Lincoln Electric Power Wave 355M Users Manual SVM181

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

2015-02-09

: Lincoln-Electric Lincoln-Electric-Power-Wave-355M-Users-Manual-574379 lincoln-electric-power-wave-355m-users-manual-574379 lincoln-electric pdf

Open the PDF directly: View PDF PDF.
Page Count: 137 [warning: Documents this large are best viewed by clicking the View PDF Link!]

SVM181-A
January, 2008
Safety Depends on You
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
For use with machine code numbers 11141, 11142
POWER WAVE 355M/405M
WARNING
WARNINGAVISO DE
PRECAUCION
ATTENTION
!!
!!
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
Loremipsumdolorsitametconsectetueradipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit,eddiamnon
elit,eddiamnonumm
ummynibheuismodtinciduntut
ynibheuismodtinciduntut
laoreetdoloremagnaaliquamer
laoreetdoloremagnaaliquamerat
at
WARNING
REMOTEPOWER
OFF
ON
POWER W A V E 3 55
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
View Safety Info View Safety Info View Safety Info View Safety Info
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
RETURN TO MAIN MENU
SAFETY
i i
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing 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 posi-
tion 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.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.
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.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase 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.
WARNING
Mar ‘95
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.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
SAFETY
ii ii
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 prod-
ucts.
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.
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.
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.
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.
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.
Aug ‘06
SAFETY
iii iii
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Mar ‘95
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.
CYLINDER may explode
if damaged.
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.
WELDING SPARKS can
cause fire or explosion.
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.
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.
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.
SAFETY
iv iv
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Mar ‘93
PRÉCAUTIONS DE SÛRETÉ
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 suiv-
antes:
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 met-
allique 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 defonc-
tionnement.
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 rayon-
nement 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, pan-
talons sans revers, et chaussures montantes.
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.
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 debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
SAFETY
v v
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems 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;
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
vi vi
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. 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 equip-
ment 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 con-
nection 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.
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 applica-
tions. 1
_________________________
1Portions 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 -
I I
POWER WAVE 355M/405M
RETURN TO MAIN INDEX
Page
Safety ...........................................................................i-vi
Installation..................................................................SectionA
Operation ..................................................................SectionB
Accessories ................................................................SectionC
Maintenance ................................................................SectionD
TheoryofOperation ..........................................................SectionE
TroubleshootingandRepair ...................................................SectionF
ElectricalDiagrams ..........................................................SectionG
PartsManual .............................................................P-418Series
RETURN TO MAIN MENU
TABLE OF CONTENTS - INSTALLATION SECTION
A-1 A-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
Installation.............................................................................A-1
TechnicalSpecifications355M ..........................................................A-2
TechnicalSpecifications405M ..........................................................A-3
Safety Precautions .....................................................................................................................................A-4
Stacking......................................................................................................................................................A-4
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
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
Dip Switch Settings and Locations..........................................................................................................A-13
INSTALLATION
A-2 A-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TECHNICAL SPECIFICATIONS -
POWER WAVE 355
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
(continuous)
* Overall Length Including Handle, 21.6” (549mm) without handle.
Voltage
200
208
230
380
400
415
460
575
200
208
230
380
400
415
460
575
Phases
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
300Amps @
32Volts(100%)
Not
Recommended
76
69
Not
Recommended
Not
Recommended
41
36
31
41
39
36
23
22
22
19
16
350Amps @
34Volts(60%)
Not
Recommended
94
85
Not
Recommended
Not
Recommended
64
42
37
50
50
42
28
27
26
23
18
Line Cord
AWG
2
4
---
6
8
8
6
6
8
8
8
8
8
8
Fuse size
---
125A
125A
---
---
80A
70A
50A
80A
80A
70A
50A
50A
50A
50A
35A
POWER WAVE 355 INPUT CURRENT
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
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.
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
100%
60%
CURRENT
300
350
LENGTH UP 200FT.(61m)
1/0
1/0
200-250 FT. (61-76m)
1/0
2/0
Notes
Note 1
Note 2
Note 2
Note 1
Note 1
Note 2
Note 2
Note 2
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
Power
Wave
355
K2152-1
200-208
220-240
380-415
440-480
575
60/50 HZ
350A / 34V / 60%
1 & 3 Phase
300A / 32V / 100%
1 & 3 Phase
AMPS
5-425
(81.5 lbs.)
(37.0 kg.)
14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm
*Includes
Handles
INSTALLATION
A-3 A-3
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TECHNICAL SPECIFICATIONS -
POWER WAVE 405
INPUT AC VOLTAGE & DC OUTPUT
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
(continuous)
335500AA // 3344VV // 6600%% 1144..77””xx1122..55””xx
PPoowweerr220000--220088 //33 PPhhaassee 2277..88””**
WWaavveeKK 22115522--22 222200--224400// 332200AA // 3333VV // 6600%% AAMMPPSS8866..55llbbss((337733xx331188xx
440055338800--441155//11 PPhhaassee 55--442255((3377..44 kkgg)) 770066**))mmmm
33//5500//6600
6
60
0/
/5
50
0
H
Hz
z
227755AA // 3311VV //110000%%
11 PPhhaassee
330000AA // 3322VV // 110000%%** IInncclluuddeess
33 PPhhaassee hhaannddlleess
* Overall Length Including Handle, 21.6” (549mm) without handle.
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) 61-76m (200-250 FT)
100% 275 1/0 1/0
60% 350 1/0 2/0
POWER WAVE 405 INPUT CURRENT
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
1. Not rated is indicated by 4-x's in the box on the rating plate
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
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
INSTALLATION
A-4 A-4
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DIS-
CONNECT 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.
----------------------------------------------------------------------
WARNING
SAFETY PRECAUTIONS
SELECT SUITABLE LOCATION
In order to assure long life and reliable operation,
the owner of this machine should follow these sim-
ple preventative measures:
• The machine must be located where there is free cir-
culation of clean air such that air movement in the
back, out the sides and bottom will not be restricted.
• 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.
• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.
• 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 volt-
age 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.
CAUTION
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200-
230.
For higher voltages: Position the large switch to
380-575.
• Move the "A" lead to the appropriate terminal.
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.
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.
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.
WARNING
REMOTEPOWER
OFF
ON
A AMPS
A
V VOLTS
WELD TERMINALS
SELECT
OUTPUT
LINCOLN
ELECTRIC
INVERTEC V350-PRO
WARNING
WARNINGAVISO DE
PRECAUCION
ATTENTION
!!
!!
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
CAUTION
Machine
PW 355
PW 405
Cord Length
10 Feet
5 Meters
Lead Color Single Phase Three Phase
Connect to
ground per NEC
Power Lead
Power Lead
Power Lead
Connect to
ground per NEC
Power Lead
Power Lead
Tape, provide
600V insulation
Green
Black
White
Red
INSTALLATION
A-5 A-5
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
14.79
12.44
3.44 21.60
27.82
5.50
10.00
MOUNTING HOLE LOCATIONS
M19527
13.10
1/4-20 NUT (4 PLACES)
NOTE: MOUNTING SCREWS CA
4/01
N NOT PROTRUDE MORE THAN
0.5 INCHES INSIDE THE MACHINE.
11.84
3.50
UNDERCARRIAGE MOUNTINGS
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.
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 weld-
ing characteristics, if undersized welding cables
are used.
------------------------------------------------------------------------
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode 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 con-
tact. 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 additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
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.
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 condi-
tions. 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.
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 con-
trol cable, and is automatically enabled for all semi-
automatic processes. The WORK sense lead (21) con-
nects 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 informa-
tion on the WORK sense lead (21), see"Work Voltage
Sensing” in the following paragraph.
CAUTION
CAUTION
CAUTION
INSTALLATION
A-6 A-6
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
* 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:
• 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.
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.
WARNING
O
N
12 3 456 78
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 auto-
matically configured through software. The 67 elec-
trode 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 config-
ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme-
ly high welding outputs.
------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMATIC POW-
ERFEED WIRE FEEDER INTERCONNEC-
TIONS
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 communica-
tion, and one lead for voltage sensing. The cables are
designed to be connected end to end for ease of exten-
sion. 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 feed-
er, 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.
INSTALLATION
A-7 A-7
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SYSTEM DESCRIPTION
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 sec-
tion for further details.
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 PF-
10 bench model feeder.
The most common Arclink configuration (called a sim-
ple 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 posi-
tion. The same is true for the minimum system consist-
ing of a power source and one UI (Example: a stick
welding system).
FIGURE A.1
System Model
Maximum
Configuration
INSTALLATION
A-8 A-8
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SYSTEM SET-UP
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.
• 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 sys-
tem ignores all ID numbers, therefore “FH0” will func-
tion.
• Each node must be connected to the Linc-Net com-
munication 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.
FIGURE A.2
Simple System
Group and Feed
Head ID numbers are
ignored in a simple
system.
INSTALLATION
A-9 A-9
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE A.3
Multiple Group System
No “FH0 Allowed!
FIGURE A.4
Single Group Multi-Head System
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.
INSTALLATION
A-10 A-10
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE A.5
Single Group Multi-Head System (Alternate Method)
No “FH0 Allowed!
When a standard
User Interface is used
in a group with multi-
ple Feed Heads, all of
the Feed Heads use a
single set of proce-
dures.
INSTALLATION
A-11 A-11
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WELDING WITH MULTIPLE POWER
WAVES
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.
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 puls-
ing 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 cover-
age.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.6)
CAUTION
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.
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communi-
cation 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.
CAUTION
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
Travel
Direction
POWER W
POWER WAAVVE 355/405E 355/405
POWER WPOWER WAAVVE 355/405E 355/405
TWO POWER WAVES
FIGURE A.6
INSTALLATION
A-12 A-12
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
INSTALLATION
A-13 A-13
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
TABLE A.3
VOLTAGE SENSE RECEPTACLE
PIN LEAD# FUNCTION
3 21A Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
PIN LEAD# FUNCTION
2 253 RS232 Receive
3 254 RS232 Transmit
4#Pin5
5#Pin4
6 # # Pin20
20 # # Pin6
7 251 RS232 Common
DIP SWITCH SETTINGS AND
LOCATIONS
DIP switches on the P.C. Boards allow for custom con-
figuration of the Power Wave. To access the DIP switch-
es:
1. Turn off power to the power source at the dis-
connect 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.
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
12 3 456 78
WARNING
CONTROL BOARD DIP SWITCH:
switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8* = work sense lead
switch 8*
work sense lead
off work sense lead not connected
on work sense lead connected
*Factory setting for Switch 8 is OFF.
CONTROL BOARD (DIP Switch Location)
FIGURE A.7
NOTE: For PF10M Dual Boom Feeder set/up and op -
eration. 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).
INSTALLATION
A-14 A-14
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode 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 con-
tact. The electrode cable should be sized according to
the specifications given in the output cable connec-
tions 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 additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
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), tradi-
tional 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).
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.)
B
A
C
FIGURE A.3
POWER
WAVE
WORK
A
C
B
POWER
WAVE
FIGURE A.4
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
C
A
B
WORK
SLIDING WORK
TABLE OF CONTENTS - OPERATION SECTION
B-1 B-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions.......................................................................................................................................B-2
General Description .....................................................................................................................................B-2
Recommended Processes and Equipment .................................................................................................B-2
Required Equipment ....................................................................................................................................B-3
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
Pulse Welding (GMAW-P) ............................................................................................................................B-8
Pulse-on-Pulse (GMAW-PP) ......................................................................................................................B-10
Benefits of Pulse-on-Pulse Welding ..........................................................................................................B-10
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the elec-
trode and drive mechanism are
always electrically energized and
could remain energized several sec-
onds 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.
