The machine does not have welding output.

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS

1. Make sure the reconnect switch
is configured correctly for the
input voltage applied.
2. Primary current limit has been
exceeded. Possible short in
output circuit. Turn machine
off. Remove all loads from the
output of the machine. Turn
back on. If condition persists,
turn power off, and contact an
authorized Lincoln Electric Field
Service Facility.

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Observe Safety Guidelines detailed in the beginning of this manual.

3. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes
by the status LED.
4. If an error code is displayed
see Fault Code Explanations.
If thermal light is on, wait for
machine to cool.

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The POWER WAVE 355M/405M
will not produce full output.

1. The input voltage may be too
low, limiting the output capability of the machine. Make certain the input voltage is correct
for the machine and the reconnect switch and jumper lead
configuration are correct.
2. The output current or voltage
may not be calibrated correctly.
Check the values displayed on
the Power Feed 10/11 versus
readings on an external voltage
and ammeter.

F-5

RECOMMENDED
COURSE OF ACTION
1. Check the reconnect switch and
associated leads for loose or
faulty connections. See the
wiring diagram.
2. Perform the DC Bus Board
Test.
3. Perform the Main Switch
Board Test.
4. Perform the Power Board
Test.
5. Perform the Output Diode
Module Test.
6. The control board may be faulty.
7. The input filter capacitors may
be faulty. Check and replace if
necessary.

1. Perform the Output Rectifier
Test.
2. Perform the Main Switch
Board Test.
3. Perform the Power Board
Test.
4. Perform the Current
Transducer Test.
5. The control board may be
faulty.

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3. The welding current may be too
high . The machine will fold
back to 100 amps if the welding current exceeds 450 amps.

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 1-888-935-3877.
POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

F-6
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Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

The machine regularly overheats
and the yellow thermal light is ON
indicating a thermal overload.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. The welding application may
be exceeding the recommended
duty cycle of the POWER WAVE
355M/405M.

3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around the
machine.

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2. Dirt and dust may have clogged
the cooling channels inside the
machine.

4. Make certain the fan as needed
(F.A.N.) is operating properly.
The fan should operate when
welding voltage is present
and/or when there is an over
temperature condition.

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An attached wire feeder will not
function correctly. Apparently the
wire feeder is not being poweredup.

F-6

RECOMMENDED
COURSE OF ACTION
1. The 115VAC fan motor is controlled by the control board via
the main switch board. Perform
the Fan Motor And Control
Test.
1. A thermostat or associated circuitry may be faulty. See the
wiring diagram. One normally
closed thermostat is located on
the output choke, one on the DC
Bus Board and the other is
located on the main switch
board heat sink. See the wiring
diagram.
Note: The Main Switch Board
Removal Procedure will be
required to gain access to
the heat sink thermostat.

1. Make certain the wire feeder
control cable is connected to
the wire feeder receptacle. See
the Wiring Diagram.

1. Check for 40 VDC on pin “D” (+)
and pin “E” (-) at the Power Wave
wire feeder receptacle. See
Wiring Diagram.

2. Check the two circuit breakers
located at the front of the
machine. Reset if tripped.

If 40 volts DC is Not present at
the Power Wave wire feeder
receptacle, perform the DC Bus
Board Test.

3. The wire feeder or control cable
may be faulty.

2. Check the DC Bus Board rectifier. See Wiring Diagram.
3. Perform the T1 Auxiliary transformer Test.
4. If the 40 volts DC is present at
the Power Wave wire feeder
receptacle, the problem is in the
control cable or the wire
drive/control box.

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 1-888-935-3877.
POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

F-7
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Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

F-7

RECOMMENDED
COURSE OF ACTION

The machine often “noodle welds”
with a particular procedure. The
output is limited to approximately
100 amps.

1. The machine may be trying to
deliver too much power. When
the average output current
exceeds a maximum limit, the
machine will “phase back” to
protect itself. Adjust the procedure or reduce the load to lower
the current draw from the Power
Wave machine.

1. Perform
the
Transducer Test.

Current

Excessively long and erratic arc.

1. Check for proper configuration
and implementation of voltage
sensing circuits.

1. Check the connections between
the voltage sense receptacle
and the control board. See the
Wiring Diagram.

2. The control board may be faulty.

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 1-888-935-3877.
POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

F-8
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Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

Auxiliary receptacle is “dead” no
auxiliary voltage.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Circuit breaker CB1 (on case
front) may have opened. Reset.

F-8

RECOMMENDED
COURSE OF ACTION
1. Perform the Auxiliary
Transformer Test.

2. Circuit breaker CB3 (in reconnect area) may have opened.
Reset.

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3. On PW 405 models, the circuit
breaker CB4 protects the
220VAC receptacle. Reset if
tripped.
A fault or error code is displayed.

1. See Fault Code Explanations.

General degradation of the weld
performance.

1. Check for feeding problems,
bad connections, excessive
loops in cabling, etc.

1. Perform the Voltage and
Current Calibration Procedure
using the Power Wave software
program.

2. Verify weld mode is correct for
processes.

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3. The power source may require
calibration.
4. Check the actual current displayed on the Power Feed 10
vs. actual current measured via
external meter.

2. Perform the Current
Transducer Test.
2. Perform the Output Diode
Module Test.
5. The control board may be
faulty.

5. Check the actual voltage displayed on the Power Feed 10
vs. actual voltage measured via
external meter.

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6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.

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 1-888-935-3877.
POWER WAVE 355M/405M

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TROUBLESHOOTING AND REPAIR

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user
interface, and feed head) has a status light, and when
a problem occurs it is important to note the condition
of each. In addition, errors displayed on the user
interface in most cases indicate only that a problem
exists in the power source, not what the problem may
be. Therefore, prior to cycling power to the system, check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays “Err 006”
or “Err 100”.
Included in this section is information about the

F-9

power source Status LED, and some basic troubleshooting charts for both machine and weld performance.
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.
NOTE: The POWER WAVE 355M/405M status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.

LIGHT CONDITION

INDICATION

Status LED is solid green (no blinking)

1. System OK. Power source communicating normally with wire feeder and its components.

Status LED is blinking green

2. Occurs during a reset, and indicates the
POWER WAVE 355M/405M is mapping (identifying) each component in the system. Normal
for first 1-10 seconds after power is turned on,
or if the system configuration is changed during
operation.

Status LED is blinking red and green

3. Non-recoverable system fault. If the PS Status
light is flashing any combination of red and
green, errors are present in the POWER WAVE
355M/405M. Read the error code before the
machine is turned off.

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F-9

Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with a
long pause between digits. The codes will be
separated by a green light. There may be more
than one error code indicated.

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To clear the error, turn power source off, and
back on to reset.
Status LED is solid red (no blinking).

Non-recoverable hardware fault. Generally indicates nothing is connected to the POWER
WAVE 355M/405M wire feeder receptacle. See
Trouble Shooting Section.

Status LED is blinking red.

Not applicable
POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-10

ERROR CODES FOR THE POWER WAVE

The following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status light
If connected to a PF-10/11 these error codes will generally be accompanied by an “Err 006” or “Err 100” on the
user interface display.
Individual code digits are flashed in RED with a long pause between digits. Complete codes are seprated by one
GREEN light. There may be more than one error code indicated
Example: Error code 31
- Red, red, red pause, red, green.
Error codes 32 & 34 - Red, red, red, pause Red,red, Green, Red,red,red, pause
Red,red,red,red, Green. Sequence will repeat continuously.

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STATUS LED ERROR CODE TABLE
11

CAN communication bus off.

Probably due to excessive number of communication errors.

User interface time out error.

UI is no longer responding to the Power Source. The most
likely cause is a fault/bad connection in the communication
leads or control cable.

Unprogrammed weld mode.

Contact the service department for instructions on reloading
the Welding Software.

Empty weld table.

Contact the service department for instructions on reloading
the Welding Software.

Weld table checksum error.

Contact the service department for instructions on reloading
the Welding Software.

Primary overcurrent error.

Excessive Primary current present. May be related to a
short in the main transformer or output rectifier.

Capacitor “A” under voltage.

Low voltage on the main capacitors. May be caused by
improper input configuration.

Capacitor “B” under voltage.

When accompanied by an overvoltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.

Capacitor “A” overvoltage.

Excessive voltage on the main capacitors. May be caused
by improper input configuration.

Capacitor “B” overvoltage.

When accompanied by an under voltage error on the same
side, it indicates no capacitor voltage present on that side,
and is usually the result of an open or short in the primary
side of the machine.

Thermal error.

Indicates over temperature. Usually accompanied by thermal LED. Check fan operation. Be sure process does not
exceed duty cycle limit of the machine.

Softstart error.

Capacitor precharge failed. Usually accompanied by codes
32-35.

Secondary overcurrent error

The secondary (weld) current limit has been exceeded.
When this occurs the machine output will phase back to
100 amps, typically resulting in a condition referred to as
“noodle welding”
NOTE: The secondary limit is 570 for the standard stud, and
325 amps for all single phase operation.
POWER WAVE 355M/405M

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Other

TROUBLESHOOTING AND REPAIR

Capacitor delta error.

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F-11

The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors
32-35. Check the output diodes.

Error codes that contain three or four digits are defined as
fatal errors. These codes generally indicate internal errors
on the Control Board. If cycling the input power on the
machine does not clear the error, try reloading the operating
system. If this fails, replace the Control Board.

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F-11

POWER WAVE 355M/405M

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F-12

NOTES

POWER WAVE 355M/405M

F-12

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F-13

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This procedure will drain off any charge stored in the four large capacitors that are part
of the switch board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine.

MATERIALS NEEDED

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5/16” Nut Driver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
DC Volt Meter

POWER WAVE 355M/405M

F-13

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F-14

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse box
before working on equipment.
• Do not touch electrically hot parts.

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• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
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F-14

4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not with the machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the eight capacitor terminals shown in figure F.1.
6. Using electrically insulated gloves and pliers, hold
the body of the resistor with the pliers and connect the resistor leads across the two capacitor
terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS
WITH YOUR BARE HANDS.
7. Repeat the discharge procedure for the other
three capacitors.

DISCHARGE PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using the 5/16” wrench remove the screws from
the case wraparound cover.
3. Be careful not to make contact with the capacitor
terminals located at the top and bottom of the
switch board.

8. Check the voltage across the terminals of all
capacitors with a DC voltmeter. Polarity of the
capacitor terminals is marked on the PC board
above the terminals. Voltage should be zero. If
any voltage remains, repeat this capacitor discharge procedure.

