Lincoln Electric Power Wave Svm156 A Users Manual

SVM156-A to the manual ab7b28c4-cf35-45da-89fe-87a300e58766

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SVM156-A
October, 2001
TM

POWER WAVE 455/R
For use with machines having Code Numbers: 10675
10676

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Safety Depends on You

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

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IEC 60974-1

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SERVICE MANUAL

• World's Leader in Welding and Cutting Products •
• 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

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SAFETY

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

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

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

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

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________

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

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.

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.

Mar ‘95

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ELECTRIC SHOCK can kill.

ARC RAYS can burn.

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.

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.

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.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

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.

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.

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

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SAFETY

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.

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. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. 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.d. 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.

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5.e. Also see item 1.b.

Mar ‘95

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iii

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.

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

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iii

SAFETY

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.

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

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

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Mar ‘95

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

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
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU
Page
Safety .................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance ..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams ..............................................................................................................Section G
Parts Manual ................................................................................................................................P-377

POWER WAVE 455/R

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Section A

TABLE OF CONTENTS
- INSTALLATION SECTION -

Installation.............................................................................................................................Section A
Technical Specifications ..............................................................................................................A-2
Safety Precautions ......................................................................................................................A-4
Select Suitable Location..............................................................................................................A-4
Lifting ....................................................................................................................................A-4
Stacking ................................................................................................................................A-4
Machine Grounding.....................................................................................................................A-4
High Frequency Protection..........................................................................................................A-4
Input Connection .........................................................................................................................A-5

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Input Fuse and Supply Wire Considerations ........................................................................A-5
Input Voltage Change Over (For Multiple Input Voltage Machines Only).............................A-6
Welding with Multiple Power Waves ...........................................................................................A-6
Electrode and Work Cable Connections .....................................................................................A-7
Negative Electrode Polarity.........................................................................................................A-7
Voltage Sensing ..........................................................................................................................A-8
Work Voltage Sensing ..........................................................................................................A-9
Electrode Voltage Sensing ...................................................................................................A-9
Power Wave / Power Feed Wire Feeder Interconnections.........................................................A-9
Control Cable Specifications ................................................................................................A-9
External I/O Connector .........................................................................................................A-9

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Dip Switch Settings and Locations .....................................................................................A-10
Control Board Dip Switch ...................................................................................................A-10
Feed Head Board Dip Switch .............................................................................................A-10
Devicenet/Gateway Board Dip Switch, Bank (S2)..............................................................A-11

POWER WAVE 455/R

Section A

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A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT
VOLTS

OUTPUT
CONDITIONS

INPUT
CURRENT
AMPS

(K1761-1)
208/230/460V - 60HZ

450A@38V 100%
570A@43V 60%

70/65/35
87/82/48

200/220/440V - 50HZ

400A@36V 100%
500A@40V 60%

64/58/32
79/74/41

(K1761-2)
208/230/460/575V-60HZ

450@38V 100%
570@43V 60%

58/53/25/22
82/78/37/31

200/220/440V - 50HZ

400@36V 100%
500A@40V 60%

49/45/23
67/61/31

IDLE
POWER

POWER FACTOR
EFFICIENCY
@ RATED OUTPUT @ RATED OUTPUT

0.89 MIN
400 Watts
MAX

88%
0.95 MIN

OUTPUT
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A-2

OPEN
CIRCUIT
VOLTAGE
75 VDC

PULSE
CURRENT
PULSE AND
PULSE
STT
AUXILIARY POWER
FREQUENCY VOLTAGE BACKGROUND PARAMETERS (CIRCUIT BREAKER
RANGE
TIME RANGE
RANGE
PROTECTED)
5 - 570

0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. 40-325 AMPS
-3.3 SEC.