-----------------------------------------------------------
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.
-----------------------------------------------------------
Observe additional guidelines detailed in the
beginning of this manual.
OPERATION
B-2 B-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process weld-
ing 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 sys-
tem 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 perfor-
mance, digitally controlled inverter welding power
source capable of complex, high-speed waveform con-
trol. Properly equipped, it can support the GMAW,
GMAW-P, FCAW, SMAW, GTAW, and CAC-A process-
es. 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 fac-
tory 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.
WARNING
OPERATION
B-3 B-3
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
REQUIRED EQUIPMENT
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 feed-
ers cannot be used.
• POWER WAVE 355M/405M Output Limitations
The POWER WAVE 355M/405M will support maxi-
mum average output current of 350 Amps @ 60%
duty cycle.
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.
CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates sys-
tem errors. Normal operation is a steady green light.
Error conditions are indicated, per table B.1.
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
Light
Condition
Steady Green
Blinking
Green
Alternating
Green and
Red
Steady Red
Blinking Red
Meaning
System OK. Power source communicating
normally with wire feeder and its components
if other feeder & components show they are
powered up.
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
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.
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 sepa-
rated by a green light.
To clear the error, turn power source off, and
back on to reset.
Non recoverable hardware fault. Generally
indicates nothing is connected to the
POWER WAVE 355M/405M wire feeder
receptacle. See Trouble Shooting Section.
Not applicable.
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper-
ature 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.
OPERATION
B-4 B-4
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE B.1
10
4
6
1
3
2
5
7
8
9
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
The Power Wave is designed to operate with 3/4" elec-
trode stick-out for CV and Pulse processes.
FRINGE PROCEDURES
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.
MAKING A WELD
The serviceability of a product or structure utiliz-
ing 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.
------------------------------------------------------------------------
WARNING
The steps for operating the Power Wave will vary
depending upon the options installed in the user inter-
face (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.
First, consider the desired welding process and the
part to be welded. Choose an electrode material, diam-
eter, shielding gas and process (GMAW, GMAW-P,
etc.)
Second, find the program in the welding software that
best matches the desired welding process. The stan-
dard software shipped with the Power Waves encom-
passes a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales repre-
sentative.
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 con-
tains the switches, knobs, and digital displays neces-
sary 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.
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 para-
meter, controlling all other variables. The user adjusts
WFS according to factors such as weld size, penetra-
tion requirements, heat input, etc. The Power Wave
then uses the WFS setting to adjust its output charac-
teristics (output voltage, output current) according to
pre-programmed settings contained in the Power
Wave.
OPERATION
B-5 B-5
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
• 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 set-
ting of 1.000 is a good starting point for most condi-
tions.
• 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.
• 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 set-
ting 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.
CONSTANT VOLTAGE WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The nominal preprogrammed volt-
age 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 automati-
cally adjusts the voltage level correspondingly to main-
tain similar arc characteristics throughout the WFS
range.
Non Synergic CV:
This type of CV mode behaves more like a convention-
al CV power source. Voltage and WFS are independent
adjustments. Therefore to maintain the arc characteris-
tics, the operator must adjust the voltage to compen-
sate 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)
FIGURE B.2
Current
CURRENT WAVE FORM (CV)
OPERATION
B-6 B-6
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TIG GTAW
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.
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 set-
ting 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 proce-
dure 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
NOTE: Later versions of weld software
eliminated the Arc Control Function
in TIG mode and only allow for
“Touch Start” operation.
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 penetrat-
ing 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 tech-
nique. 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.
MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel
WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L
WIRE SIZE 0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035
GAS 100% Agr. 100% Agr. 100% CD275/25 Ar/CO2100% CD275/25 Ar/CO2100% CD275/25 Ar/CO2Tri-mix Tri-mix
22 ga. Not
recommended 100 / 0.8 Not
recommended 90 / 1.0
20 ga. 120 / 1.0 120 / 1.0 100 / 0.7 100 / 1.0 80 / 1.5 50 / 0.5
18 ga. 140 / 1.7 140 / 1.5 110 / 1.5 110 / 1.5 100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0
16 ga. 190 / 2.0 190 / 2.0 125 / 2.0 125 / 2.0 125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7
14 ga. 400 / 2.0 400 / 2.5 260 / 3.0 260 / 3.0 160 / 2.3 160 / 2.3 160 / 3.8 160 / 3.5 210 / 3.0 190 / 3.5
12 ga. 330 / 5.0 330 / 4.5 230 / 3.5 230 / 3.5 200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0
10 ga. 500 / 7.0 500 / 7.0 300 / 6.0 300 / 6.0 240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0
3/16 570 / 90 600 / 7.8 400 / 7.5 400 / 7.0
1/4 700 / 9.1 700 / 8.5
COMMENTS
Not
Recommended
below 400
WFS
Not
Recommended
below 400
WFS
MATERIAL THICKNESS
WFS / POWER MODE SETTING
TABLE B.2
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 experimenta-
tion until the desired output result is established.
In the Power Mode variables need to be set:
• Wire Feed Speed
• Output
• Arc Control
Setting up a Power Mode procedure is similar to set-
ting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
• For steel, use 75/25 Ar/CO2 shield gas.
• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
Start by setting the wire feed speed based upon mate-
rial 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.
OPERATION
B-7 B-7
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
• Creating a welding groove or grooves in two pieces
of steel butted together. (See Example below)
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".
POWER MODE™
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.
• Aluminum MIG welding.
STEEL BUTTED TOGTHER
WELD GROOVES CREATED BY ARC GOUGING
OPERATION
B-8 B-8
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
SPECIAL WELDING PROCESSES
AVAILABLE ON THIS MACHINE
PULSE WELDING (GMAW-P)
The pulsed-arc process is, by definition, a spray trans-
fer 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.
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” main-
tains the arc between pulses. (See Figure B.3).
FIGURE B.3
PEAK AMPS
FREQUENCY
SPRAY TRANSITION
CURRENT
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
Pulsed MIG is an advanced form of welding that takes
the best of all the other forms of transfer while mini-
mizing 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 appear-
ance. This is especially important with stainless, nick-
el 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.
OPERATION
B-9 B-9
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE B.3
Current
Time
CURRENT WAVE FORM (PULSE)
PULSE WELDING
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 impracti-
cal, and instead the arc length is set by adjusting
"trim".
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.
All pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automati-
cally recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes "adaptive control" to compen-
sate 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 cur-
rent, 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-posi-
tion welding.
OPERATION
B-10 B-10
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PULSE-ON-PULSE™ (GMAW-PP)
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.
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)
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 trans-
fer 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.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
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 val-
ues in the table can be helpful as a starting point to
establish a welding procedure. From there, adjust-
ments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).
The comments on the table below show values of WFS
below which it is not recommended to weld. The rea-
son 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.
PEAK
AMPS
BACKGROUND
AMPS
TIME
HIGH HEAT
PULSES
LOW HEAT
PULSES
"N" PULSES "N" PULSES
Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356
100% Ar. 100% Ar. 100% Ar. 100% Ar.
E4043 E4043 E5356 E5356
0.035 3/64 0.035 3/64
14 ga. 250 / 0 200 / 0 230 / 0 225 / 0
10 ga. 400 / 0 280 / 0 425 / 0 400 / 0
3/16 550 / 0 340 / 0 670 / 0 500 / 0
1/4 600 / 0 400 / 0 700 / 0 550 / 0
WFS /
ARC CONTROL
MATERIAL
THICKNESS
MATERIAL
GAS
WIRE
WIRE SIZE
Not Recommended
below 200 WFS
COMMENTS
Not Recommended
below 200 WFS
Not Recommended
below 100 WFS
Not Recommended
below 200 WFS
WELDING PROCEDURES FOR PULSE-ON-PULSE
TABLE B.3
TABLE OF CONTENTS - ACCESSORIES SECTION
C-1 C-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Equipment ....................................................................................................................................C-2
Field Installed .................................................................................................................................C-2
Compatible Lincoln Equipment......................................................................................................C-2
ACCESSORIES
C-2 C-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
NOTE: No Linc-Net semi-automatic wire feeding equip-
ment is compatible. Specifically, the semi-automatic
Power Feed family (PF-10, PF-10X2, PF-11) will not
work with a PW355M/405M.
TABLE OF CONTENTS - MAINTENANCE SECTION
D-1 D-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions.......................................................................................................................................D-2
Capacitor Discharge Procedure ..................................................................................................................D-2
Visual Inspection..........................................................................................................................................D-2
Routine Maintenance...................................................................................................................................D-2
Periodic Maintenance..................................................................................................................................D-2
Major Component Locations .......................................................................................................................D-3
MAINTENANCE
D-2 D-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
-----------------------------------------------------------------------
WARNING
VISUAL INSPECTION
Clean interior of machine with a low pressure air
stream. Make a thorough inspection of all compo-
nents. 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.
PERIODIC MAINTENANCE
Calibration of the POWER WAVE 355M/405M is critical
to its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improper-
ly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali-
bration of output Voltage and Current should be
checked yearly.
Calibration is accomplished with our Diagnostic Utility
software found on the Lincoln Electric Service
Navigator CD or on our web site at www.lincoln -
electric.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).
All meters used for calibration checks must be calibrat-
ed and traceable to National Standards. Some digital
meters may not function properly with inverter sup-
plies. Try an analog type meter and calibrate around
300 amps @ 30V loading in all cases.
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.
------------------------------------------------------------------------
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 resis-
tor terminals across the two studs in the position
shown. Hold in each position for 1 second. Repeat
for all four capacitors.
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capaci-
tors.
CAPACITOR
TERMINALS
RESISTOR
MAINTENANCE
D-3 D-3
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
WARNINGAVISO DE
PRECAUCION
ATTENTION
!!
!!
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
Lorem ipsum dolor sit amet consectetuer adipiscing
Loremipsumdolorsitametconsectetueradipiscing
elit, ed diam nonummy nibh euismod tincidunt ut
elit,eddiamnonummynibheuismodtinciduntut
laoreet dolore magna aliquam erat
laoreetdoloremagnaaliquamerat
WARNING
REMOTEPOWER
OFF
ON
STATUSTHERMAL
LINCOLN
ELECTRIC
POWER WAVE 355
207
209
5
2
3
1
4
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
1. Center Panel
2. Case Back
3. Case Front
4. Base Assembly
5. Case Wraparound
Use parts page exploded views to also help iso-
late and identify smaller parts. Parts page num-
bers can be found on the Master Table of
Contents in the front of this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
D-4 D-4
POWER WAVE 355M/405M
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1 E-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
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
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
Control Board
Choke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
Current
Feedback
Reconnect
Switch
Output Voltage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
Fan
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
Fan Control
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGBT Drive Signal
Primary
Current
Sensor
Primary
Current
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
65VAC
DC
Bus
Board Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc
Link
Electrode
Sense 21 Lead
Voltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
To
Feeder
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.
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 com-
municate with Arc Link (a digital communications sys-
tem).