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FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS

EIGHT
CAPACITOR
TERMINALS
-

INSULATED
PLIERS

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POWER
RESISTOR

POWER WAVE 355M/405M

INSULATED
GLOVES

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F-15

TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST

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TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning
correctly. This test will NOT indicate if the entire PC board is functional. This resistance
test is preferable to a voltage test with the machine energized because this board can be
damaged easily. In addition, it is dangerous to work on this board with the machine energized.

MATERIALS NEEDED

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Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench

POWER WAVE 355M/405M

F-15

TROUBLESHOOTING AND REPAIR
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS

202

207

J22

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204

205

208

J21

J20

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TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver, remove the case
wraparound.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
207

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+
206

203
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+
209

201

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F-16

MAIN SWITCH BOARD TEST (continued)

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F-16

4. Using a 7/16” wrench locate, label and remove
leads 201, 202, 203, 204, 205, 206, 207 and
208 from the switch board. Note lead and
washer placement for reassembly. Clear
leads.
5. Using the Analog ohmmeter, perform the resistance tests detailed in Table F.1. Refer to figure F.2 for test point locations. Note: Test
using an Analog ohmmeter on the Rx1 range.
Make sure the test probes are making electrical contact with the conductor surfaces on the
PC board.

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-17

MAIN SWITCH BOARD TEST (continued)
6. If any test fails replace the switch board. See
Main Switch Board Removal and Replacement.
7. If the switch board resistance tests are OK, check
connections on plugs J20, J21, J22 and all associated wiring. See wiring diagram.

8. Reconnect leads 201, 202, 203, 204, 205, 206,
207, and 208 to the switch board. Ensure that the
leads are installed in their proper locations. PreTorque all leads nuts to 25 inch lbs. before tightening them to 44 inch lbs.
9. Replace the case wraparound cover using a 5/16”
nut driver.

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TABLE F.1. SWITCH BOARD RESISTANCE TEST

APPLY POSITIVE TEST
PROBE TO TERMINAL

APPLY NEGATIVE TEST
PROBE TO TERMINAL

NORMAL
RESISTANCE READING

+206
+208
+202
+201
+205
+203
+204
+207

-205
-203
-204
-207
-206
-208
-202
-201

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

POWER WAVE 355M/405M

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F-18

NOTES

POWER WAVE 355M/405M

F-18

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F-19

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST

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TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.

MATERIALS NEEDED
Analog Voltmeter/Ohmmeter (Multimeter)
5/16” Nut Driver
Phillips Head Screwdriver
Wiring Diagram

POWER WAVE 355M/405M

F-19

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F-20

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (CONTINUED)

TEST PROCEDURE
1. Remove input power to the POWER
WAVE 355M/405M machine.
2. Using a 5/16” nut driver, remove the case
wraparound cover.
3. Perform the Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the input rectifier and associated
leads. See Figure F.3.

6. Using a phillips head screwdriver,
remove leads 207, 207A, and 209 from
the input rectifier.
7. Use the analog ohmmeter to perform the
tests detailed in Table F.2. See the
Wiring Diagram.
8. Visually inspect the three MOV’S for
damage (TP1,TP2,TP3). Replace if necessary.

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5. Carefully remove the silicone sealant
from leads 207, 207A, and 209.
Figure F.3 Input Rectifier
Small Lead "H1"
To Auxiliary Transformer

#207
#207A

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3/16" ALLEN
BOLTS

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#209
FRONT
REAR

POWER WAVE 355M/405M

Small Lead "A"
To Circuit Breaker

F-20

TROUBLESHOOTING AND REPAIR

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F-21

INPUT RECTIFIER TEST (CONTINUED)
Table F.2 Input Rectifier Test Points

ANALOG METER
X10 RANGE

TEST POINT TERMINALS
+ PROBE

- PROBE

Acceptable Meter Readings

A
B
C

207
207
207

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms

A
B
C

207A
207A
207A

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms

A
B
C

209
209
209

Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

207
207
207

A
B
C

Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

207A
207A
207A

A
B
C

Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

209
209
209

A
B
C

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms

9. If the input rectifier does not meet the
acceptable readings outlined in Table F.2
the component may be faulty. Replace
Note: Before replacing the input rectifier,
check the input power switch and reconnect switches. Perform the Main Switch
Board Test. Also check for leaky or
faulty filter capacitors.

11. If the input rectifier is faulty, see the
Input Rectifier Bridge Removal &
Replacement procedure.
12. Replace the case wraparound cover.

10. If the input rectifier is good, be sure to
reconnect leads 207, 207A, and 209 to
the correct terminals and torque to 31
inch lbs. Apply silicone sealant.
POWER WAVE 355M/405M

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F-22

NOTES

POWER WAVE 355M/405M

F-22

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F-23

TROUBLESHOOTING AND REPAIR
POWER BOARD TEST

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TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages and also
if the power board is regulating and producing the correct DC voltages.

MATERIALS NEEDED
Volt-Ohmmeter
3/8” Nut Driver

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Wiring Diagram

POWER WAVE 355M/405M

F-23

TROUBLESHOOTING AND REPAIR
J41

J42

J43

12 11 10 9

8 7

J42

J41

4 3

J43

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F-24

FIGURE F.4 – POWER BOARD TEST

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F-24

TEST PROCEDURE

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1. Remove input power to the Power Wave
355M/405M.
2. Using the 3/8” nut driver, remove the case
top.
3. Perform
the
Procedure.

Capacitor

Discharge

4. Locate the Power Board and plugs J42 and
J43. Do not remove plugs or leads from
the Power Board. Refer to Figure F.8.
5. Carefully apply input power to the Power
Wave 355M/405M.

6. Turn on the Power Wave 355M/405M.
Carefully test for the correct voltages at the
Power Board according to Table F.4.
7. If either of the 40 VDC voltages is low or not
present at plug J41, perform the DC Bus PC
Board Test. See the Wiring Diagram. Also
perform the T1 Auxiliary Transformer
Test.
8. If any of the DC voltages are low or not present at plugs J42 and/or 43, the Power
Board may be faulty.
9. Install the case top using the 3/8” nut driver.

WARNING

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ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.

POWER WAVE 355M/405M

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F-25

TROUBLESHOOTING AND REPAIR

F-25

POWER BOARD TEST (CONTINUED)
TABLE F.3 – POWER BOARD VOLTAGE CHECKS

CHECK POINT
LOCATION

POWER BOARD
CONNECTOR
PLUG J41

TEST
DESCRIPTION

CONNECTOR
PLUG PIN NO.

LEAD NO. OR
IDENTITY

CHECK 40 VDC
INPUT FROM
DC BUS BOARD

2 (+)
1 (-)

477 (+)

475

NORMAL
ACCEPTABLE
VOLTAGE
READING
38 – 42 VDC

477

475 (-)
POWER BOARD
CONNECTOR
PLUG J42

CHECK +15
VDC SUPPLY FROM
POWER BOARD

+15 VDC

1 (+)
5 (-)

412

412 (+)

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410 (-)
410

POWER BOARD
CONNECTOR
PLUG J42

CHECK +5 VDC
SUPPLY FROM
POWER BOARD

3 (+)
5 (-)

+5 VDC
408 (+)

408

410 (-)
410

POWER BOARD
CONNECTOR
PLUG J42

CHECK -15 VDC
SUPPLY FROM
POWER BOARD

411

2 (+)
5 (-)

-15 VDC
411 (+)
410 (-)

410

POWER BOARD
CONNECTOR
PLUG J43

CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD

5 (+)
10 (-)

+5 VDC
1104

1104 (+)
1103 (-)

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1103

POWER BOARD
CONNECTOR
PLUG J43

4 (+)
9 (-)

CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD

+5 VDC
406

406 (+)
405 (-)

405

POWER BOARD
CONNECTOR
PLUG J43

CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD

403

+5 VDC

3 (+)
12 (-)

403 (+)
401 (-)
401

POWER WAVE 355M/405M

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F-26

NOTES

POWER WAVE 355M/405M

F-26

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F-27

TROUBLESHOOTING AND REPAIR
DC BUS BOARD TEST

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TEST DESCRIPTION
This test will determine if the DC Bus Power Supply PC Board is receiving and processing the proper voltages.

MATERIALS NEEDED
3/8” Nut driver
Volt/ohmmeter
Wiring Diagram

POWER WAVE 355M/405M

F-27

TROUBLESHOOTING AND REPAIR

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DC BUS BOARD TEST (CONTINUED)

FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD

DC BUS BOARD

STA

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F-28

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TEST PROCEDURE

WARNING

1. Remove input power to the machine.

ELECTRIC SHOCK can kill.

2. Using the 3/8” nut driver, remove the wraparound cover.

High voltage is present when
input power is applied to the
machine.

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3. Locate the DC Bus Board. See Figure F.5.
4. Carefully apply input power to the Power
Wave 355M/405M.

5. Turn on the Power Wave 355M/405M. The
LED on the DC Bus Power Supply PC Board
should light.

FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD

J47

Bus
Rectifier

475

477

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L11078-1

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J46
66

J46
POWER WAVE 355M/405M

Thermostat

F-28

TROUBLESHOOTING AND REPAIR

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F-29

DC BUS BOARD TEST(CONTINUED)

6. Check the DC Bus Board input and output
voltages according to Table F.4. See Figure
F.6 and the Wiring Diagram.

WARNING
ELECTRIC SHOCK can kill.

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High voltage is present at the terminals of Capacitor C3 near
where testing is to be done.

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F-29

7. If all the voltages are correct, the DC Bus
Board is operating properly.
8. If any of the output voltages are not correct
and the input voltage is correct, the DC Bus
Board may be faulty.
9. If the input voltage is not correct, check the
leads between the DC Bus Board and the
Bus Rectifier. See the Wiring Diagram.
10. When finished testing, replace the case
wraparound cover.

TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE

Positive Meter Probe
Test Point

Negative Meter Probe
Test Point

Approximate Voltage
Reading

Conditions/Comments

Plug P46 – Pin 1

Plug P46 – Pin 3

65 – 75 VDC

Lead 65

Lead 66

Should be same as the
Bus Rectifier

Plug P47 – Pin 8(+)
Lead 52

Plug P47 – Pin 1(-)
Lead 51

38.0 – 42.0 VDC

Supply to the Wire
Feeder Receptacle

Plug P47 – Pin 3(+)
Lead 477

Plug P47 – Pin 6(-)
Lead 475

38.0 – 42.0 VDC

Supply to Power Board

POWER WAVE 355M/405M

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F-30

NOTES

POWER WAVE 355M/405M

F-30

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F-31

TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER MODULES TEST

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TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.