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 car-
ries 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 volt-
ages. 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 three different secondary voltages. The
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 limit-
ing 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 con-
trol 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 out-
put will be disabled. Other possible faults may also
cause the input relays to drop out.
THEORY OF OPERATION
E-2 E-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE E.2 - GENERAL DISCRIPTION
Control Board
Choke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
Current
Feedback
Reconnect
Switch
Output Voltage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
Fan
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
Fan Control
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGBT Drive Signal
Primary
Current
Sensor
Primary
Current
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
65VAC
DC
Bus
Board Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc
Link
Electrode
Sense 21 Lead
Voltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
To
Feeder
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
THEORY OF OPERATION
E-3 E-3
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 volt-
age position the capacitor pairs are in parallel - that is,
two series capacitors in parallel with two series capac-
itors. 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 dis-
abling 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 microsec-
ond 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 activat-
ed 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.
FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER
Control Board
Choke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
Current
Feedback
Reconnect
Switch
Output Voltage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
Fan
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
Fan Control
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGBT Drive Signal
Primary
Current
Sensor
Primary
Current
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
65VAC
DC
Bus
Board Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc
Link
Electrode
Sense 21 Lead
Voltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
To
Feeder
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
THEORY OF OPERATION
E-4 E-4
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS
Control Board
Choke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
Current
Feedback
Reconnect
Switch
Output Voltage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
Fan
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
Fan Control
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGBT Drive Signal
Primary
Current
Sensor
Primary
Current
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
65VAC
DC
Bus
Board Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc
Link
Electrode
Sense 21 Lead
Voltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
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 regu-
lates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Power Board and the wire
feed receptacles.
POWER BOARD
The power board, utilizing a switching power supply,
processes the 40VDC input and develops several reg-
ulated positive and negative DC supplies. Three DC
supplies are fed to the control board for machine con-
trol supplies. A +5VDC is used for the RS232 connec-
tion 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 genera-
tor and weld files exist within the Control Board hard-
ware and software. Digital command signals received
from the user interface/feed head and feedback infor-
mation 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 ther-
mostats, 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.
THEORY OF OPERATION
E-5 E-5
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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.
FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE
Control Board
Choke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
Current
Feedback
Reconnect
Switch
Output Voltage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
Fan
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
Main Switch Board
115VAC Fan Supply
Fan Control
V/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
Primary Current Feedback(2)
IGBT Drive Signal
Primary
Current
Sensor
Primary
Current
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
65VAC
DC
Bus
Board Wire
Feeder
Recp.
40VDC
Can Supply +5VDC
Arc
Link
Electrode
Sense 21 Lead
Voltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
To
Feeder
THEORY OF OPERATION
E-6 E-6
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
THERMAL PROTECTION
Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are con-
nected 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 tempera-
tures may be caused by a lack of cooling air or oper-
ating the machine beyond its duty cycle or output rat-
ing. 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 self-
resetting 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 turn-
ing or the air intake louvers are obstructed, then the
power must be removed from the machine, and the
fan problem or air obstruction corrected.
PROTECTIVE CIRCUITS
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.
OVER CURRENT PROTECTION
If the average current exceeds 450 amps for one sec-
ond, 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.
UNDER/OVER VOLTAGE PROTECTION
Protective circuits are included on the switch and con-
trol 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 dis-
abled. 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.
THEORY OF OPERATION
E-7 E-7
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
An IGBT is a type of transistor. IGBT are semiconduc-
tors well suited for high frequency switching and high
current applications.
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 ter-
minal of the IGBT may be connected to a voltage sup-
ply; 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
capable of conducting current. A voltage supply con-
nected to the drain terminal will allow the IGBT to con-
duct 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.
FIGURE E.6 – IGBT
DRAIN
SOURCE GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
DRAIN
SOURCE GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
POSITIVE
VOLTAGE
APPLIED
B. ACTIVE
A. PASSIVE
THEORY OF OPERATION
E-8 E-8
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PULSE WIDTH
MODULATION
The term Pulse Width Modulation is used to describe
how much time is devoted to conduction in the posi-
tive 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.
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 mini-
mum output signal possible over a 50-microsecond
time period.
The positive portion of the signal represents one IGBT
group1conducting for one microsecond. The negative
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.
MAXIMUM OUTPUT
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 indi-
cates that more power is present.
1An IGBT group consists of two IGBT modules feed-
ing one transformer primary winding.
FIGURE E.7 — TYPICAL IGBT OUTPUTS.
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
F-1 F-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
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
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
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
Retest after Repair............................................................................................................................F-78
TROUBLESHOOTING AND REPAIR
F-2 F-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, 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 con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely com-
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent 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.
HOW TO USE TROUBLESHOOTING GUIDE
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.
---------------------------------------------------------------------------------------------------------------------------
WARNING
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.
-----------------------------------------------------------------------------------------------------------------------------------
TROUBLESHOOTING AND REPAIR
F-3 F-3
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems 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.
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:
PC board can be damaged by static electricity.
- Remove your body’s static
charge before opening the static-
shielding 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.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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.
- 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-shield-
ing 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 prop-
er 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 reports 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.
PC BOARD TROUBLESHOOTING PROCEDURES
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
WARNING
CAUTION
OUTPUT PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
TROUBLESHOOTING AND REPAIR
F-4 F-4
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Major physical or electrical damage
is evident when the sheet metal
cover is removed.
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.
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.
2. Check the main input line fuses.
If open , replace.
3. Check the 15 amp circuit break-
er (CB1). Reset if tripped. Also
check CB3.
4. Make sure the reconnect switch
and jumper lead is configured
correctly for the applied input
voltage.
5. If the machine is being operated
with single phase input voltage
make sure the correct lead is not
connected. See the Installation
Section.
1. Perform the Auxiliary Trans -
former Test.
2. Perform the DC Bus Board Test.
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.
The main input fuses (or breaker)
repeatedly fail.
1. Make certain the fuses or break-
ers 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 cur-
rent 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 Output Diode
Module Test.
5. The Input Filter Capacitors may
be faulty. Check, and if any are
faulty replace all four.
OUTPUT PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
TROUBLESHOOTING AND REPAIR
F-5 F-5
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
The machine does not have weld-
ing output.
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.
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.
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.
The POWER WAVE 355M/405M
will not produce full output.
1. The input voltage may be too
low, limiting the output capabili-
ty of the machine. Make cer-
tain the input voltage is correct
for the machine and the recon-
nect 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.
3. The welding current may be too
high . The machine will fold
back to 100 amps if the weld-
ing current exceeds 450 amps.
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.
FUNCTION PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
TROUBLESHOOTING AND REPAIR
F-6 F-6
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
The machine regularly overheats
and the yellow thermal light is ON
indicating a thermal overload.
1. The welding application may
be exceeding the recommended
duty cycle of the POWER WAVE
355M/405M.
2. Dirt and dust may have clogged
the cooling channels inside the
machine.
3. Air intake and exhaust louvers
may be blocked due to inade-
quate clearance around 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.
1. The 115VAC fan motor is con-
trolled by the control board via
the main switch board. Perform
the Fan Motor And Control
Test.
1. A thermostat or associated cir-
cuitry 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.
An attached wire feeder will not
function correctly. Apparently the
wire feeder is not being powered-
up.
1. Make certain the wire feeder
control cable is connected to
the wire feeder receptacle. See
the Wiring Diagram.
2. Check the two circuit breakers
located at the front of the
machine. Reset if tripped.
3. The wire feeder or control cable
may be faulty.
1. Check for 40 VDC on pin “D” (+)
and pin “E” (-) at the Power Wave
wire feeder receptacle. See
Wiring Diagram.
If 40 volts DC is Not present at
the Power Wave wire feeder
receptacle, perform the DC Bus
Board Test.
2. Check the DC Bus Board rectifi-
er. See Wiring Diagram.
3. Perform the T1 Auxiliary trans-
former 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.
FUNCTION PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
TROUBLESHOOTING AND REPAIR
F-7 F-7
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 proce-
dure or reduce the load to lower
the current draw from the Power
Wave machine.
1. Perform the Current
Transducer Test.
2. The control board may be faulty.
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.
FUNCTION PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
TROUBLESHOOTING AND REPAIR
F-8 F-8
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Auxiliary receptacle is “dead” no
auxiliary voltage.
1. Circuit breaker CB1 (on case
front) may have opened. Reset.
2. Circuit breaker CB3 (in recon-
nect area) may have opened.
Reset.
3. On PW 405 models, the circuit
breaker CB4 protects the
220VAC receptacle. Reset if
tripped.
1. Perform the Auxiliary
Transformer Test.
A fault or error code is displayed. 1. See Fault Code Explanations. 1. See Fault Code Explanations.
General degradation of the weld
performance.
1. Check for feeding problems,
bad connections, excessive
loops in cabling, etc.
2. Verify weld mode is correct for
processes.
3. The power source may require
calibration.
4. Check the actual current dis-
played on the Power Feed 10
vs. actual current measured via
external meter.
5. Check the actual voltage dis-
played on the Power Feed 10
vs. actual voltage measured via
external meter.
6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.
1. Perform the Voltage and
Current Calibration Procedure
using the Power Wave software
program.
2. Perform the Current
Transducer Test.
2. Perform the Output Diode
Module Test.
5. The control board may be
faulty.
TROUBLESHOOTING AND REPAIR
F-9 F-9
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 sys-
tem, 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
power source Status LED, and some basic trou-
bleshooting charts for both machine and weld perfor-
mance.
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 nor-
mally 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 (identi-
fying) 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. Not applicable
Status LED is solid red (no blinking). Non-recoverable hardware fault. Generally indi-
cates nothing is connected to the POWER
WAVE 355M/405M wire feeder receptacle. See
Trouble Shooting Section.
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.
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.
To clear the error, turn power source off, and
back on to reset.
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.
STATUS LED ERROR CODE TABLE
TROUBLESHOOTING AND REPAIR
F-10 F-10
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
11
12
CAN communication bus off.
User interface time out error.
Probably due to excessive number of communication errors.
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.
21 Unprogrammed weld mode. Contact the service department for instructions on reloading
the Welding Software.
22 Empty weld table. Contact the service department for instructions on reloading
the Welding Software.
23 Weld table checksum error. Contact the service department for instructions on reloading
the Welding Software.
31 Primary overcurrent error. Excessive Primary current present. May be related to a
short in the main transformer or output rectifier.
32 Capacitor “A” under voltage. Low voltage on the main capacitors. May be caused by
improper input configuration.
33 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.
34 Capacitor “A” overvoltage. Excessive voltage on the main capacitors. May be caused
by improper input configuration.
35 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.
36 Thermal error. Indicates over temperature. Usually accompanied by ther-
mal LED. Check fan operation. Be sure process does not
exceed duty cycle limit of the machine.
37 Softstart error. Capacitor precharge failed. Usually accompanied by codes
32-35.
41 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.
TROUBLESHOOTING AND REPAIR
F-11 F-11
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
43 Capacitor delta error. The maximum voltage difference between the main capaci-
tors has been exceeded. May be accompanied by errors
32-35. Check the output diodes.
Other
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-12 F-12
POWER WAVE 355M/405M
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.
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 trou-
bleshooting 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 pre-
caution, before conducting any test or repair procedure that requires you to touch inter-
nal components of the machine.
MATERIALS NEEDED
5/16” Nut Driver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
DC Volt Meter
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
TROUBLESHOOTING AND REPAIR
F-13 F-13
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-14 F-14
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
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.
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 fig-
ure F.1.
6. Using electrically insulated gloves and pliers, hold
the body of the resistor with the pliers and con-
nect the resistor leads across the two capacitor
terminals. Hold the resistor in place for 10 sec-
onds. DO NOT TOUCH CAPACITOR TERMINALS
WITH YOUR BARE HANDS.
7. Repeat the discharge procedure for the other
three capacitors.
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 dis-
charge procedure.
WARNING
- +- + - +- +
- +- + - +- +
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
GLOVES
INSULATED
PLIERS
EIGHT
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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 ener-
gized.
MATERIALS NEEDED
Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench
MAIN SWITCH BOARD TEST
TROUBLESHOOTING AND REPAIR
F-15 F-15
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-16 F-16
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
MAIN SWITCH BOARD TEST (continued)
FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS
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.
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 resis-
tance tests detailed in Table F.1. Refer to fig-
ure F.2 for test point locations. Note: Test
using an Analog ohmmeter on the Rx1 range.
Make sure the test probes are making electri-
cal contact with the conductor surfaces on the
PC board.
- +- + - +- +
- +- + - +- +
208
201
207
209
204
205
206
203
J21 J20
J22
202
207
TROUBLESHOOTING AND REPAIR
F-17 F-17
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
MAIN SWITCH BOARD TEST (continued)
TABLE F.1. SWITCH BOARD RESISTANCE TEST
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 asso-
ciated 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. Pre-
Torque all leads nuts to 25 inch lbs. before tight-
ening them to 44 inch lbs.
9. Replace the case wraparound cover using a 5/16”
nut driver.
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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-18 F-18
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
INPUT RECTIFIER TEST
TROUBLESHOOTING AND REPAIR
F-19 F-19
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-20 F-20
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
5. Carefully remove the silicone sealant
from leads 207, 207A, and 209.
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 nec-
essary.
INPUT RECTIFIER TEST (CONTINUED)
#207A
#207
#209A
B
C
3/16" ALLEN
BOLTS
FRONT
REAR
Small Lead "A"
To Circuit Breaker
Small Lead "H1"
To Auxiliary Transformer
Figure F.3 Input Rectifier
A
B
C
A
B
C
A
B
C
207
207
207
207A
207A
207A
209
209
209
TROUBLESHOOTING AND REPAIR
F-21 F-21
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 recon-
nect switches. Perform the Main Switch
Board Test. Also check for leaky or
faulty filter capacitors.
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.
11. If the input rectifier is faulty, see the
Input Rectifier Bridge Removal &
Replacement procedure.
12. Replace the case wraparound cover.
INPUT RECTIFIER TEST (CONTINUED)
Table F.2 Input Rectifier Test Points
TEST POINT TERMINALS ANALOG METER
X10 RANGE
207
207
207
207A
207A
207A
209
209
209
A
B
C
A
B
C
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
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
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
+ PROBE - PROBE Acceptable Meter Readings
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-22 F-22
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Wiring Diagram
POWER BOARD TEST
TROUBLESHOOTING AND REPAIR
F-23 F-23
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TEST PROCEDURE
1. Remove input power to the Power Wave
355M/405M.
2. Using the 3/8” nut driver, remove the case
top.
3. Perform the Capacitor Discharge
Procedure.
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.
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
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 pre-
sent at plugs J42 and/or 43, the Power
Board may be faulty.
9. Install the case top using the 3/8” nut driver.
TROUBLESHOOTING AND REPAIR
F-24 F-24
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
J42 J41 J43
FIGURE F.4 – POWER BOARD TEST
J41
2 1
J42
6 5 4
6 5 4 3 2 1
12 11 10 9 8 7
J43
3 2 1
4 3
WARNING
TROUBLESHOOTING AND REPAIR
F-25 F-25
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER BOARD TEST (CONTINUED)
TABLE F.3 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO. OR
IDENTITY
NORMAL
ACCEPTABLE
VOLTAGE
READING
475 477
412
410
408
410
411
410
1103
1104
405
406
401
403
POWER BOARD
CONNECTOR
PLUG J41
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J42
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
POWER BOARD
CONNECTOR
PLUG J43
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
CHECK +15
VDC SUPPLY FROM
POWER BOARD
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD
CHECK +5 VDC
“RS-232” SUPPLY
FROM POWER BOARD
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
2 (+)
1 (-)
1 (+)
5 (-)
3 (+)
5 (-)
2 (+)
5 (-)
5 (+)
10 (-)
4 (+)
9 (-)
3 (+)
12 (-)
477 (+)
475 (-)
412 (+)
410 (-)
408 (+)
410 (-)
411 (+)
410 (-)
1104 (+)
1103 (-)
406 (+)
405 (-)
403 (+)
401 (-)
38 – 42 VDC
+15 VDC
+5 VDC
-15 VDC
+5 VDC
+5 VDC
+5 VDC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-26 F-26
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the DC Bus Power Supply PC Board is receiving and process-
ing the proper voltages.
MATERIALS NEEDED
3/8” Nut driver
Volt/ohmmeter
Wiring Diagram
DC BUS BOARD TEST
TROUBLESHOOTING AND REPAIR
F-27 F-27
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TEST PROCEDURE
1. Remove input power to the machine.
2. Using the 3/8” nut driver, remove the wrap-
around cover.
3. Locate the DC Bus Board. See Figure F.5.
4. Carefully apply input power to the Power
Wave 355M/405M.
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
5. Turn on the Power Wave 355M/405M. The
LED on the DC Bus Power Supply PC Board
should light.
TROUBLESHOOTING AND REPAIR
F-28 F-28
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
DC BUS BOARD
WARNING
REMOTEPOWER
OFF
ON
STATUSTHERMAL
LINCOLN
ELECTRIC
FIGURE F.5 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
FIGURE F.6 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD
DC BUS BOARD TEST (CONTINUED)
J46
J47
475
52
51
477
66 65
L11078-1
J46
J47
Thermostat
Bus
Rectifier
WARNING
TROUBLESHOOTING AND REPAIR
F-29 F-29
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
ELECTRIC SHOCK can kill.
High voltage is present at the ter-
minals of Capacitor C3 near
where testing is to be done.
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.
Plug P46 – Pin 1
Lead 65
Plug P47 – Pin 8(+)
Lead 52
Plug P47 – Pin 3(+)
Lead 477
Plug P46 – Pin 3
Lead 66
Plug P47 – Pin 1(-)
Lead 51
Plug P47 – Pin 6(-)
Lead 475
65 – 75 VDC
38.0 – 42.0 VDC
38.0 – 42.0 VDC
Should be same as the
Bus Rectifier
Supply to the Wire
Feeder Receptacle
Supply to Power Board
Positive Meter Probe
Test Point
Negative Meter Probe
Test Point
Approximate Voltage
Reading
Conditions/Comments
TABLE F.4 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE
WARNING
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-30 F-30
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter
Wiring Diagram
OUTPUT RECTIFIER MODULES TEST
TROUBLESHOOTING AND REPAIR
F-31 F-31
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-32 F-32
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
OUTPUT RECTIFIER MODULES TEST (continued)
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.
3. Remove any output cables and load from the
output terminals.
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 cor-
rect, the test will have erroneous results.
FIGURE F.7 Machine Output Terminals
STSTAATUSTUS THERMALTHERMAL
_+
NEGATIVE
OUTPUT
TERMINAL
POSITIVE
OUTPUT
TERMINAL
TROUBLESHOOTING AND REPAIR
F-33 F-33
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
OUTPUT RECTIFIER MODULES TEST (continued)
5. If 200 ohms is measured then the output
diodes are not “shorted”.
NOTE: There is a 250 ohm resistor across
the welding output terminals. See Wiring
Diagram
6. If less than 200 ohms is measured, one or
more diodes or the snubber board may be
faulty.
7. Perform the Filter Capacitor Discharge
Procedure detailed in the maintenance sec-
tion.
8. Locate the output diode modules and snub-
ber board. See Figure F.9.
9. Test all output diode modules individually.
Test for open diodes also.
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.
Figure F.8 Terminal Probes
_+
- PROBE
+ PROBE
TROUBLESHOOTING AND REPAIR
F-34 F-34
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Figure F.9 Snubber and Output Diode Locations
LEFT SIDE
Snubber
Board
Output Diode
Modules
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of aux-
iliary transformer and also if the correct voltage is being induced on the secondary wind-
ings of the transformer.
MATERIALS NEEDED
Volt-ohmmeter (Multimeter)
5/16” Nut Driver
Wiring Diagram
AUXILIARY TRANSFORMER TEST
TROUBLESHOOTING AND REPAIR
F-35 F-35
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-36 F-36
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
AUXILIARY TRANSFORMER TEST (continued)
TEST 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 Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the auxiliary transformer. See Figure
F.10.
5. Locate the secondary leads and plug P52.
See Figure F.10 and F.11.
FIGURE F.10 Auxiliary Transformer
FIGURE F.11 Plug Lead Connections Viewed From Transformer Lead Side of Plug
WARNING
REMOTEPOWER
OFF
ON
Auxiliary
Transformer
Secondary Lead
Plugs P52
STATUSTHERMAL
LINCOLN
ELECTRIC
Com 2
532
PW405
Only
(220V)
(115V)
(31)
Plug P52
TROUBLESHOOTING AND REPAIR
F-37 F-37
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 proper-
ly. If any of the secondary voltages are miss-
ing or low, check to make certain the primary
is configured correctly for the input voltage
applied. See Wiring Diagram.
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.
TABLE F.5
LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE
COM 2 (31) TO 115V (532) 115 VAC
42 TO COM 1A (quick connects) 42 VAC
AUXILIARY TRANSFORMER TEST (continued)
WARNING
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-38 F-38
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring are function-
ing correctly.
MATERIALS NEEDED
Volt-ohmmeter
5/16” Nut Driver
Grid Bank
External DC Ammeter
CURRENT TRANSDUCER TEST
TROUBLESHOOTING AND REPAIR
F-39 F-39
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-40 F-40
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TEST PROCEDURE
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.
5. Apply the correct input power to the POWER
WAVE 355M/405M.
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 miss-
ing, the control board may be faulty.
FIGURE F.12 Metal Plate Removal & Plug J8 Location
802
801
804
806
Plug J8
FIGURE F.13. Plug J8 Viewed From Lead Side of Plug
WARNING
REMOTE POWER
OFF
ON
Plug J8
STATUSTHERMAL
LINCOLN
ELECTRIC
CURRENT TRANSDUCER TEST (continued)
TROUBLESHOOTING AND REPAIR
F-41 F-41
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
AUXILIARY TRANSFORMER TEST (continued)
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 volt-
ages per Table F.6.
A. Pin 1 (lead 801) to Pin 6 (lead 806) should
read 2.4 VDC (machine loaded to 300
amps).
9. If for any reason the machine cannot be
loaded to 300 amps, Table F.6. shows what
feedback voltage is produced at various cur-
rent loads.
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.
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.
TABLE F.6
OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
300
250
200
150
100
2.4
2.0
1.6
1.2
0.8
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-42 F-42
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
5/16” Nut Driver
FAN CONTROL AND MOTOR TEST
TROUBLESHOOTING AND REPAIR
F-43 F-43
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
FAN CONTROL AND MOTOR TEST (continued)
TROUBLESHOOTING AND REPAIR
F-44 F-44
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
TEST PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M machine.