MATERIALS NEEDED
Analog Voltmeter/Ohmmeter
Wiring Diagram

POWER WAVE 355M/405M

F-31

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F-32

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER MODULES TEST (continued)
FIGURE F.7 Machine Output Terminals

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POSITIVE
OUTPUT
TERMINAL

NEGATIVE
OUTPUT
TERMINAL

TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Locate the output terminals on the front
panel of the machine. See Figure F.7.

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3. Remove any output cables and load from the
output terminals.

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THERMAL

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STA
ST
ATUS

4. Using the analog ohmmeter test for more
than 200 ohms resistance between positive
and negative output terminals. Positive test
lead to the positive terminal; Negative test
lead to the negative terminal. See Figure
F.8.
NOTE: The polarity of the test leads is most
important. If the test leads polarity is not correct, the test will have erroneous results.

POWER WAVE 355M/405M

F-32

TROUBLESHOOTING AND REPAIR

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Figure F.8 Terminal Probes

_
- PR
OB E

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OUTPUT RECTIFIER MODULES TEST (continued)

+
E
R OB
+P

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F-33

5. If 200 ohms is measured then the output
diodes are not “shorted”.

9. Test all output diode modules individually.
Test for open diodes also.

NOTE: There is a 250 ohm resistor across
the welding output terminals. See Wiring
Diagram

NOTE: This may require the disassembly of
the leads and the snubber board from the
diode modules.
Refer to the Output
Rectifier
Modules
Removal
and
Replacement Procedure for detailed
instructions.

6. If less than 200 ohms is measured, one or
more diodes or the snubber board may be
faulty.

8. Locate the output diode modules and snubber board. See Figure F.9.
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7. Perform the Filter Capacitor Discharge
Procedure detailed in the maintenance section.

POWER WAVE 355M/405M

F-33

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F-34
Figure F.9 Snubber and Output Diode Locations

TROUBLESHOOTING AND REPAIR

Output Diode
Modules

Snubber
Board

LEFT SIDE

POWER WAVE 355M/405M

F-34

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F-35

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER TEST

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TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of auxiliary transformer and also if the correct voltage is being induced on the secondary windings of the transformer.

MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
5/16” Nut Driver

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Wiring Diagram

POWER WAVE 355M/405M

F-35

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F-36

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.10 Auxiliary Transformer

Auxiliary
Transformer
Secondary Lead
Plugs P52

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TEST PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.

4. Locate the auxiliary transformer. See Figure
F.10.

2. Using a 5/16” nut driver, remove the case
wraparound cover.

5. Locate the secondary leads and plug P52.
See Figure F.10 and F.11.

3. Perform the Input Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug

PW405
Only
(220V)

532

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(115V)

Plug P52

Com 2
(31)
POWER WAVE 355M/405M

F-36

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F-37

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER TEST (continued)
TABLE F.5

LEAD IDENTIFICATION

NORMAL EXPECTED VOLTAGE

COM 2 (31) TO 115V (532)

115 VAC

42 TO COM 1A (quick connects)

42 VAC

7. Carefully apply the correct input voltage to the
POWER WAVE 355M/405M and check for the
correct secondary voltages per table F.5.
Make sure the reconnect jumper lead and
switch are configured correctly for the input
voltage being applied. Make sure circuit
breaker (CB3) is functioning properly.
NOTE: The secondary voltages will vary if the
input line voltage varies.
8. If the correct secondary voltages are present,
the auxiliary transformer is functioning properly. If any of the secondary voltages are missing or low, check to make certain the primary
is configured correctly for the input voltage
applied. See Wiring Diagram.

WARNING
High voltage is present at primary of
Auxiliary Transformer.
9. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are not
correct, the auxiliary transformer may be
faulty.
10. Remove the input power to the POWER WAVE
355M/405M.
11. Install the case wraparound cover using a
5/16” nut driver.

POWER WAVE 355M/405M

F-37

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F-38

NOTES

POWER WAVE 355M/405M

F-38

TROUBLESHOOTING AND REPAIR

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F-39

CURRENT TRANSDUCER TEST

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TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring are functioning correctly.

MATERIALS NEEDED
Volt-ohmmeter
5/16” Nut Driver
Grid Bank

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External DC Ammeter

POWER WAVE 355M/405M

F-39

TROUBLESHOOTING AND REPAIR

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F-40

CURRENT TRANSDUCER TEST (continued)
FIGURE F.12 Metal Plate Removal & Plug J8 Location

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Plug J8
TEST PROCEDURE

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1. Remove input power to the POWER WAVE
355M/405M.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
3. Perform the Input Capacitor Discharge
Procedure.
4. Locate plug J8 on the control board. Do not
remove the plug from the P.C. Board.

6. Check for the correct DC supply voltages to
the current transducer at plug J8. See Figure
F.12.
A. Pin 2 (lead 802+) to pin 6 (lead 806-)
should read +15 VDC.
B. Pin 4 (lead 804+) to pin 6 (lead 806-)
should read -15 VDC.
7. If either of the supply voltages are low or missing, the control board may be faulty.

5. Apply the correct input power to the POWER
WAVE 355M/405M.
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug

802

804

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801
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F-40

Plug J8
806
POWER WAVE 355M/405M

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F-41

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER TEST (continued)
TABLE F.6

OUTPUT LOAD CURRENT

EXPECTED TRANSDUCER FEEDBACK
VOLTAGE

300

2.4

250

2.0

200

1.6

150

1.2

100

0.8

8. Check the feedback voltage from the current
transducer using a resistive load bank and
with the POWER WAVE 355M/405M in mode
200. Mode 200 is a constant current test
mode. This mode can be accessed using a
wire feeder placed in mode 200 or a laptop
computer and the appropriate software. Apply
the grid load across the output of the POWER
WAVE 355M/405M. Set machine output to
300 amps and enable WELD TERMINALS.
Adjust the grid load to obtain 300 amps on the
external ammeter and check feedback voltages per Table F.6.
A. Pin 1 (lead 801) to Pin 6 (lead 806) should
read 2.4 VDC (machine loaded to 300
amps).

Before replacing the current transducer, check
the leads and plugs between the control board
(J8) and the current transducer (J90). See The
Wiring Diagram. For access to plug J90 and
the current transducer refer to: Current
Transducer Removal and Replacement
Procedure.
11. Remove input power to the POWER WAVE
355M/405M.
12. Replace the control box top and any cable ties
previously removed.
13. Install the case wraparound cover using the
5/16” nut driver.

9. If for any reason the machine cannot be
loaded to 300 amps, Table F.6. shows what
feedback voltage is produced at various current loads.

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10. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or not
correct the current transducer may be faulty.

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F-41

POWER WAVE 355M/405M

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F-42

NOTES

POWER WAVE 355M/405M

F-42

TROUBLESHOOTING AND REPAIR

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F-43

FAN CONTROL AND MOTOR TEST

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TEST DESCRIPTION
This test will help determine if the fan motor, control board, switch board, or associated
leads and connectors are functioning correctly.

MATERIALS NEEDED
Voltmeter

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5/16” Nut Driver

POWER WAVE 355M/405M

F-43

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F-44

TROUBLESHOOTING AND REPAIR

F-44

FAN CONTROL AND MOTOR TEST (continued)

TEST PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M machine.

3. Perform the Input Filter Capacitor Discharge
Procedure.

2. Using the 5/16” nut driver, remove the case
wraparound cover.

4. Locate plug J22 on the main switch board. Do
not remove the plug from the board. See
Figure F.14.

FIGURE F.14 PLUG J22 LOCATION

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J22

J21

J20

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5. Carefully apply the correct input power to the
machine.

6. Carefully check for 115VAC at plug J22 pin-2
to J22 pin-3. (leads 32A to 31B(C) See Figure
F.15. WARNING: HIGH VOLTAGE IS PRESENT AT THE MAIN SWITCH BOARD.

FIGURE F.15 PLUG J22

207

Fan Lead

Lead 32A

Lead 31B(C)

Fan Lead

Plug J22
POWER WAVE 355M/405M

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F-45

TROUBLESHOOTING AND REPAIR

FAN CONTROL AND MOTOR TEST (continued)

7. If the 115VAC is low or not present check circuit breaker CB2 located on the front panel. If
the circuit breaker is OK, perform The
Auxiliary Transformer Test. Check plug J22,
circuit breaker CB2 and associated leads for
loose or faulty connections. See the Wiring
Diagram.
8. Energize the weld output terminals with the
PW 355M/405M in mode 200. This mode can
be accessed using a wire feeder placed in
mode 200 or a laptop computer and the appropriate software. Carefully check for 115VAC at
plug J22 pin-1 to J22 pin-4 (fan leads). See
Figure F.15. If the 115VAC is present and the
fan is not running then the fan motor may be
faulty. Also check the associated leads
between plug J22 and the fan motor for loose
or faulty connections. See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.

1. Locate plug J20 on the switch board. Do not
remove the plug from the switch board. See
Figure F.14 and F.16.
2. Energize the weld output terminals (Select
Weld Terminals ON) and carefully check for
+15VDC at plug J20 pin-6+ to J20 pin-2(leads 715 to 716). See Figure F.16. If the
15VDC is present and the fan is not running
then the switch board may be faulty. If the
15VDC is not present when the weld terminals
are energized then the control board may be
faulty. Also check plugs J20, J7, and all associated leads for loose or faulty connections.
See the Wiring Diagram.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE SWITCH BOARD.
3. Remove the input power to the POWER WAVE
355M/405M.
Note: The fan motor may be accessed by the
removal of the rear panel detailed in The
Current
Transducer
Removal
and
Replacement Procedure.

9. If the 115VAC is NOT present in the previous
step then proceed to the fan control test.

4. Replace the case wrap-around cover.

FAN CONTROL TEST PROCEDURE

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FIGURE F.16 PLUG J20

Lead 716-

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Lead 715+

F-45

Plug J20

POWER WAVE 355M/405M

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F-46

NOTES

POWER WAVE 355M/405M

F-46

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F-47

TROUBLESHOOTING AND REPAIR

CONTROL BOARD REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the control board for maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
Flathead Screwdriver

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Phillips Head Screwdriver

POWER WAVE 355M/405M

F-47

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F-48

TROUBLESHOOTING AND REPAIR

F-48

CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 - CONTROL BOARD LOCATION

STA

S
TH

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Control Board
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.

4. Locate the control board behind the front panel of
the machine. See Figure F.17.

2. Using a 5/16” nut driver remove the case wraparound cover.

5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.18.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.18 CASE FRONT SCREW REMOVAL

ST
STA
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Phillips Head
Screws

THERMAL

Phillips Head
Screws

5/16"
Mounting Screws

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-49

CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS

J6
J5

J7
J8
J9

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J10A

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8. The front of the machine may now gently be pulled
forward to gain access to the Control Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.