2. Using the 5/16” nut driver, remove the case
wraparound cover.
3. Perform the Input Filter Capacitor Discharge
Procedure.
4. Locate plug J22 on the main switch board. Do
not remove the plug from the board. See
Figure F.14.
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 PRE-
SENT AT THE MAIN SWITCH BOARD.
207
J21 J20
J22
Plug J22
Fan Lead 12
34
Lead 31B(C)
Lead 32A
Fan Lead
FIGURE F.15 PLUG J22
FIGURE F.14 PLUG J22 LOCATION
FAN CONTROL AND MOTOR TEST (continued)
TROUBLESHOOTING AND REPAIR
F-45 F-45
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Plug J20
Lead 715+
1234
78
65
Lead 716-
7. If the 115VAC is low or not present check cir-
cuit 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 appro-
priate 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.
9. If the 115VAC is NOT present in the previous
step then proceed to the fan control test.
FAN CONTROL TEST PROCEDURE
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 asso-
ciated 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.
4. Replace the case wrap-around cover.
FIGURE F.16 PLUG J20
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-46 F-46
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the control board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
Flathead Screwdriver
Phillips Head Screwdriver
CONTROL BOARD REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-47 F-47
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
TROUBLESHOOTING AND REPAIR
F-48 F-48
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the control board behind the front panel of
the machine. See Figure F.17.
5. Using a 5/16” nut driver remove the two screws
from the bottom of the front of the machine. See
Figure F.18.
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
STSTAATUSTUS THERMALTHERMAL
_+
Phillips Head
Screws
Phillips Head
Screws
5/16"
Mounting Screws
FIGURE F.17 - CONTROL BOARD LOCATION
FIGURE F.18 CASE FRONT SCREW REMOVAL
WARNING
REMOTEPOWER
OFF
ON
Control Board
STATUSTHERMAL
LINCOLN
ELECTRIC
TROUBLESHOOTING AND REPAIR
F-49 F-49
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.
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.
7. Using a phillips head screwdriver remove the four
screws from around the two welder output termi-
nals on the front of the machine. See Figure F.18.
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.
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.
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.
11. Working your way down the left side of the board,
label and remove plugs #J4 and #J2. See Figure
F.19.
CAUTION
WARNING
REMOTEPOWER
OFF
ON
STATUSTHERMAL
LINCOLN
ELECTRIC
J2
J4
J5 J6 J7 J8J9
J10A
J10B
FIGURE F.19 - CONTROL BOARD ALL PLUG LOCATIONS
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-50 F-50
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
13. Cut any necessary cable ties.
14. Replace the control board.
15. Replace the two 3/8” mounting nuts at the top
two corners of the control board.
16. Replace any previously removed cable ties.
17. Replace plugs #J2, #J4, #J5, #J6, #J7, #J8, #J9,
#J10B, and #J10A previously removed.
18. Replace the two screws and their washers from
above and below the input power switch.
19. Replace the four screws from around the two
welder output terminals on the front of the
machine.
20. Replace the two case front mounting screws at
the bottom of the front of the machine.
21. Replace the case wraparound cover.
FIGURE F.20 CONTROL BOARD MOUNTING SCREW LOCATION
Right Side
Mounting
Nuts (3/8")
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
3/8” Nut Driver
MAIN SWITCH BOARD REMOVAL & REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-51 F-51
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-52 F-52
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove the input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in perma-
nent damage to equipment.
4. Locate the main switch board and all associat-
ed plug and lead connections. See figure F.21.
See Wiring Diagram.
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.
CAUTION
FIGURE F.21 – MAIN SWITCH BOARD LEAD LOCATIONS
- +- + - +- +
- +- + - +- +
208
201
207
209
204
205
206
203
J21 J20
J22
202
207
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-53 F-53
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE F.22 – 3/16” ALLEN BOLT LOCATION
- +- + - +- +
- +- + - +- +
207
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.
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
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.
14. Reconnect the three harness plugs previous-
ly 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-54 F-54
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the snubber board for main-
tenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
7/16 Socket or Nut Driver
SNUBBER BOARD REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-55 F-55
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-56 F-56
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the snubber board.. See Figure F.23.
5. Remove small lead #B1 from the board. See
Figure F.24.
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 associ-
ated washers upon removal.
7. Carefully remove the snubber board.
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.
LEFT SIDE
Snubber
Board
FIGURE F.23 – SNUBBER BOARD LOCATION
Lead B1
Lead 30
Lead 10
FIGURE F.24 – SNUBBER BOARD LEADS (CLOSE UP)
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the power board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Nut Driver
POWER BOARD REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-57 F-57
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
POWER BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-58 F-58
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the power board. See Figure F.25.
LEFT SIDE
Power Board
FIGURE F.25 POWER BOARD LOCATION
POWER BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-59 F-59
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Observe static precautions detailed in PC
Board Troubleshooting Procedures at the
beginning of this section.
5. Locate the three plug connections. J41, J42 and
J43 on the Power Board. See figure F.26.
6. Carefully disconnect the three plugs from the
Power Board.
7. Remove the three nuts at the corners of the board
using a 3/8” nut driver. Board is ready for removal.
8. Replace the power board.
9. Secure the new power board into its proper posi-
tion 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.
CAUTION
J42 J41 J43
FIGURE F.26 – POWER BOARD LEAD LOCATION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-60 F-60
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the DC Bus Board for main-
tenance or replacement.
MATERIALS NEEDED
5/16” Nut Driver
3/8” Open End Wrench
Flat Head Screwdriver
Phillips Head Screwdriver
DC BUS BOARD REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-61 F-61
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-62 F-62
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
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.
DC BUS BOARD
WARNING
REMOTEPOWER
OFF
ON
STATUS THERMAL
LINCOLN
ELECTRIC
FIGURE F.27 DC BUS BOARD LOCATION
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-63 F-63
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
9. Label and remove two thermostat leads and four
leads from the bus rectifier.
10. Using a 3/8” open end wrench, remove the three
DC Bus Board mounting nuts. See Figure F.29.
11. Replace the DC Bus Board.
12. Secure the new DC Bus Board in its proper loca-
tion using the 3/8” mounting nuts.
13. Reconnect previously removed leads to their prop-
er locations.
14. Replace the four phillips head screws mounting
the two welder output terminals to the front of the
machine.
15. Replace the two phillips head screws from above
and below the input power switch.
STSTAATUSTUS THERMALTHERMAL
_+
Phillips Head
Screws
Phillips Head
Screws
5/16"
Mounting Screws
FIGURE F.28 CASE FRONT SCREW REMOVAL
FIGURE F.29 CASE FRONT SCREW REMOVAL
L11078-1
J46
J47
3/8" Mounting
Nuts Thermostat
Bus
Rectifier
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-64 F-64
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
16. Replace the two 5/16” mounting screws to the
bottom of the case front.
17. Replace the case wraparound cover.
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for mainte-
nance or replacement.
MATERIALS NEEDED
3/16” Allen wrench
5/16” Nut Driver
Flathead Screwdriver
Penetrox A-13 Heatsink Compound
Silicon Sealant
INPUT RECTIFIER REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-65 F-65
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-66 F-66
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
4. Locate the input rectifier. See figure F.30.
5. Carefully remove the silicon sealant insulating the
six input rectifier terminals.
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.
7. Using a 3/16”in. allen wrench remove the two
mounting screws and washers from the input
bridge. See Figure F.31.
8. Remove the input bridge.
NOTE: Any instructions that are packaged with the
replacement board will supercede these
instructions.
INPUT
RECTIFIER
WARNING
REMOTEPOWER
OFF
ON
STATUSTHERMAL
LINCOLN
ELECTRIC
FIGURE F.30 – INPUT RECTIFIER LOCATION
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-67 F-67
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
9. Apply a thin coat of Penetrox A-13 heatsink com-
pound to the point of contact between the input
rectifier and the mounting surface.
10. Secure the new input bridge into its proper posi-
tion 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.
#207A
#207
#209A
B
C
3/16" ALLEN
BOLTS
FRONT
REAR
Small Lead "A"
To Circuit Breaker
Small Lead "H1"
To Auxiliary Transformer
FIGURE F.31 – INPUT RECTIFIER (CLOSE-UP)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-68 F-68
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Penetrox A-13 Heatsink Compound
Thin Knife/Screwdriver
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-69 F-69
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
TROUBLESHOOTING AND REPAIR
F-70 F-70
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Locate the output diode modules located behind
the snubber board. See figure F.32.
5. Before the output rectifier modules can be
reached, the Snubber Board Removal
Procedure must be performed.
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 instruc-
tions.
LEFT SIDE
Snubber
Board
Output Diode
Modules
FIGURE F.32 – OUTPUT RECTIFIER MODULE LEAD LOCATIONS
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)
TROUBLESHOOTING AND REPAIR
F-71 F-71
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
8. Under the copper plate previously removed, there
is an allen bolt. Remove it using a 9/64” allen
wrench. See Figure F.33.
9. Using a 7/16” socket remove the mounting bolts at
the top and bottom of the modules. See Figure
F.33.
10. The output rectifier modules are ready for removal
and/or replacement.
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.
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).
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).
14. Using a 7/16” socket, tighten each mounting bolt
to between 5 and 10 inch pounds.
15 Tighten the center allen screw to between 12 and
18 inch pounds.
16. Tighten each mounting bolt again (30 to 40 inch
pounds this time).
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.
Mounting
3/16" Allen
Bolts
9/64" Allen
Bolts
X4 X2
Mounting
Bolts
Bolts
40 20
FIGURE F.33 – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTES
F-72 F-72
POWER WAVE 355M/405M
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Phillips Head Screwdriver
Hammer
Crescent Wrench
Pliers
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT
TROUBLESHOOTING AND REPAIR
F-73 F-73
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
WARNING
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-74 F-74
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
PROCEDURE
1. Remove input power to the POWER WAVE
355M/405M.
2. Using a 5/16” nut driver remove the case wrap-
around cover.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
4. Using a 5/16” nut driver remove the four screws
from the bottom and right side of the rear assem-
bly. See Figure F.34.
OFFO FF OFFO FF OFFOF F
Plastic
Nut
5/16" Mounting Screws
REAR
FIGURE F.34 – CASE BACK SCREW LOCATIONS
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-75 F-75
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 bot-
tom of the rear assembly. See Figure F.35.
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.
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.
Metal Nut
Plastic Nut
WARNING
REMOTEPOWER
OFF
ON
STATUSTHERMAL
LINCOLN
ELECTRIC
#203
#207A
#206
#202
FIGURE F.35 LEAD LOCATIONS
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-76 F-76
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
11. The back of the machine may now gently be
pulled away to gain access to the current trans-
ducer. Note: The rear of the machine cannot be
removed completely.
12. Carefully swing the rear of the machine open to
the left while facing the rear of the machine.
13. Perform the Snubber Board Removal
Procedure.
14. Remove leads #X2 and #20 from the output diode
module.
15. Remove leads #X4 and #40 from the other output
diode module.
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.
17. Cut any necessary cable ties and carefully remove
the heavy lead from the diode heatsink using a
1/2” nut driver.
18. Remove the output diode heatsink assembly
through the rear of the machine.
19. Remove plug #J90 from the current transducer.
20. Using a 3/8” nut driver, remove the two mounting
nuts from the current transducer.