CAUTION
Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.

9. Beginning at the right side of the control board
remove plugs J10A and J10B. Note: Be sure to
label each plugs position upon removal. See
Figure F.19.

6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
the input power switch. See Figure F.18.

10. Working your way across the top of the board
from right to left, label and remove plugs #J9, #J8,
#J7, #J6, and #J5. See Figure F.19.

7. Using a phillips head screwdriver remove the four
screws from around the two welder output terminals on the front of the machine. See Figure F.18.

11. Working your way down the left side of the board,
label and remove plugs #J4 and #J2. See Figure
F.19.

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-50

CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
12. Using a 3/8” nut driver remove the two mounting
nuts from the top two corners of the control
board. See Figure F.20.

14. Replace the control board.

13. Cut any necessary cable ties.

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FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION

e
d
i
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t
h
g
i
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Mounting
Nuts (3/8")

15. Replace the two 3/8” mounting nuts at the top
two corners of the control board.

19. Replace the four screws from around the two
welder output terminals on the front of the
machine.

16. Replace any previously removed cable ties.

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17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9,
#J10B, and #J10A previously removed.

20. Replace the two case front mounting screws at
the bottom of the front of the machine.
21. Replace the case wraparound cover.

18. Replace the two screws and their washers from
above and below the input power switch.

POWER WAVE 355M/405M

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F-51

TROUBLESHOOTING AND REPAIR

MAIN SWITCH BOARD REMOVAL & REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the main switch board for
maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver
Flathead Screwdriver
7/16” mm Socket
3/16” Allen Wrench

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3/8” Nut Driver

POWER WAVE 355M/405M

F-51

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F-52

TROUBLESHOOTING AND REPAIR

MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS

202

207

J22

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+
209

201
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F-52

204

205

208

J21

J20

+
206

203

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PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

207

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CAUTION
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in permanent damage to equipment.

5. Using a 3/8” nut driver, remove the input lead
shield from the area at the bottom of the main
switch board.
6. Using a 7/16” socket, remove leads 201, 202,
203, 204, 205, 206, 207, 208, 209 from the
switch board. Note lead terminal locations and
washer positions upon removal.
7. Locate and disconnect the three harness plugs
associated with the main switch board. Plugs
#J20, #J21, #J22. See Figure F.21.
8. Locate the eight capacitor terminals and
remove the nuts using a 7/16” socket or nut
driver. Note the position of the washers behind
each nut for replacement.

4. Locate the main switch board and all associated plug and lead connections. See figure F.21.
See Wiring Diagram.

POWER WAVE 355M/405M

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F-53

TROUBLESHOOTING AND REPAIR

MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION

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3/16" ALLEN BOLTS

9. Using a 3/16” allen wrench remove four allen
bolts and washers as shown in Figure F.22.
At this point, the board is ready for removal.

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10. Carefully maneuver the board out of the
machine.
11. Apply a thin coat of Penetrox A-13 to the
IGBT heatsinks on the back of the new
207
switch boards mating surfaces. Note: Keep
compound away from the mounting holes.
12. Replace the four allen bolts and washers
previously removed.
13. Replace the eight capacitor terminal nuts,
washers, and necessary leads previously
removed.

15. Reconnect the nine leads (#201-#209) that
were previously removed.
16. Replace any necessary cable ties previously
removed.
17. Pre-torque all screws to 25 inch lbs. before
tightening to 44 inch lbs.
18. Replace the input lead shield previously
removed.
19. Replace the case wraparound cover.
NOTE: Any instructions that are packaged with
the replacement board will supercede
these instructions.

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14. Reconnect the three harness plugs previously removed.

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POWER WAVE 355M/405M

F-53

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F-54

NOTES

POWER WAVE 355M/405M

F-54

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F-55

TROUBLESHOOTING AND REPAIR

SNUBBER BOARD REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the snubber board for maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver

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7/16 Socket or Nut Driver

POWER WAVE 355M/405M

F-55

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F-56

TROUBLESHOOTING AND REPAIR

SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)

F-56

PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

2. Using a 5/16” nut driver remove the case wraparound cover.

4. Locate the snubber board.. See Figure F.23.

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FIGURE F.23 – SNUBBER BOARD LOCATION

Snubber
Board
LEFT SIDE

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5. Remove small lead #B1 from the board.
Figure F.24.

See

6. Remove the four bolts using a 7/16” socket. Two
of these bolts have leads #30 and #10 connected
to them. Note the position of all leads and associated washers upon removal.

8. Replace the snubber board.
9. Replace the bolts, leads, and washers previously
removed. Torque bolt to 30-40 Inch Lbs.
10. Reconnect small lead B1 previously removed.
11. Replace the case wraparound cover.

7. Carefully remove the snubber board.
FIGURE F.24 – SNUBBER BOARD LEADS (CLOSE UP)

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Lead 30

Lead B1

Lead 10

POWER WAVE 355M/405M

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F-57

TROUBLESHOOTING AND REPAIR

POWER BOARD REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the power board for maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver

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3/8” Nut Driver

POWER WAVE 355M/405M

F-57

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F-58

TROUBLESHOOTING AND REPAIR

POWER BOARD REMOVAL AND REPLACEMENT (continued)

F-58

FIGURE F.25 POWER BOARD LOCATION

Power Board

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LEFT SIDE

PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.

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2. Using a 5/16” nut driver remove the case wraparound cover.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the power board. See Figure F.25.

POWER WAVE 355M/405M

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F-59

TROUBLESHOOTING AND REPAIR

POWER BOARD REMOVAL AND REPLACEMENT (continued)

7. Remove the three nuts at the corners of the board
using a 3/8” nut driver. Board is ready for removal.

CAUTION

8. Replace the power board.

Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.

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5. Locate the three plug connections. J41, J42 and
J43 on the Power Board. See figure F.26.

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9. Secure the new power board into its proper position with the three 3/8” nuts previously removed.
10. Reconnect the three plugs previously removed.
Plugs J41, J42 and J43.
11. Replace the case wraparound cover.

6. Carefully disconnect the three plugs from the
Power Board.

FIGURE F.26 – POWER BOARD LEAD LOCATION

J42

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F-59

J41

POWER WAVE 355M/405M

J43

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F-60

NOTES

POWER WAVE 355M/405M

F-60

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F-61

TROUBLESHOOTING AND REPAIR

DC BUS BOARD REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the DC Bus Board for maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver
3/8” Open End Wrench
Flat Head Screwdriver

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Phillips Head Screwdriver

POWER WAVE 355M/405M

F-61

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F-62

TROUBLESHOOTING AND REPAIR

DC BUS BOARD REMOVAL AND REPLACEMENT (continued)

PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

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4. Locate the DC Bus Board. See Figure F.27.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.28.

6. Using a phillips head screwdriver remove the two
screws and their washers from above and below
the input power switch. See Figure F.28.
7. Using a phillips head screwdriver remove the four
screws mounting the two welder output terminals
on the front of the machine. See Figure F.28.
8. The front of the machine may now gently be pulled
forward to gain access to the DC Bus Board.
Note: The front of the machine cannot be removed
completely, only pulled forward a few inches.

FIGURE F.27 DC BUS BOARD LOCATION

DC BUS BOARD

ST
AT
U

S
TH
ER
MA
L

LIN
CO
EL LN
EC
TR

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F-62

POWER WAVE 355M/405M

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F-63

TROUBLESHOOTING AND REPAIR

DC BUS BOARD REMOVAL AND REPLACEMENT (continued)

F-63

FIGURE F.28 CASE FRONT SCREW REMOVAL

STA
ATUS
ST

THERMAL

Phillips Head
Screws

5/16"
Mounting Screws

9. Label and remove two thermostat leads and four
leads from the bus rectifier.

13. Reconnect previously removed leads to their proper locations.

10. Using a 3/8” open end wrench, remove the three
DC Bus Board mounting nuts. See Figure F.29.

14. Replace the four phillips head screws mounting
the two welder output terminals to the front of the
machine.

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12. Secure the new DC Bus Board in its proper location using the 3/8” mounting nuts.

15. Replace the two phillips head screws from above
and below the input power switch.

FIGURE F.29 CASE FRONT SCREW REMOVAL

J47
Bus
Rectifier

3/8" Mounting
Nuts

L11078-1

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11. Replace the DC Bus Board.

J46
POWER WAVE 355M/405M

Thermostat

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TROUBLESHOOTING AND REPAIR

DC BUS BOARD REMOVAL AND REPLACEMENT (continued)

16. Replace the two 5/16” mounting screws to the
bottom of the case front.
17. Replace the case wraparound cover.

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F-64

POWER WAVE 355M/405M

F-64

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F-65

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for maintenance or replacement.

MATERIALS NEEDED
3/16” Allen wrench
5/16” Nut Driver
Flathead Screwdriver
Penetrox A-13 Heatsink Compound

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Silicon Sealant

POWER WAVE 355M/405M

F-65

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F-66

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)

PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case
wraparound cover.

6. Remove the six screws from the terminals using a
flathead screwdriver. Carefully note the position of
all leads and their positions upon removal. See
Figure F.31.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

7. Using a 3/16”in. allen wrench remove the two
mounting screws and washers from the input
bridge. See Figure F.31.

4. Locate the input rectifier. See figure F.30.

8. Remove the input bridge.

5. Carefully remove the silicon sealant insulating the
six input rectifier terminals.

NOTE: Any instructions that are packaged with the
replacement board will supercede these
instructions.

FIGURE F.30 – INPUT RECTIFIER LOCATION

INPUT
RECTIFIER

ST
AT

US
TH

ER
MA
L

LIN
CO
EL LN
EC
TR
IC
WA

R EM

O TE

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F-66

O FF

POWER WAVE 355M/405M

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F-67

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)

9. Apply a thin coat of Penetrox A-13 heatsink compound to the point of contact between the input
rectifier and the mounting surface.
10. Secure the new input bridge into its proper position with the two 3/16”in. allen mounting screws
previously removed. Torque to 44 inch pounds.

11. Reconnect the previously removed leads to their
proper locations. Torque to 31 inch pounds.
12. Cover the input rectifier and its six terminals with
silicon sealant.
13. Replace the case wraparound cover.

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FIGURE F.31 – INPUT RECTIFIER (CLOSE-UP)
Small Lead "H1"
To Auxiliary Transformer

3/16" ALLEN
BOLTS

#207

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#207A

#209

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FRONT
REAR

F-67

Small Lead "A"
To Circuit Breaker

POWER WAVE 355M/405M

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F-68

NOTES

POWER WAVE 355M/405M

F-68

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F-69

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the output rectifier modules
for maintenance or replacement.

MATERIALS NEEDED
3/16” Allen wrench
9/64” Allen wrench
5/16” Nut Driver
7/16” Wrench
Flathead Screwdriver

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Penetrox A-13 Heatsink Compound
Thin Knife/Screwdriver

POWER WAVE 355M/405M

F-69

TROUBLESHOOTING AND REPAIR

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F-70

OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

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4. Locate the output diode modules located behind
the snubber board. See figure F.32.

6. After the snubber board is removed, remove the
four leads connected to the modules using a 3/16”
allen wrench. These leads are #X4, #X2, #20, #40.
Note their positions for reassembly. See Figure
F.33.
7. Remove the copper plates from the tops of the
modules.
NOTE: Any instructions that are packaged with the
replacement part will supercede these instructions.

5. Before the output rectifier modules can be
reached, the Snubber Board Removal
Procedure must be performed.
FIGURE F.32 – OUTPUT RECTIFIER MODULE LEAD LOCATIONS

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Output Diode
Modules
Snubber
Board

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LEFT SIDE
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F-70

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-71

OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
8. Under the copper plate previously removed, there
is an allen bolt. Remove it using a 9/64” allen
wrench. See Figure F.33.

13. The screw threads may catch on the threads of
the heat sink, so be sure to get the face of the
screw into contact with the surface of the module
(using just hand torque).

9. Using a 7/16” socket remove the mounting bolts at
the top and bottom of the modules. See Figure
F.33.

14. Using a 7/16” socket, tighten each mounting bolt
to between 5 and 10 inch pounds.

10. The output rectifier modules are ready for removal
and/or replacement.

15 Tighten the center allen screw to between 12 and
18 inch pounds.

11. Before replacing the diode module, apply a thin
even coat of Penetrox A-13 heatsink compound
to the bottom surface of the diode module. Note:
Keep the compound away from the mounting
holes.

16. Tighten each mounting bolt again (30 to 40 inch
pounds this time).

12. Press the module firmly against the sink while
aligning the mounting holes. Insert each outer
screw through a spring washer and then a plain
washer and into the holes. Start threading all
three screws into the heat sink (2 or 3 turns by
hand).

15. Replace leads #X2, #X4, #20, #40 to their original
terminals in their proper positions. Torque bolts to
30-40 Inch Pounds.
16. Perform the Snubber Board Replacement
Procedure detailed earlier in this section.
17. Replace the case wraparound cover.

FIGURE F.33 – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS

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F-71

Mounting
Bolts

X4 X2

3/16" Allen
Bolts
9/64" Allen
Bolts

Mounting
Bolts
POWER WAVE 355M/405M

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F-72

NOTES

POWER WAVE 355M/405M

F-72

TROUBLESHOOTING AND REPAIR

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F-73

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT

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DESCRIPTION
The following procedure will aid the technician in removing the current transducer for
maintenance or replacement.

MATERIALS NEEDED
5/16” Nut Driver
1/4” Nut Driver
1/2” Nut driver
3/8” Nut Driver
Channel Locks
Flathead Screwdriver

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Phillips Head Screwdriver
Hammer
Crescent Wrench
Pliers

POWER WAVE 355M/405M

F-73

TROUBLESHOOTING AND REPAIR

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F-74

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)

PROCEDURE
4. Using a 5/16” nut driver remove the four screws
from the bottom and right side of the rear assembly. See Figure F.34.

1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

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FIGURE F.34 – CASE BACK SCREW LOCATIONS

REAR
OFF

OFF

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OFF

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Plastic
Nut
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F-74

5/16" Mounting Screws

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-75

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)

5. Label and remove the four leads connected to the
reconnect panel. Pliers may be necessary.
6. Label and remove the two leads connected to the
CB2 circuit breaker.
7. Using a crescent wrench, remove the large plastic
nut from around the input power line located at bottom of the rear assembly. See Figure F.35.

9. Using a hammer and a flathead screwdriver, firmly
tap the metal nut from the bottom of one of its ribs.
This tapping will loosen the nut. Note: Be sure to
tap from the bottom so the nut loosens in a counter
clockwise fashion if viewed from the front of the
machine.
10. Using a 3/8” nut driver label and remove leads
#202, #203, #206, #207A from the reconnect
switches. See Figure F.35.

FIGURE F.35 LEAD LOCATIONS

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8. Locate the steel nut located directly on the other
side of the rear assembly behind the plastic nut
that was previously removed. See Figure F.35.

#206
#202
#207A

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#203

US
TH

ER
M

LIN
CO
EL LN
EC
TR
IC
WA

R EM

O TE

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O FF

t
u
ut
N
N
l
a
t
tic
e
s
M Pla

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-76

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)

11. The back of the machine may now gently be
pulled away to gain access to the current transducer. Note: The rear of the machine cannot be
removed completely.

16. Using a 3/8” wrench, remove the three mounting
screws from the output diode heatsink assembly.
Take note placement of insulation for reassembly.
See Figure F.36.

12. Carefully swing the rear of the machine open to
the left while facing the rear of the machine.

17. Cut any necessary cable ties and carefully remove
the heavy lead from the diode heatsink using a
1/2” nut driver.

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13. Perform the
Procedure.

Snubber

Board

Removal
18. Remove the output diode heatsink assembly
through the rear of the machine.

14. Remove leads #X2 and #20 from the output diode
module.

19. Remove plug #J90 from the current transducer.

15. Remove leads #X4 and #40 from the other output
diode module.

20. Using a 3/8” nut driver, remove the two mounting
nuts from the current transducer.

FIGURE F.36 – OUTPUT HEATSINK MOUNTING SCREW LOCATION

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3/8"
MOUNTING
BOLTS

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F-76

POWER WAVE 355M/405M

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F-77

TROUBLESHOOTING AND REPAIR

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)

29. The rear of the machine may now be placed back
into its original position.

21. Replace the current transducer.
22. Replace the two 3/8” mounting nuts previously
removed.
23. Reconnect plug #J90 to the current transducer.
24. Replace any necessary cable ties previously cut.

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25. From the rear of the machine, replace the heavy
flex lead to the bottom of the output diode
heatsink assembly using a 1/2” wrench. Note:
Don’t forget to include all washers.

30. Using a 3/8” wrench, replace leads #202, #203,
#206, and #207A previously removed from the
reconnect switches.
31. Tighten the metal nut previously removed from the
inside of the rear wall on the back of the machine.
Channel locks may be necessary.
32. Replace the large plastic nut from around input
power line located at the back of the machine.

26. Replace the output diode heatsink assembly previously removed using a 3/8” wrench.

33. Replace the four leads to the reconnect panel in
their proper locations.

Note: Be sure to place insulation in its original
location.

34. Replace the two CB2 circuit breaker leads previously removed.

27. Replace leads X2, #20, X4, #40 previously
removed from the two output diode modules.
Torque to 30-40 inch lbs.

35. Using a 5/16” nut driver, replace the four screws
from the rear assembly.
36. Replace the case wraparound cover.

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28. Perform the Snubber Board Replacement
Procedure.

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F-77

POWER WAVE 355M/405M

TROUBLESHOOTING AND REPAIR

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F-78

RETEST AFTER REPAIR
Retest a machine:
If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s
electrical characteristics.

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If you repair or replace any electrical components.

INPUT IDLE AMPS AND WATTS
Input Volts/Hertz

Maximum Idle Amps

Maximum Idle KW

208/60
230/60
400/60
460/60
575/60

4.0
3.3
2.1
2.0
1.8

0.45
0.45
0.45
0.45
0.45

MAXIMUM OUTPUT VOLTAGES

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Input Volts/Hertz

208/60
230/60
400/60
460/60
575/60

Output Terminals
- No load

50-70 VDC

X1 - X2

115 Volt Receptacles

OCV

10 Amp Load

115 - 123 VAC

111 - 119 VAC

48.5 - 55 VDC

POWER WAVE 355M/405M

TABLE OF CONTENTS - DIAGRAM SECTION

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G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (G4131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Entire Machine Schematic (G4132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Control PC Board Schematic #1 (G3789-1D0/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Control PC Board Schematic #2 (G3789-1D0/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5

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Control PC Board Schematic #3 (G3789-1D0/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Control PC Board Schematic #4 (G3789-1D0/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Control PC Board Assembly (S25385-[ ]for 355, S25425-[ ] for 405) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Digital Power Supply PC Board Schematic (G3631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Digital Power Supply PC Board Assembly (G3632-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*
Switch PC Board Schematic (L11487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
Switch PC Board Assembly (G3830-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Snubber PC Board Schematic (S24761) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
Snubber PC Board Assembly (M19532-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12

Return to Master TOC

40 VDC Buss PC Board Schematic (M19330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
40 VDC Buss PC Board Assembly (L11832-[ ]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*

* NOTE:

Many PC Board Assemblies are now totally encapsulated and are therefore considered to be
unserviceable. The Assembly drawings are provided for reference only.

POWER WAVE 355M/405M

ELECTRICAL DIAGRAMS

RIGHT SIDE OF MACHINE

202

REAR OF MACHINE

CB3

INPUT
BRIDGE

380415V

440460V

N.F.

209

200208V

207A

220230V

207

MAIN
TRANSFORMER

+
_
E
_

TP1

N.E.

COM2
115V

42V

NOTES:

532

CB2

32A

31B
31D

PW405
MODEL

L2
REACTOR

TP2

602

J47

SNB

COM1A

CB2

S
N
U
B
B
E
R

66C
66B

65B

CONTROL
RECTIFIER

32A
31B

CURRENT
TRANSDUCER

PW355
MODEL

N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDSFOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE
TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT; CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES WITH BROWN, BLACK AND BLUE POWER CORDSFOR SINGLE PHASE INPUT: CONNECT GREEN/YELLOW LEAD TO GROUND PER NATIONAL
ELECTRICAL CODE. CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT. WRAP BLACK
LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN/YELLOW GROUND PER NATIONAL ELECTRICAL
CODE. CONNECT BLUE, BLACK & BROWN LEADS TO SUPPLY CIRCUIT.

N.B.
N.C.
N.D.
N.E.
N.F.

802
806
801

477

J90

1 234

J4
8

J2
8

253
251
254

403A

WIRE FEEDER
RECEPTACLE

J41

J43

903

LEFT SIDE OF MACHINE

SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR
550-575V OPERATION (PW405 ONLY GO TO 415VAC)
INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
TOP CENTER
ON PW405, MOV'S ARE IN THE INPUT POWER LINE FILTER.
PANEL
220VWINDING IS ONLY PRESENT ON PW405.