3/8"
MOUNTING
BOLTS
FIGURE F.36 – OUTPUT HEATSINK MOUNTING SCREW LOCATION
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-77 F-77
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
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.
26. Replace the output diode heatsink assembly pre-
viously removed using a 3/8” wrench.
Note: Be sure to place insulation in its original
location.
27. Replace leads X2, #20, X4, #40 previously
removed from the two output diode modules.
Torque to 30-40 inch lbs.
28. Perform the Snubber Board Replacement
Procedure.
29. The rear of the machine may now be placed back
into its original position.
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.
33. Replace the four leads to the reconnect panel in
their proper locations.
34. Replace the two CB2 circuit breaker leads previ-
ously removed.
35. Using a 5/16” nut driver, replace the four screws
from the rear assembly.
36. Replace the case wraparound cover.
TROUBLESHOOTING AND REPAIR
F-78 F-78
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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.
OR
If you repair or replace any electrical components.
INPUT IDLE AMPS AND WATTS
MAXIMUM OUTPUT VOLTAGES
RETEST AFTER REPAIR
Input Volts/Hertz
208/60
230/60
400/60
460/60
575/60
Maximum Idle Amps
4.0
3.3
2.1
2.0
1.8
Maximum Idle KW
0.45
0.45
0.45
0.45
0.45
Input Volts/Hertz
208/60
230/60
400/60
460/60
575/60
50-70 VDC 48.5 - 55 VDC
OCV
115 - 123 VAC
10 Amp Load
111 - 119 VAC
Output Terminals
- No load
X1 - X2 115 Volt Receptacles
TABLE OF CONTENTS - DIAGRAM SECTION
G-1 G-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWER WAVE 355M/405M
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
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
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.
ELECTRICAL DIAGRAMS G-2
POWER WAVE 355M/405M
WIRING DIAGRAM - POWERWAVE 355/405 - G4131
NOTES:
N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDS-
FOR 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 CORDS-
FOR 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.
LEFT SIDE OF MACHINE
WIRING DIAGRAM - POWER WAVE 355/405
ELECTRICAL SYMBOLS PER E1537
2
1
6
12
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWEDFROM COMPONENT SIDE OF BOARD)
J4, J43
1
7
J8,J20,
J21, J47
4
8
1
5
J9, J42
3
6
1
4
J2,J5,J11,
J22, J41, J46
2
1
4
3
J1,J6,J7
8
16
1
9
PROTECTIVE BONDING CIRCUIT
J10A,
J10B
LEGEND
ALL MACHINES
OPTION
COMPONENT OUTLINE
FAN
FRONT VIEW OF MACHINE
MAIN
TRANSFORMER
205
201
H3
H2
RECONNECT
H5
H4
FAN
10
X3
20
X2
3
2
6
A
204
A
A
208
B
REAROFMACHINE
30
40
X4
X1
SEC
BOOST
RIGHT SIDE OF MACHINE
7
206
( 380-575VAC POSITION )
207A
CONTROL
BOARD
R(B)
BA
G(G/Y)
W
W(N)
V
C
B(U)
U
2
3
4
1
1
5
403A
402
401A
408
405 410
411
412
407
7
2
3
8
9
46 1
10
5
11
12
2
3
4
1
502
503
1020
1002
H1
B
TP1 TP3
A
A
TP2
C
205
206 203
208
+
201
204
202 207
3200/300
C2,C4
xxxxxxx
209
SWITCH
207
209
207A
203
202
H6
575V
550- 460V
440- 230V
220-
380-
415V 208V
200-
H5 H6
H2 H3 H4
AUXILIARY
TRANSFORMER
H1
7
2
3
8
9
4
6
1
5
10
11
12
13
14
15
16
609
602 611
607
901
903
804
903
2
3
1
6
5
4
7
8
802
806
801
BRIDGE
INPUT
_
+A
B
E
FC
D
_
901
PRIMARY
PRI-IN
PRI-OUT PRI-OUT
PRI-IN
SEC
BOOST
OUTPUT
RECTIFIER
CURRENT
TRANSDUCER
504
505
L2
REACTOR
CHOKE
REACTOR
L1
INPUT
PER
N.A.
}
406
612
608
4
3
2
1
42V COM1
115V
16
15
715
716
615
616
615
607
611
612
3200/300
C1,C3
+
CONTROL
RECTIFIER
41
65
+
C5
42
~
~
66
-
+
610
605
5 8
J21 3
1
J20
1
2
3
6
54
2608
605
616
610
10
30
65B
66B
J90
CB3
S
N
U
B
B
E
R
10
X2
X4
20
40
SNB
1
22
1010
1001
6
715
716
7
8
6
5
1020
1010
1001
1002
FAN
4
12
3
FAN
J22
31B 32A
FAN
COM2
7
84
609
602
503
xxxxxxx
506
N.D.
802
804
801
806
505
J11
J10BJ10A
J8
J9
J7
J6
J1
J5
J4
_
+
903B
R1
901B
4
3
12
251
254
253
J2
N.C.
J47
J46
DC BUS
BOARD
A
2
3
7
8
41
9
5
10
J3
13 25
14
1
251
253
254
405
477 406
401
402
403
408
410
412 411
J43
J41
J42 POWER
65
12
11
4
3
2
10
9
8
7
1
1
12
2
3
3
4
456
407
54 53 1104
1103
21
2 B
2 W
1 B
1 W
8
7
4
3
2 B
2 W
1W
1B
RED/GREEN
STATUS
LED
YELLOW
THERMAL
LED
4
31
2
WIRE FEEDER
RECEPTACLE VOLTAGE SENSE
RECEPTACLE
67
11041103
54
53 51
52
67
L5 L4
L3
BC
E
D3
4
2
1
401
403
2
3
1
6
5
4
7
8
4
3
12
65C66C
65
66
475
477
475
51
52
65C
66C
32A
31B
42 COM1A CB1
41
31
532
401A
403A
L6
CB2
1
220V
PW355
MODEL
CB2 31
532
32A
31B
5201
31D
J52-1 J52-3 J52-11
CB4
PW405
MODEL
xxxxxxx
504
502
J52
()COLORS FOR PW405
N.E.
FLAT SIDE OF LED
ALIGNED WITH
WHITE LEAD
COLOR CODE:
B = BLACK
G = GREEN
R = RED
U = BLUE
N = BROWN
W = WHITE
Y = YELLOW
N.B. 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.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR
550-575V OPERATION (PW405 ONLY GO TO 415VAC)
N.D. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
N.E. ON PW405, MOV'S ARE IN THE INPUT POWER LINE FILTER.
N.F. 220VWINDING IS ONLY PRESENT ON PW405. BASE
CASE FRONT
TOP CENTER
PANEL
FAN SHROUD
N.F.
J52
1
6
5
10
R2
10
FLAT SIDE OF LED
ALIGNED WITH
BLACK LEAD
G4131
A
G-2
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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-3
POWER WAVE 355M/405M
SCHEMATIC - COMPLETE MACHINE
EN-170
G4132
POWERWAVE 355/405
MACHINE SCHEMATIC
NONE
G4093
F.Valencic
L.Petrila
J.O'Connor
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
WITH PUBLISHED STANDARDS.
MATERIAL TOLERANCE (" ") TO AGREE
t
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
G4132
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
RW CRM33683
1
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER: No
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
A
7/15/02
Released from "X"
CHANGE DETAIL:
SOLID EDGE
N.B. N.C.
( ) COLOR FOR PW405
Dashed lines represent
copper bus connections.
N.D.
FLAT SIDE OF LED
ALIGNED WITH BLACK LEAD
SPI
POWER
SUPPLY
GREEN
G
GND
POWER
BOARD
(Sch. G3631)
FAN
FAN
32A
31B
A
H1
C
B
A
BLACK
RED
WHITE
SNB
B1
X10
X40
X30
X20
66B
65B
41
42
406
405
403A
402
401A
PULSE TRANSFORMER GATE DRIVE
PRIMARY CURRENT SENSE #2 (+)
VOLTAGE / FREQUENCY CONVERTER #2 (-)
VOLTAGE / FREQUENCY CONVERTER #2 (+)
PRIMARY CURRENT SENSE #2 (-)
J6-15
801
802
804
806
PRIMARY CURRENT SENSE #1 (+)
VOLTAGE / FREQUENCY CONVERTER #1 (-)
VOLTAGE / FREQUENCY CONVERTER #1 (+)
609
602
616
608
1001
1002
505
504
505
506
503
506
xxxxxxx
POWER DOWN SIGNAL J42-4
J4-1
J4-2
J4-3
GND SPI (b)
+15V SPI (b)
+5V SPI (b)
J10A-2
J10A-1
J6-8
J6-16
J6-2
609
602
616
608
1001
1002 PRIMARY CURRENT SENSE #1 (-)
+15V
MAIN RELAY CONTROL
J6-9
I OUT
-15V
GND
+15V
J90-4
J90-3
J90-2
J90-1
MAIN TRANSFORMER
J21-2
SOFT
START
J20-3
J20-7
(+)
(-)
PULSE
TRANSFORMER
J20-5
J20-1
FAN POWER
FAN CONTROL
J20-6
J20-2
CR1
J20-8
J20-4
J21-3
J21-7
J21-6
FAN
J22-3
J22-2
J22-1
J22-4
J43-9
J43-4
J43-12
J43-6
GND (d)
+20 (d)
SUPPLY
POWER
CHOPPER GND (c)
+20 (c)
J43-1
J43-7
J43-2
J43-8
R1
903B
901B
RS232
SUPPLY
+5 RS232 (e)
GND (e)
+5 SPI (b)
+15 SPI (b)
SPI GND (b)
SUPPLY
POWER
CONTROL
MACHINE
J43-3
GND (a)
-15 (a)
+5 (a)
+15 (a)
J42-2
J42-5
J42-3
J42-1
J41-1
J41-2
SNUBBER
BOARD
(Sch. S24761)
REACTOR
REACTOR
INPUT
LINES
J7-15 + 15 (a)
S
X3
X2
X1
X4
S
BK-IN FR-IN
S
2
3
S
B-IN
S
A-OUT
6
7
S
A-IN
SB-OUT
INPUT SWITCH
TP3
TP1
AC3
AC1
L3
V
WL1
L2 AC2
POS
NEG
U
J21-1
J21-5
J21-8
J21-4
Shown connected for
200 - 240Volt Input Voltage
RECONNECT SWITCH
CR1
MAIN
INPUT
RELAY
V/F CONVERTER # 1
V/F CONVERTER # 2
SWITCH BOARD
(Sch. L11487)
+
-
202
208
+
-
+
J4-5
J4-6
J4-11
J4-10
J4-8
J4-12
J5-2
J5-3
J4-7
J7-16
J6-5
J6-11
J6-7
J6-12
J10B-2
J10B-1
J6-10
J9-3
J9-1
J8-6
J8-4
J8-2
-
203
207
201
204
xxxxxxx
206
209
205
MAIN CHOKE
THERMOSTAT
POWERDOWN SIGNAL (HIGH=RUN)
801
802
804
806
901
903
610
1010
503
502
GND (a)
GND (e)
TRANSDUCER
CURRENT
FAN CONTROL
GND (a)
PULSE TRANSFORMER GATE DRIVE
SOFT START CONTROL
CONTROL BOARD COMMON
THERMOSTAT
THERMOSTAT
407
412
716
605
715
611
607
615
612
1020
(+) STUD VOLTAGE SENSE
(-) STUD VOLTAGE SENSE
+5V RS232 (e)
+5V (a)
411
410
408
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
NOTES :
-15V
+15V
CURRENT FEEDBACK ( 4V=500A )
TP3
C2/TP2
C1/TP1
J8-1
160J
320V
600V
.05uF
80J
150V
160J
320V
600V
.05uF
CONTROL BOARD
(Sch. G3789)
+15V (a)
-15V (a)
POSITIVE
-NEGATIVE
+
COM2
42
COM1
COM1A
J52-8
115V
J52-5
(440-460)
H5
(550-575)
H6
42V
(380-415)
(220-230)
(200-208)
H4
H3
H2
H1
6.0A
AUXILIARY
TRANSFORMER
4200 uF
4200 uF
+40 VDC
250 Ohms
115 VAC
406
405
403
402
401
407
412
411
410
408
610
1010
716
605
715
611
607 615 612
1020
OUTPUT
DIODES
+
-
4200 uF
4200 uF
N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON PW405.