901

VOLTAGE SENSE
RECEPTACLE
51

( )COLORS FOR PW405

G(G/Y)

903B

901B

W(N)
W

R(B)
V

B(U)
U

LEGEND
ALL MACHINES
OPTION
COMPONENT OUTLINE
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
U = BLUE
N = BROWN
Y = YELLOW

FRONT VIEW OF MACHINE

FAN SHROUD CASE FRONT BASE
PROTECTIVE BONDING CIRCUIT
ELECTRICAL SYMBOLS PER E1537

11 12

POWER

R2
10

403

401A 401
405
402
403 406
1

401

403A 401A
408 407
405 410
412 411
402

FLAT SIDE OF LED
ALIGNED WITH
WHITE LEAD

251

254
253

406

407 410
477
412 411 408 475

J42

2 10

502
503

STATUS
RED/GREEN
LED

475

J11

CONTROL
BOARD

12 11 10

65C
65

THERMAL
YELLOW
LED

1104

J10A J10B

5
15

54 53

605
610
612
611

1103 1104

CB1

J46

DC BUS
BOARD

COM1

609
502

65C66C

65
66

608
616
607
615

505

506
503

OUTPUT
RECTIFIER

1B
1W

1 5 8

31 42
532

X4 40

L1
REACTOR

CHOKE

T
OS
BO

1002 1020
1103
1001 1010

5201

J52-11

J52-3

804

2B
716
2W
715

504

J52

TP3

H1 H2 H3 H4 H5 H6
220V

C
SE

901

201

PR
I-O
UT

208

N.C.

204

202

AUXILIARY
TRANSFORMER

Return to Master TOC

505

FAN

( 380-575VAC POSITION )

CB4

Return to Master TOC

+C2,C4

205

FAN FAN

207A

Return to Section TOC

504

PRIMARY
RECONNECT

550575V

Return to Section TOC

3200/300 207

903

PR
I-IN

Return to Master TOC

Return to Section TOC

FAN
FAN
32A
31B

206

201

204

xxxxxxx

J22

203

J21

1010
1020
610
605
608
616
1001
1002

802
804
801
806

208

209

205

PR
I-I

FLAT SIDE OF LED
ALIGNED WITH
BLACK LEAD

203

PR
I-O
UT

C1,C3
3200/300

N.D.

J20

607
615
716
715
611
612
609
602

206

xxxxxxx

SWITCH

J52-1

G-2

WIRING DIAGRAM - POWER WAVE 355/405

xxxxxxx

INPUT
PER
N.A.

Return to Master TOC

WIRING DIAGRAM - POWERWAVE 355/405 - G4131

}

Return to Section TOC

G-2

1
6

J52

J1,J6,J7

8
16

J2,J5,J11,
J22, J41, J46
1

J9, J42

J8,J20,
J21, J47

CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWEDFROM COMPONENT SIDE OF BOARD)

J4, J43

J10A,
J10B
1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

G4131

POWER WAVE 355M/405M

ELECTRICAL DIAGRAMS

ENGINEERING CONTROLLED CHANGE DETAIL: Released from "X"
MANUFACTURER: No

42V
42
15A

J20-7

615

J20-3

J20-5

607

715

612

66B

J46-2

66
66C

J46-3
J46-4

B-OUT
S
X3
0

X2
0

BK-IN

X4
0

506

SNB

503

250 Ohms

FR-IN

X1
X4

506

903B

TP3
150V
80J

THERMOSTAT

C1/TP1 320V
.05uF 160J
600V

611

502

477

COMMON J47-6

+40VDC J47-8
FEEDER

COMMON J47-1

DC BUS
BOARD
(Sch. M19330)

J42-4
J42-1
J42-3

J42-5
J42-2

+5 SPI (b) J43-3
SPI
+15 SPI (b) J43-6
POWER
SUPPLY SPI GND (b) J43-12
+5 RS232 (e) J43-4
RS232
GND (e) J43-9
SUPPLY
J43-11
+20 (c) J43-8
CHOPPER GND (c) J43-2
POWER
SUPPLY +20 (d) J43-7
GND (d) J43-1
CAN

J8-1
J8-2
J8-4
J8-6

32A

2.5A

PW405
MODEL

J9,J42
1
3

J8,J20,
J21,J47
4
1

J4, J43

CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)

6
12

J10A,
J10B
1
2

1
6

J52

3J7

VOLTAGE / FREQUENCY CONVERTER #2 (+)
VOLTAGE / FREQUENCY CONVERTER #2 (-)
PRIMARY CURRENT SENSE #2 (-)
PRIMARY CURRENT SENSE #2 (+)
GND (a)
SOFT START CONTROL
PULSE TRANSFORMER GATE DRIVE
PULSE TRANSFORMER GATE DRIVE
+ 15 (a)
FAN CONTROL

408
410

407
412
408
410

J4-7
J4-12
J4-8
J4-10

POWERDOWN SIGNAL (HIGH=RUN)
+15V (a)

403

403A

411

402
401
406

405
401A

R2
10 Ohms

+5 J43-5
GND J43-10

405

21
67
54
53
1104
1103

GND (a)
-15V (a)

J4-2

+15V SPI (b)

RED/GREEN
LED

FLAT SIDE OF LED
ALIGNED WITH WHITE LEAD

+5V SPI (b)

GND SPI (b)
+5V RS232 (e)

J4-5

GND (e)

J9-6
J9-4
J11-1
J11-2
J11-4
J11-3

N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
N.C. ON PW405, MOV's ARE IN THE INPUT POWER LINE FILTER.
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN SI FOR 550-575V
OPERATION (PW405 ONLY GO TO 415 VAC).

STATUS

+5V (a)

J4-11
J4-1
J4-6

THERMOSTAT

J4-3

402
401A
406

YELLOW
LED

4J7

J6-5
J6-10
J10B-1
J10B-2
J6-11
J6-12
J6-15
J6-7
J7-15
J7-16

NOTES :

7J7

605
610
1010
1020
611
612
615
607
715
716

THERMAL LED

THERMOSTAT

J2-1
J2-3

VOLTAGE SENSE
LINCNET
LINCNET

67
52

J1,J6,J7

STATUS LED (HI FOR GREEN)

8J7

502

407
412

THERMAL

THERMAL LED

J5-3
J5-2

53
54

J2,J5,J11,
J22,J41,J46
2
1

FLAT SIDE OF LED
ALIGNED WITH BLACK LEAD

(+) STUD VOLTAGE SENSE
(-) STUD VOLTAGE SENSE

STATUS LED (HI FOR RED)

31D

CURRENT FEEDBACK ( 4V=500A )
+15V
-15V
CONTROL BOARD COMMON

NEGATIVE

31B

CB4

J9-1
J9-3

901
903

503

POWER DOWN SIGNAL
+15 (a)
+5 (a)
GND (a)
SUPPLY
-15 (a)

J41-2
+40 VDC
J41-1

475

801
802
804
806

+15V
MAIN RELAY CONTROL
VOLTAGE / FREQUENCY CONVERTER #1 (+)
VOLTAGE / FREQUENCY CONVERTER #1 (-)
PRIMARY CURRENT SENSE #1 (-)
PRIMARY CURRENT SENSE #1 (+)

C2/TP2
320V
.05uF 160J
600V

505

POWER MACHINE
BOARD CONTROL
(Sch. G3631) POWER

J6-9
J6-2
J6-16
J6-8
J10A-1
J10A-2

J52-11

J52-3

CB2
532 2.5A

901B

POSITIVE

504

+40VDC POWER J47-3

32A

MAIN CHOKE

505

J46-1

65C

PW355
MODEL
SEE BELOW
FOR PW405

J52-1

REACTOR

504

SOFT
START

801
802
804
806

CURRENT
TRANSDUCER

1010

1020

31B

65B

201

(+)

J20-1

FAN

32A

COM1A

J21-4
J21-8

+15

I OUT J90-3
+15V J90-1
-15V J90-2
GND J90-4

609
602
616
608
1001
1002

CONTROL BOARD
(Sch. G3789)

251
253
254

J2-4

WIRE FEEDER
RECEPTACLE

251

254
253

A LINCNET -

B LINCNET +
C ELECTRODE SENSE

D +40 VDC
E 0VDC

VOLTAGE SENSE
RECEPTACLE
1
2
3
4

ELECTRICAL SYMBOLS PER E1537
LEGEND
ALL MACHINES
OPTION
COMPONENT OUTLINE

DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY& CONFIDENTIAL:THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION

REFERENCE:

ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

SCALE:

ON 2 PLACE DECIMALS IS ± .02

EN-170

ON 3 PLACE DECIMALS IS ± .002

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

DO NOT SCALE THIS DRAWING

DRAWN BY:
ENGINEER:

F.Valencic
L.Petrila

APPROVED: J.O'Connor

G4093

NONE

EQUIPMENT TYPE:
SUBJECT:

MATERIAL
DISPOSITION:

APPROVAL
DATE:

POWERWAVE 355/405
MACHINE SCHEMATIC

7/15/02

PROJECT
NUMBER:

CRM33683

1
1 OF ___
PAGE ___

DOCUMENT
NUMBER:

G4132

DOCUMENT
REVISION:

SOLID EDGE

J20-2
FAN CONTROL
J20-6

J22-4
J22-1
J22-2
FAN POWER
J22-3

(200-208)
(220-230)
(380-415)
(440-460)
(550-575)
H1
H2
H3
H4
H5
H6
COM2

COM1

FAN

J52-8

115V
J52-5

220V
J52-1

716

610

J21-3

xxxxxxx

Return to Master TOC

FAN

115 VAC

605

xxxxxxx

CB2
2.5A

4200 uF

(-)

CB1

5201

Return to Master TOC

207

Shown connected for
200 - 240 Volt Input Voltage

532

V/F CONVERTER # 2

PULSE
TRANSFORMER

Dashed lines represent
copper bus connections.

31B

J21-7

B-IN S

CB3

N.D.

AUXILIARY
TRANSFORMER

X1
0

4200 uF

OUTPUT
DIODES

6.0A

204
A-OUT

NEG

MAIN TRANSFORMER

202

A
GND

208

Return to Master TOC

AC2
AC1

203

REACTOR

TP1

J21-2 608
J21-1 1001
J21-5 1002

SNUBBER
BOARD
(Sch. S24761)

4200 uF

POS

AC3

J21-6 616

V/F CONVERTER # 1

( ) COLOR FOR PW405

TP3 TP2

G GREEN
(GREEN/YELLOW)

Return to Section TOC

205

4200 uF

L1
W WHITE
(BROWN)
INPUT
L2
LINES V RED
(BLACK)
L3
U BLACK
(BLUE)

Return to Section TOC

N.C.