N.C. ON PW405, MOV's ARE IN THE INPUT POWER LINE FILTER.
ONLY. ALL COMPONENTS ARE NOT SHOWN.
TP2
(BROWN)
(BLACK)
(BLUE)
(GREEN/YELLOW)
13 25
14
1
ELECTRICAL SYMBOLS PER E1537
CB3
+15
+15
J2-4
J2-3
J2-1 251
253
254
251
253
254
R2
10 Ohms
LINCNET -
A
LINCNET +
1W
1B
RED/GREEN
STATUS
LED
53
54
67
B
THERMAL LED
THERMAL LED 2B
2W
7J7
3J7
4J7
YELLOW
THERMAL
LED
E
3
0VDC
8J7
L5
ELECTRODE SENSE
STATUS LED (HI FOR RED)
21
C
51
STATUS LED (HI FOR GREEN)
15A 475
477
66C
66
65
65C
+40VDC POWER
52
COMMON
+40VDC
FEEDER
COMMON
CB1
VOLTAGE SENSE
J11-2
J11-1
J9-4
6
12
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
J4, J43
1
7
J8,J20,
J21,J47
4
8
1
5
J9,J42
3
6
1
4
J2,J5,J11,
J22,J41,J46
2
1
4
3
J1,J6,J7
8
16
1
9
J10A,
J10B
2
1
53
54
67
J46-3
J46-4
J46-2
J46-1
J47-3
J47-1
J47-8
J47-6
51
COMPONENT OUTLINE
OPTION
A
LL MACHINES
LEGEND
LINCNET
LINCNET
401A
J43-11
J9-6
21
VOLTAGE SENSE
RECEPTACLE
WIRE FEEDER
RECEPTACLE
J11-3
J11-4
1104
1103
J43-10
J43-5
+5
GND
CAN
C5
220V
J52-1
CB2
2.5A
31
532
32A
31
532
32A
31B
5201
31D
PW355
MODEL
SEE BELOW
FOR PW405
PW405
MODEL
31B
J52-1 J52-3 J52-11
CB4
2.5A
4
2
1
52 D+40 VDC
L4
L3
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION (PW405 ONLY GO TO 415 VAC).
xxxxxxx
504
502
DC BUS
BOARD
(Sch. M19330)
CB2
2.5A
J52 5
10
1
6
FLAT SIDE OF LED
ALIGNED WITH WHITE LEAD
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-4
POWER WAVE 355M/405M
SCHEMATIC - DIGITAL CONTROL PC BOARD #1
G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-5
POWER WAVE 355M/405M
SCHEMATIC - DIGITAL CONTROL PC BOARD #2
G-5
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-6
POWER WAVE 355M/405M
SCHEMATIC - DIGITAL CONTROL PC BOARD #3
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-7
POWER WAVE 355M/405M
SCHEMATIC - DIGITAL CONTROL PC BOARD #4
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-8
POWER WAVE 355M/405M
SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD
.1
C53
Vfb2
Vref 1
100K
R29
CNY17-3
OCI2
42
1
6
5
.5W
27V
DZ2
VFB
CS
COMPRT/CT
VCC
OUT
VREF
GND
X4
2
3
5
1
6
4
8
7
.5W
27V
DZ3
Vref 2
15.0K
R1
4.7
35V
C3
.022
C49
221K
R34
10.0K
R56
100V
150p
C27
200V
1
C26
56.2K
R38
gnd_mcps
1.0A
30V
D23
T2
12
3
+5V
2000V
.0015
C31
50V
0.1
C2
J42
4
50V
0.1
C25
1.0
35V
C23
D10
1.00K
R26
J43
9
D9
4.7
35V
C24
D25
G
D
S
21A
200V
Q2
150p
C52
1.0A
30V
D20
3W
0.05
R30
1.21K
R37
75K
R31
15.0
R32
3W
18V
DZ7
OV2
Detect
600V
1A
30-55 VDC
<30VDC
Undervoltage
1A
600V
ADJ
IN
OUT
X3
1.82K
R20
15
R43
J43
1
5.62K
R28
D2
T2
14
1
OV1
4.7
35V
C1
D15
3W
3.3V
DZ4
D14 D17
4.7
35V
C33
4.7
35V
C10
D1
D12
T2
10
5
50V
0.1
C5
5.62K
R45
GND
IN
OUT
X6
OV2
GND
IN
OUT
X7
1.0
35V
C29
D13
100V
10p
C28
T2
11
4
Shutdown
249
R33
1.0
35V
C30
50V
0.1
C9
J43
5
150
R44
J43
4
150
R25
J43
10
> 55 VDC
Overvoltage
600V
1A
600V
1A
.33W
CAN
+5Volts, .100 Amp
RS232
+5Volts, .100 Amp
.33W
50V
820p
C4
Shut Down
Capacitor
DC Input (+)
1A
OV1
600V
56.2K
R39
J41
1
J41
4
4.7
35V
C6
3W
24V
DZ1
+
t
R55
T1
7
6
100V
10p
C32
50V
820p
C8
J41
3
6.19K
R3
J41
2
D3
VFB
CS
COMPRT/CT
VCC
OUT
VREF
GND
X5
2
3
5
1
6
4
8
7
DC Input (-)
50V
0.1
C7
Machine Control
100K
R10
5.62K
R12
1.0A
30V
D21
GND
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD M AY CHANGE
NUMBER.
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOTES :
15Volts, .250Amps
SPI
.33W
Operation
J43
6
10.0K
R22
J43
3
100V
150p
C46
43.2K
R18
+
t
60V
.13
R40
J43
11
X2
TL431
REF
8
1
6
44.2K
R42
J43
12
CNY17-3
OCI3
42
1
6
5
50V
2700p
C16
Vfb2
Vref 2
+5Volts, 3 Amps
SPI
475K
R21
200V
1
C13
10.0K
R4
6A
200V
D4
10.0K
R27
10.0K
R2
Operation
10-55 VDC
33.2
R15
100
16V
C43
47.5
R58
T1
1
2
11
12
10.0
R60
+
t
60V
.13
R50
10.0
R9
47.5
R6
47.5
R7
10.0
R61
+5Volts, .750 Amp
100
16V
C41
332
R53
50V
0.1
C39
6A
200V
D18
33.2
R16
LED2
+5V
Vref 1
Machine Control Power Supply
47.5
R57
T1
10
3
1.0A
30V
D22
2000V
.0015
C12
J42
3
43.2K
R49
100K
R5
221K
R52
44.2K
R51
50V
2700p
C42
10.0K
R13
CNY17-3
OCI1
42
1
6
5
1.82K
R14
D24
J42
5
J42
2
J42
6
3A
600V
D19
G
D
S
21A
200V
Q1
30.1
R35
475
R8
30.1
R36
3W
18V
DZ8
3W
0.05
R11
T1
5
8
22
35V
C11
50V
0.1
C14
.33W
1.0
35V
C47
1.21K
R46
ADJ
IN
OUT
X8
ADJ
IN
OUT
X9
T1
9
4
1.0
35V
C40
J42
1
X1
TL431
REF
8
1
6
1.21K
R48
50V
0.1
C44
4.7
35V
C38
gnd_mcps
Vfb1
Vfb1
.750 Amp
+15Volts
-15Volts, .100Amp
1A
600V
.33W
D8
100V
150p
C45
2.49K
R23
50V
0.1
C21
J43
2
J43
7
150
R64
J43
8
+
t
.24
R17
150
R62
LED1
2.49K
R19
100
16V
C35
150
R63
332
R41
50V
0.1
C34
100
16V
C37
16A
200V
D16
100
16V
C36
D7
D6
4.7
35V
C19
4.7
35V
C20
T2
8
7
4.7
35V
C18
4.7
35V
C17
T2
13
2
50V
0.1
C22
+
t
.24
R24
.33W
.33W
1A
1A
600V
600V
.33W.33W.33W
.200 Amps
Gate Drive
+20Volts
Gate Drive
+20Volts
.200 Amps
T2
9
6
SOLID EDGE
EN-170
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE
SCALE:
DO NOT SCALE THIS DRAWING
ON 3 PLACE DECIMALS IS ±.002
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.
DESIGN INFORMATION
t
DRAWN BY:
WITH PUBLISHED STANDARDS.
DATE:
ON 2 PLACE DECIMALS IS ±.02
MATERIAL TOLERANCE (" ") TO AGREE
ON ALL ANGLES IS ±.5 OF A DEGREE
SUBJECT:
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
JP\TK
Digital Systems
Schematic, Digital Power Supply
G
NONE 11-30-98
REFERENCE:
SUPERSEDING:
APPROVED: 3631
Chg. Sheet No."X" INFO.
6-2-2000A
10-27-2000E
EARTH GROUND CONNECTION
POWER SUPPLY SOURCE POINT
VOLTAGE NET
SUPPLY
R-
FRAME CONNECTION
LAST NO. USED
COMMON CONNECTION
D-
C-
LABELS
CAPACITORS =
UNLESS OTHERWISE SPECIFIED)
DIODES =
FILENAME: G3631-2D2
MFD
(
GENERAL INFORMATION
UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms (
(UNLESS OTHERWISE SPECIFIED)
1A, 400V
ELECTRICAL SYMBOLS PER E1537
1/4W
.022/50V
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-9
POWER WAVE 355M/405M
SCHEMATIC - SWITCH PC BOARD
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTE: 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 pro-
vided 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.
ELECTRICAL DIAGRAMS G-10
POWER WAVE 355M/405M
PC BOARD ASSEMBLY - SWITCH PC BOARD
SOLID EDGE
EN-170
MANUFACTU RING TOLE RAN CE PER E2056
UNLES S OT HERWISE SP ECIFI ED TOLER ANCE
SCALE:
DO NOT SCALE THIS DRAWING
ON 3 PLACE DECIMALS IS ± .002
THIS SH EET CONTAINS PROPRIETARY INFORMATIO N OWNED BY THE LINC OLN ELECTRIC COMP ANY AND IS NOT TO BE RE PRODUC ED, DIS CLOSED OR USED WITHOUT THE EXPRES S WRITTEN PERMISSION OF THE LINCOLN ELEC TRIC COMPAN Y, C LEVELAND, OHIO U. S.A.
DESIGN INFORMATION
t
DRAWN BY:
WITH PUBLISHED STANDARDS.