N.B.

602

J20-8

CR1

206

609

J20-4

S
7

209

RECONNECT SWITCH

+15

MAIN
CR1
INPUT
RELAY

A-IN

SWITCH BOARD
(Sch. L11487)

INPUT SWITCH

Return to Section TOC

G-3

xxxxxxx

G4132

Return to Master TOC

SCHEMATIC - COMPLETE MACHINE

Return to Section TOC

G-3

POWER WAVE 355M/405M

Return to Master TOC

SCHEMATIC - DIGITAL CONTROL PC BOARD #1

ELECTRICAL DIAGRAMS

G-4

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

Return to Master TOC

SCHEMATIC - DIGITAL CONTROL PC BOARD #2

ELECTRICAL DIAGRAMS

G-5

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-5

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

Return to Master TOC

SCHEMATIC - DIGITAL CONTROL PC BOARD #3

ELECTRICAL DIAGRAMS

G-6

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-6

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

Return to Master TOC

SCHEMATIC - DIGITAL CONTROL PC BOARD #4

ELECTRICAL DIAGRAMS

G-7

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-7

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

ELECTRICAL DIAGRAMS

Return to Master TOC

Return to Section TOC

G-8

SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD

G-8

+5V

Machine Control Power Supply

R50

D18

D22
1.0A
30V

VCC

OUT

VREF

VFB

RT/CT

COMP 1

GND

100K

R15

R16

OCI1

OUT

CNY17-3
2

C11
22
35V

475

C14
0.1
50V

C47
1.0
35V

1.21K
.33W

Vfb1

R52

1.82K

221K

R14

OV1

R46

D21
1.0A
30V

6.19K

C7
0.1
50V

C6
4.7
35V

C8
820p
50V

R39

R12

56.2K

5.62K

C45
150p
100V
3W
0.05

C32
10p
100V

J41
3

C42

R13

2700p
50V

10.0K
1

GND

C44
0.1
50V

C38
4.7
35V

C40
1.0
35V

DZ1
24V
3W

30.1

R36

R35

R26

1.00K
D2
1A
600V

CNY17-3
2

R34

C26
1
200V

150p
100V

OUT

VREF

VFB

RT/CT

COMP 1

GND

R32
15.0

D20
1.0A
30V

Vfb2

75K

C53
.1

OV2

C4
820p
50V

R31

C2
0.1
50V

C3
4.7
35V

Overvoltage
Shutdown

D10

R29

Q2
21A
200V

J43

DZ7
18V
3W

R28

56.2K

5.62K

249

3W
0.05

J43

R40

3
+t
.13
60V

D16
16A
200V
LED1

+5Volts, 3 Amps
150
.33W

X7
IN

OUT

1A
600V

C5
0.1
50V

C30
1.0
35V

R44

GND

C1
4.7
35V

150
.33W

+5Volts, .100 Amp

OCI3

CNY17-3

J43

D7
1A
600V

.24

C17
4.7
35V

C18
4.7
35V

C21
0.1
50V

2.49K
.33W

C46
150p
100V

.24

150
.33W

T2
8

RS232

C20
4.7
35V

C19
4.7
35V

C22
0.1
50V

R23

+5Volts, .100 Amp
R25

C29
1.0
35V

2700p
50V

10.0K

D6
1A
600V

GND

C9
0.1
50V

C16

R22

7
4

OUT

1.82K
R20

J43

R24

J43
X6

C10
4.7
35V

Vfb2

R21

J43

D1
1A
600V

475K

+20Volts
.200 Amps
Gate Drive

D12

J43

R17

CAN

SPI

J43

D15

2.49K
.33W

R42

332

C33
4.7
35V

Vref 2

44.2K

150
.33W

R18

150
.33W

43.2K

C34
0.1
50V

R43

C35
100
16V

R41

C36
100
16V

R63

C37
100
16V

T2
D13

Return to Master TOC

15Volts, .250Amps
SPI

C28
10p
100V

D17

DZ4
3.3V
3W

1.21K
.33W

OV1
D14

C23
1.0
35V

C25
0.1
50V

C24
4.7
35V

> 55 VDC
OV2

OUT

ADJ

100K
C52
150p

R38

D9
1A
600V

R19

5.62K

R45

gnd_mcps

VCC

15.0K

C27
DZ3
27V
.5W

221K

R62

10.0K

R56

Vref 2

R30

D25

D
4

C49
.022

R33

J42
4

J42

gnd_mcps

C31
.0015
2000V

D23
1.0A
30V

J42

OUT

R64

OCI2

-15Volts, .100Amp

D8
1A
600V

Operation
30-55 VDC

1.21K
.33W

ADJ

+5V

Undervoltage
Detect
<30VDC

8
X1
TL431 REF

R37

R48

J41

DC Input (-)

DZ2
27V
.5W

Return to Section TOC

.750 Amp
1

3A
600V

J42

ADJ

Machine Control
Shut Down
Capacitor

R10

D24
D19

DZ8
18V
3W

Vfb1

+15Volts

Q1
21A
200V

R55

Return to Master TOC

Return to Section TOC

10.0

Vref 1

R51

J41

33.2

R11

33.2
332

D
G

DC Input (+)

Vref 1

D3
1A
600V

C39
0.1
50V

44.2K

R60

R61

C13
1
200V

C41
100
16V

10.0
10.0

J41

C43
100
16V

43.2K

10.0K

+5Volts, .750 Amp

C12
.0015
2000V

R49

10.0K

R27

10.0K

+t
.13
60V

LED2
T1

10-55 VDC
Operation

J42
3

6A
200V

R53

47.5

R57

47.5

R58

47.5

D4
6A
200V

47.5

+20Volts
.200 Amps
Gate Drive

8
X2
TL431 REF
6

J43
11

J43

J43
1

FILENAME: G3631-2D2
GENERAL INFORMATION

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537
MFD ( .022/50V
CAPACITORS =
UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms (
1/4W UNLESS OTHERWISE SPECIFIED)
1A, 400V
DIODES =
(UNLESS OTHERWISE SPECIFIED)

NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.

RC-

LABELS

D-

SUPPLY

VOLTAGE NET

POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

"X" INFO.

Chg. Sheet No.
6-2-2000A
10-27-2000E

DO NOT SCALE THIS DRAWING

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

DESIGN INFORMATION

REFERENCE:

DRAWN BY: JP\TK
ENGINEER:
APPROVED:

SUPERSEDING:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

Digital Systems
Schematic, Digital Power Supply
DATE: 11-30-98 DRAWING No.:

G 3631

SOLID EDGE

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056

EN-170

Return to Master TOC

Return to Section TOC

EARTH GROUND CONNECTION

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.

POWER WAVE 355M/405M

Return to Master TOC

SCHEMATIC - SWITCH PC BOARD

ELECTRICAL DIAGRAMS

G-9

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-9

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

ELECTRICAL DIAGRAMS

R122

C14
DZ16

DZ15

R78

B211

R97

R87

R59
R45

DZ10
Q3

C23

R49
R48
R50

R33

R68

D14

C11

B212
Q5

B204

DZ12

D12

R67
C28
R61

R69
R70

DZ18

DZ19

DZ7

DZ13

R27
DZ20

R100

DZ8

DZ5

DZ6

B206

C24

R82

R28

R79

R22
R26
C6

R129

R53

R52

B205

N.D.
(16 PLACES)

R46
R47
R134

R32

B216

R105
C16

R58
TP1

B209

N.L.

CR2

J22

R138

R137

OCI1
CR1

R140

R139

C25

2
N.H.
(2 PLACES)

OCI4

D18

C27
R141

R109

D19

J20

N.P.

N.N.
(2 PLACES)

N.K.
(4 PLACES)

TRI1

R30

Return to Master TOC

MANUFACTURED AS:

R132

R57

R56

R55

R36
C8

R12

R10
R11

C26

G3830-1B1

PART NO.

IDENTIFICATION CODE

NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY
STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454
BEFORE HANDLING.
N.B. SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD.
N.C. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD (WHERE
POSSIBLE) WITH SEALANT PRIOR TO ENCAPSULATION.
N.D. INJECT SEALANT ITEM 8 THROUGH THE PC BOARD TO SEAL MODULE LEADS
(16 PLACES), AND ALL COMPONENT LEADS ON THE NONO-COMPONENT
SIDE OF THE BOARD, THAT ARE COVERED BY MODULE CASE.
N.E. FEMALE EYELET TO BE AGAINST THE NON-COMPONENT SIDE AS SHOWN
EYELET MUST NOT SPIN AFTER CLINCHING.
N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
NO ICICLES OR SOLDER BLOBS PERMITTED.
N.G. AFTER SOLDERING, INSPECT POWER TERMINAL CONNECTIONS
TO ENSURE SOLDER HAS PROPERLY WET COMPONENT SIDE PAD
ON A MINIMUM OF 3 OF THE 4 LEGS OF THE POWER TERMINAL.
N.H. BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES
AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE.
ENCAPSULATION MATERIAL MUST NOT EXTEND BEYOND THE MOUNTING
SURFACE PLANE. (2 PLACES)
N.J. DO NOT COAT WITH ENCAPSULATION MATERIAL, TOP AND BOTTOM, .80 +/- .05” DIA.
N.K. PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND SEALANT
FOR A DIAMETER OF .50” FOR THE LARGER HOLES, AND .25 FOR THE SMALLER
HOLES, BOTH SIDES OF BOARD. (4 PLACES).
N.L. THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT
PRIOR TO ENCAPSULATION. MATERIAL MUST BE APPLIED FROM TOP TO
COMPLETELY FILL TO UNDERSIDE OF DEVICE. THEN APPLY SEALANT AROUND
BASE OF DEVICE.
N.M. THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH
ITEM 8 PRIOR TO ENCAPSULATION. DO NOT COAT WITH ENCAPSULATION
MATERIAL ON THE TOP SURFACES NOR THE THREADS.
N.N. THESE SURFACES MUST BE MAINTAINEDCO-PLANAR WITHIN .010” THROUGH
ENTIRE SOLDERING AND SEALING PROCESS.
N.P. SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED .17” MAX.

REQ'D

PART NO.

IDENTIFICATION

2
2
2
2
2
2
2
4
9

S20500-4
S13490-130
S20500-7
T11577-57
S13490-93
S16668-7
S20500-1
S16668-6
S16668-5

CAPACITOR,PPMF,.0047,1000V,BOX
CAPACITOR,PCF,0.27,50V,5%
CAPACITOR,PPMF,.047,1600V,BOX,10%
CAPACITOR,PEF,0.1,400V,10%
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,CEMO,820p,50V,5%
CAPACITOR,PPMF,0.1,1000V,10%,BOX
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,CEMO,.022, 50V,20%

3
2
4
9

S16668-9
S14293-18
T12705-59
T12199-1

CAPACITOR,CEMO,150p, 100V,5%
RELAY,DPST,12VDC,AG-CDO
DIODE,AXLDS,3A,600V,UFR
DIODE,AXLDS,1A,400V

T12702-29

ZENER DIODE, 1W,15V,5% 1N4744A

2
4
1
4
2
1
3
1
1
4
1
16

T12702-4
T12702-40
T12702-19
T12702-45
S24016-8
S24016-4
S15000-22
S15000-29
T12704-75
T12704-73
T12704-69
T14648-5

ZENER DIODE, 1W,20V,5% 1N4747A
ZENER DIODE, 1W,6.2V,5% 1N4735A
ZENER DIODE, 1W,12V,5% 1N4742A
ZENER DIODE, 1W,18V,5% 1N4746A
CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN
CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
OPTOCOUPLER,TRIAC,DRV,RANDOM,600V
TRANSISTOR,NMF,T247,4A,900V(SS)
MOSFET,4-PIN DIP,1A,100V,RFD110(SS)
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
RESISTOR,WW,5W,3.3K,5%,SQ

4
6
1
1
1
2
1
12

S19400-1503
S19400-3321
S19400-3570
S19400-1500
S19400-4750
S19400-1652
S19400-39R2
S19400-10R0

RESISTOR,MF,1/4W,150K,1%
RESISTOR,MF,1/4W,3.32K,1%
RESISTOR,MF,1/4W,357,1%
RESISTOR,MF,1/4W,150,1%
RESISTOR,MF,1/4W,475,1%
RESISTOR,MF,1/4W,16.5K,1%
RESISTOR,MF,1/4W,39.2,1%
RESISTOR,MF,1/4W,10.0,1%

4
16

S19400-1000 RESISTOR,MF,1/4W,100,1%
S19400-1003 RESISTOR,MF,1/4W,100K,1%

4
3
14

S19400-6191 RESISTOR,MF,1/4W,6.19K,1%
S19400-2213 RESISTOR,MF,1/4W,221K,1%
S19400-1002 RESISTOR,MF,1/4W,10.0K,1%

2
2
2
2
9

S19400-4752
T12300-79
S19400-3322
S19400-2000
S19400-1001

RESISTOR,MF,1/4W,47.5K ,1%
RESISTOR,WW, 1W,1.0,1%
RESISTOR,MF,1/4W,33.2K,1%
RESISTOR,MF,1/4W,200,1%
RESISTOR,MF,1/4W,1.00K,1%

4
2
2
2
1
2
1
1
2
2

S24376-3
S19400-8251
S19400-2001
S16296-5
S13000-46
M19612
T13640-24
S15161-27
S15128-10
S15128-18

RESISTOR,WW,10W,100,5%
RESISTOR,MF,1/4W,8.25K,1%
RESISTOR,MF,1/4W,2.00K,1%
TRIMMER,MT,1/2W,10K, 10%,LINEAR
TRANSFORMER,PCB;
CURRENT-TRANSDUCER,125-TURN
MOV,175VRMS,120J,20MM
TRIAC,T220,8A,800V
VOLTAGE REF,ADJ, PRECISION,431I
OP-AMP,QUAD, HIGH-PERF,33074

CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTOR = OHMS

N.A.

ITEM
1
2
3
4
5
6
7
8

PART NO.
G3831-B
M16100-44
S23006
M19612
S24866
T9147-11
T9147-15
E2861

DESCRIPTION
P.C. BOARD BLANK
ELECTRONIC MODULE (A1, A2)
TERMINAL (B211,B218,B204,B205,B209)
CURRENT TRANSDUCER (T2, T3)
POWER TERMINAL (B201, B208)
EYELET-FEMALE
EYELET-MALE
SEALANT

QTY
1
2
5
2
2
8
8
5.0oz

MAKE PER E1911
ENCAPSULATE WITH E1844, 3 COATS
TEST PER E3817-SW

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056

NOTE:

ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING

Chg. Sheet No.
6-2-2000A

"X" INFO.

XM5626
XA

DESIGN INFORMATION

REFERENCE:

EQUIPMENT TYPE:

ENGINEER:

SUPERSEDING:

SCALE: FULL

DRAWN BY: F.V./JB
APPROVED:

SUBJECT:

INVERTER WELDERS
SWITCH P.C. BOARD ASSEMBLY

DATE:5-11-2000 DRAWING No.:

G 3830-1B1

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

SOLID EDGE

EN-170

Return to Master TOC

R133

R130

R131
R31

N.B., N.G., N.M.
(5 PLACES)

B202

R101

C30
R142
R143

Return to Section TOC

D17
R106

R29

N.K.
(4 PLACES)

EYELET DETAIL

DZ23

NON-COMPONENT
SIDE

R128

DZ1

.275
.285

N.J.
(8 PLACES)

C21

R81
R80
R66

D20

C7
R51

R34

C13
C20

B217

D16

C31
R35
R60

∅

N.C.

R44

C10

DZ2

R93
C15

B207

R99

R86

B201

R98

DZ17

R41

R43
DZ9

R85

C12

DZ3

B218

C29
R77
R75
R63

R40
R42

DZ4

R21

R19
C5

.105
CRIMP
HEIGHT
MAX.

R84
R62
R76
R64
R74

R73

R120

B208

X2
R15

R .045

R135

R72

C32
R39
R38

R20

B213

C18

OCI2

R125

R65

Return to Master TOC

R92
R107

R14
R13

C1,C23
C10,C11
C2,C24
C25,C26
C3,C18
C31,C32
C4,C21
C5,C6,C15,C16
C7,C12,C13,C14,C20,C27,C28
C29,C30
C8,C9,C22
CR1,CR2
D1,D4,D16,D17
D7,D8,D9,D12,D14,D18,D19
D20,D21
DZ1,DZ2,DZ3,DZ5,DZ6,DZ15
DZ16,DZ18,DZ19,DZ23
DZ11,DZ22
DZ4,DZ7,DZ17,DZ20
DZ8
DZ9,DZ10,DZ12,DZ13
J20,J21
J22
OCI1,OCI2,OCI3
OCI4
N.A. Q1
N.A. Q2,Q3,Q4,Q5
Q6
R1,R2,R3,R4,R7,R8,R9,R10
R124,R125,R126,R127,R130
R131,R132,R133
R11,R12,R30,R31
R13,R39,R43,R60,R81,R92
R137
R138
R139
R14,R107
R140
R15,R20,R21,R22,R27,R28
R97,R98,R99,R100,R101,R106
R29,R83,R122,R141
R32,R33,R34,R48,R49,R50
R51,R62,R63,R74,R75,R85
R86,R87,R134,R135
R35,R52,R73,R84
R36,R37,R123
R38,R40,R42,R45,R53,R59
R66,R69,R70,R72,R80,R82
R142,R143
R41,R67
R44,R68
R46,R76
R47,R64
R5,R6,R19,R26,R93,R105
R109,R128,R129
R55,R56,R57,R58
R61,R77
R65,R120
R78,R79
T1
T2,T3
TP1
TRI1
X1,X4
X2,X3

7
R124

DZ11

R37
C9

OCI3

N.E., N.F.

R127

R126

R83

DZ22

R123
C22

Return to Section TOC

J21

D21

B203

G38301

V35
0
SWITCH

Return to Section TOC

G-10
ITEM

Return to Master TOC

PC BOARD ASSEMBLY - SWITCH PC BOARD

Return to Section TOC

G-10

POWER WAVE 355M/405M

Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-11

SCHEMATIC - SNUBBER PC BOARD

ELECTRICAL DIAGRAMS

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G-11

6-2-2000
S24761

POWER WAVE 355M/405M

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - SNUBBER PC BOARD

M195321

B10

R .045

.105
CRIMP
HEIGHT
MAX.

BOXCP4
2
R4

T14710

RW5F

R2
B30

B20

B40

Return to Master TOC

0
0

.60

1.75

2.90

3.50

PART NO.
M19532-A
T13157-16
T9147-11
T9147-15

DESCRIPTION
P.C. BOARD BLANK
TAB TERMINAL
EYELET-FEMALE
EYELET-MALE

QTY
1
1
4
4

NOTES:
N.A. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN
EYELET MUST NOT SPIN AFTER CLINCHING.
N.B. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
AND ALL AROUND EYELET ON COPPER SIDE ONLY.
NO ICICLES OR SOLDER BLOBS PERMITTED.

COPPER
SIDE

MANUFACTURED AS:

M19532-1A0

MAKE PER E1911
ENCAPSULATE WITH E1844, 2 COATS
TEST PER E3817-SN

IDENTIFICATION CODE

ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

EN-166
Return to Master TOC

.275
.285

+.04

UNLESS OTHERWISE SPECIFIED TOLERANCE

Return to Section TOC

∅

EYELET DETAIL

BOXCP4

RW5F

QC1
6
T14710

RW5F

T14710

BOXCP4
B1

PART NO.
DESCRIPTION
S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX
T14648-20 RESISTOR,WW,5W,150,5%,SQ
T14648-25 RESISTOR,WW,5W,10,5%,SQ

ITEM
1
2
3
4

BOXCP4
C1

SNUBBER

.55

REQ'D
4
2
2

RW5F

Return to Master TOC

Return to Section TOC

N.A., N.B.

2.90 +.04

1.92

ITEM
C1,C2,C3,C4
R1,R3
R2,R4

Return to Section TOC

G-12

DO NOT SCALE THIS DRAWING

NOTE:

Chg. Sheet No.
6-2-2000

"X" INFO.

XM5626
XC-UF

DESIGN INFORMATION

REFERENCE:

ENGINEER:

SUPERSEDING:

DRAWN BY:

APPROVED:

F.V.

EQUIPMENT TYPE:
SUBJECT:

SCALE: NONE

INVERTER WELDERS
SNUBBER P.C. BOARD ASSEMBLY

DATE: 10-6-99

DRAWING No.:

M 19532-1

POWER WAVE 355M/405M

SOLID EDGE

Return to Master TOC

Return to Section TOC

G-12

Return to Master TOC

SCHEMATIC - 40 VDC BUSS PC BOARD

ELECTRICAL DIAGRAMS

G-13

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-13

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

POWER WAVE 355M/405M

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Lincoln Electric Power Wave 355M Users Manual SVM181

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