DATE:
ON 2 PLACE DECIM ALS IS ± .02
MAT ERIAL TOLERANCE (" ") TO AGREE
ON ALL ANGLES IS ± .5 OF A DEGREE
SUBJECT:
Chg. Sheet No.
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
F.V. /JB
INVERTER WELDERS
SWITCH P.C. BOARD ASSEMBLY
G
FULL 5-11-2000
REFERENCE:
SUPERSEDING:
APPROVED:
"X" INFO.
XM5626
XA
3830-1B1
6-2-2000A
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTOR = OHMS
G3830-1B1
MANUFACTURED AS:
IDENTIFICATION CODE
MAKE PER E1911
ENCAPSULATE WITH E1844, 3 COATS
TEST PER E3817-SW
PART NO.
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.
ITEM PART NO. DESCRIPTION QTY
1 G3831-B P.C. BOARD BLANK 1
N.A. 2 M16100-44 ELECTRONIC MODULE (A1, A2) 2
3 S23006
TERMINAL (B211,B218,B204,B205,B209)
5
4 M19612 CURRENT TRANSDUCER (T2, T3) 2
5 S24866 POWER TERMINAL (B201, B208) 2
6 T9147-11 EYELET-FEMALE 8
7 T9147-15 EYELET-MALE 8
8 E2861 SEALANT 5.0oz
N.E., N.F.
SIDE
NON-COMPONENT
.105
HEIGHT
CRIMP
76
.285
.275
EYELET DETAIL
R.045
MAX.
∅
Q6
D8
2
R63
C15
C31
B20 5
R131
R67
DZ17
OCI2
DZ13
J21
C9
D20
R62
TRI1
R125
C7
C12
R68
D1
R58
R69
R141
R45
R130
T3
R140
R57
R33
R127
C27
CR2
R107
R46
R14
C16
R123
R35
DZ11
B20 4
R59
R105
R4
R3
R29
C8
R38
R75
1
C13
B206
R13
R52
D9
CR1
B212
OCI4
R15
R39
D4
DZ15
R65
R28
R49 R61
D7
R36
C26
R79
C2
DZ22
A1
R138
R84
Q4
X2
R64
B201
R31
C3
DZ1
DZ3
C28
R66
C6
R34
C22
R8
R97
C4
R11
R78
T1
R6
R106
R27
R40
DZ20
DZ7
R74
R30
B203
R26
R41
R100
R72
R50
R44
R43
B216
R87
DZ8
R80
R51
R101
R120
C5
R129
D17
DZ18
R85
C21
B211
R128
DZ2
C32
D12
R10
SWITCH
DZ5
DZ12
2
R53
X4
DZ9
R7
R60
A2
R92
OCI1
R19
R21 DZ6
R70
R143
R98
B21 8
B21 7
B202
R20
R5
Q5
D16
R82
R83
G3830-
1
R32
R122
D19
DZ10
C20
R142
C23
DZ19
DZ4
R1
T2
R86
D14
X1
DZ16
Q3
R124
R132
C18
X3
C14
1
R134
R42
R9
R73
D18
R133
C24
R77
R81
B208
D21
R48
R139
B209
J20
Q2
B20 7
C29
R109
C10
C30
TP1
R76
C25
Q1
R55
R2
B21 3
R22
R99
J22
OCI3
R135
C1
R47
C11
R56
R37
R126
V35
0
R12
R93
R137
DZ23
A1
5
4
3
1
2
N.N.
(2 PLACES) N.H.
(2 PLACES)
N.D.
(16 PLACES)
N.K.
(4 PLACES)
N.K.
(4 PLACES)
N.B., N.G., N.M.
(5 PLACES)
N.C.
N.L.
N.J.
(8 PLACES)
N.P.
C1,C23 2S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX
C10,C11 2 S13490-130 CAPACITOR,PCF,0.27,50V,5%
C2,C24 2 S20500-7 CAPACITOR,PPMF,.047,1600V,BOX,10%
C25,C26 2 T11577-57 CAPACITOR,PEF,0.1,400V,10%
C3,C18 2 S13490-93 CAPACITOR,TAEL,27,35V,10%
C31,C32 2 S16668-7 CAPACITOR,CEMO,820p,50V,5%
C4,C21 2 S20500-1 CAPACITOR,PPMF,0.1,1000V,10%,BOX
C5,C6,C15,C16 4 S16668-6 CAPACITOR,CEMO,4700p,50V,10%
C7,C12,C13,C14,C20,C27,C28 9 S16668-5 CAPACITOR,CEMO,.022, 50V,20%
C29,C30
C8,C9,C22 3 S16668-9 CAPACITOR,CEMO,150p, 100V,5%
CR1,CR2 2 S14293-18 RELAY,DPST,12VDC,AG-CDO
D1,D4,D16,D17 4 T12705-59 DIODE,AXLDS,3A,600V,UFR
D7,D8,D9,D12,D14,D18,D19 9 T12199-1 DIODE,AXLDS,1A,400V
D20,D21
DZ1,DZ2,DZ3,DZ5,DZ6,DZ15 10 T12702-29 ZENER DIODE, 1W,15V,5% 1N4744A
DZ16,DZ18,DZ19,DZ23
DZ11,DZ22 2 T12702-4 ZENER DIODE, 1W,20V,5% 1N4747A
DZ4,DZ7,DZ17,DZ20 4 T12702-40 ZENER DIODE, 1W,6.2V,5% 1N4735A
DZ8 1 T12702-19 ZENER DIODE, 1W,12V,5% 1N4742A
DZ9,DZ10,DZ12,DZ13 4 T12702-45 ZENER DIODE, 1W,18V,5% 1N4746A
J20,J21 2 S24016-8 CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN
J22 1 S24016-4 CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN
OCI1,OCI2,OCI3 3 S15000-22 OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
OCI4 1 S15000-29 OPTOCOUPLER,TRIAC,DRV,RANDOM,600V
N.A. Q1 1 T12704-75 TRANSISTOR,NMF,T247,4A,900V(SS)
N.A. Q2,Q3,Q4,Q5 4 T12704-73 MOSFET,4-PIN DIP,1A,100V,RFD110(SS)
Q6 1 T12704-69 TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
R1,R2,R3,R4,R7,R8,R9,R10 16 T14648-5 RESISTOR,WW,5W,3.3K,5%,SQ
R124,R125,R126,R127,R130
R131,R132,R133
R11,R12,R30,R31 4 S19400-1503 RESISTOR,MF,1/4W,150K,1%
R13,R39,R43,R60,R81,R92 6 S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
R137 1 S19400-3570 RESISTOR,MF,1/4W,357,1%
R138 1 S19400-1500 RESISTOR,MF,1/4W,150,1%
R139 1 S19400-4750 RESISTOR,MF,1/4W,475,1%
R14,R107 2 S19400-1652 RESISTOR,MF,1/4W,16.5K,1%
R140 1 S19400-39R2 RESISTOR,MF,1/4W,39.2,1%
R15,R20,R21,R22,R27,R28 12 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%
R97,R98,R99,R100,R101,R106
R29,R83,R122,R141 4 S19400-1000 RESISTOR,MF,1/4W,100,1%
R32,R33,R34,R48,R49,R50 16 S19400-1003 RESISTOR,MF,1/4W,100K,1%
R51,R62,R63,R74,R75,R85
R86,R87,R134,R135
R35,R52,R73,R84 4 S19400-6191 RESISTOR,MF,1/4W,6.19K,1%
R36,R37,R123 3 S19400-2213 RESISTOR,MF,1/4W,221K,1%
R38,R40,R42,R45,R53,R59 14 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
R66,R69,R70,R72,R80,R82
R142,R143
R41,R67 2 S19400-4752 RESISTOR,MF,1/4W,47.5K ,1%
R44,R68 2 T12300-79 RESISTOR,WW, 1W,1.0,1%
R46,R76 2 S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
R47,R64 2 S19400-2000 RESISTOR,MF,1/4W,200,1%
R5,R6,R19,R26,R93,R105 9 S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
R109,R128,R129
R55,R56,R57,R58 4 S24376-3 RESISTOR,WW,10W,100,5%
R61,R77 2 S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
R65,R120 2 S19400-2001 RESISTOR,MF,1/4W,2.00K,1%
R78,R79 2 S16296-5 TRIMMER,MT,1/2W,10K, 10%,LINEAR
T1 1 S13000-46 TRANSFORMER,PCB;
T2,T3 2 M19612 CURRENT-TRANSDUCER,125-TURN
TP1 1 T13640-24 MOV,175VRMS,120J,20MM
TRI1 1 S15161-27 TRIAC,T220,8A,800V
X1,X4 2 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I
X2,X3 2 S15128-18 OP-AMP,QUAD, HIGH-PERF,33074
ITEM REQ'D PART NO. IDENTIFICATION
G-10
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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 Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-11
POWER WAVE 355M/405M
SCHEMATIC - SNUBBER PC BOARD
S24761
6-2-2000
G-11
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
NOTE: 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 pro-
vided 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.
ELECTRICAL DIAGRAMS G-12
POWER WAVE 355M/405M
PC BOARD ASSEMBLY - SNUBBER PC BOARD
EN-166
SOLID EDGE
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE
SCALE:
DO NOT SCALE THIS DRAWING
ON 3PLACE DECIMALS IS ± .002
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.
DESIGN INFORMATION
t
DRAWN BY:
WITH PUBLISHED STANDARDS.
DATE:
ON 2PLACE DECIMALS IS ± .02
MATERIAL TOLERANCE (" ") TO AGREE
ON ALL ANGLES IS ± .5 OF A DEGREE
SUBJECT:
Chg. Sheet No.
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
F.V.
INVERTER WELDERS
SNUBBER P.C. BOARD ASSEMBLY
M
NONE 10-6-99
REFERENCE:
SUPERSEDING:
APPROVED:
"X" INFO.
XM5626
XC-UF
19532-1
6-2-2000
N.A., N.B.
SIDE
COPPER
.105
HEIGHT
CRIMP
.285
.275
EYELET DETAIL
R.045
MAX.
∅
4
3
B20
T14710
R2
1 2
RW5F
C2
BOXCP4
B30
T14710
R3
1 2
RW5F
C3
BOXCP4
B40
T14710
R4
1 2
RW5F
C4
BOXCP4
B1
QC1
6
C1
BOXCP4
B10
T14710
R1
1 2
RW5F
SNUBBERM19532-
1
0
.55
1.92
2.90 +.04
0
.60 1.75 2.90 3.50 +.04
1
2
MAKE PER E1911
ENCAPSULATE WITH E1844, 2 COATS
TEST PER E3817-SN
M19532-1A0
MANUFACTURED AS:
IDENTIFICATION CODE
ITEM PART NO.
DESCRIPTION
QTY
1 M19532-A P.C. BOARD BLANK 1
2 T13157-16 TAB TERMINAL 1
3T9147-11 EYELET-FEMALE 4
4 T9147-15 EYELET-MALE 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.
ITEM REQ'D PART NO. DESCRIPTION
C1,C2,C3,C4 4 S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX
R1,R3 2 T14648-20 RESISTOR,WW,5W,150,5%,SQ
R2,R4 2 T14648-25 RESISTOR,WW,5W,10,5%,SQ
G-12
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMS G-13
POWER WAVE 355M/405M
SCHEMATIC - 40 VDC BUSS PC BOARD
G-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Navigation menu