PROCESS CURRENT RANGES (DC)

40 VDC @10 AMPS
115VAC @10 AMPS

CURRENT

MIG/MAG
FCAW
SMAW
Pulse
STT

50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
40-325 Average Amps

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RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE /
FREQUENCY

(K1761-1)
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
(K1761-2)
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ

AMPS/
DUTY
CYCLE

INPUT AMPERE
TYPE 75°C
TYPE 75°C
TYPE 75°C
RATING ON
COPPER WIRE GROUND WIRE (SUPER LAG)
IN CONDUIT
IN CONDUIT
OR BREAKER
NAMEPLATE
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)
(mm2)
(mm2)

450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
500/60%
500/60%

70/65
35
64/58
32
87/82
48
79/74
41

4
8
4
8
4
8
4
8

(25)
(10)
(25)
(10)
(25)
(10)
(25)
(10)

8 (10)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
8 (10)
10 (6)

90/90
45
90/80
45
110/110
70
100/100
60

450/100%
450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
570/60%
500/60%
500/60%

58/53
25
22
49/45
23
82/78
37
31
67/61
31

4 (25)
10 (6)
10 (6)
6 (10)
10 (6)
4 (25)
8 (10)
10 (6)
8 (10)
10 (6)

8 (10)
10 (6)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
10 (6)
8 (10)
10 (6)

70/60
35
30
70/60
30
110/100
50
40
90/80
40

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A-3

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
(continued)
PHYSICAL DIMENSIONS
HEIGHT

WIDTH

DEPTH

26.10 in
663 mm

19.86 in
505 mm

32.88 in
835 mm

WEIGHT
(K1761-1) 247 lbs.
112 kg.
(K1761-2) 254 lbs.
115 kg.

TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
-40°C to +40°C

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OPERATING TEMPERATURE RANGE
-20°C to +40°C

POWER WAVE 455/R

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A-4

INSTALLATION

SAFETY PRECAUTIONS

CAUTION

Read this entire installation section before you
start installation.

WARNING
ELECTRIC SHOCK can kill.

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.

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• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this
equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

LIFTING

• Do not touch electrically hot parts.

STACKING

• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to a
proper safety (Earth) ground.

Power Wave machines can be stacked a maximum of
three high.

CAUTION
SELECT SUITABLE LOCATION

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Do not use Power Waves in outdoor environments. The
Power Wave power source should not be subjected to
falling water, nor should any parts of it be submerged
in water. Doing so may cause improper operation as
well as pose a safety hazard. The best practice is to
keep the machine in a dry, sheltered area.

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Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at
a minimum. Do not use air filters on the air intake,
because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N.
(fan as needed) circuitry. The fan runs whenever the
output is enabled, whether under loaded or open circuit
conditions. The fan also runs for a period of time
(approximately 5 minutes) after the output is disabled,
to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing
the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the
output of the solid state fan control relay, located on the
back of the Control PC board enclosure. (See the
Wiring Diagram.)

The bottom machine must always be placed on a firm,
secure, level surface. There is a danger of machines
toppling over if this precaution is not taken.

MACHINE GROUNDING
The frame of the welder must be grounded. A ground
terminal marked with the symbol
is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.

HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.

CAUTION
The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the
equipment.

POWER WAVE 455/R

A-5

INSTALLATION

. Disconnect input power before

inspecting or servicing machine.

VOLTAGE=200-208V

W / L3
V / L2

200-208V

CR1

220-230V

U / L1

380-415V

Do not operate with covers
removed.

'A'

440-460V

ELECTRIC . Do not touch electrically live parts.
SHOCK
Only qualified persons should install,
CAN KILL
use or service this equipment.
.

VOLTAGE=220-230V

VOLTAGE=380-415V

200-208V

220-230V

380-415V

'A'

INPUT SUPPLY CONNECTION DIAGRAM

WARNING
WARNING
Disconnect input power before
inspecting or servicing machine.
Do not operate with covers
removed.
ELECTRIC
ELECTRIC
Do not touch electrically live parts.
SHOCK
SHOCK
Only qualified persons should install,
CAN KILL
CAN
KILL use or service this equipment.

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440-460V

VOLTAGE = 200-208V

W / L3
V / L2

200-208V

CR1

220-230V

U / L1

440-460V

VOLTAGE = 440-460V

VOLTAGE = 550-575V

200-208V

220-230V

550-575V

'A'

550-575V

220-230V
440-460V

440-460V

'A'

550-575V

440-460V

'A'

550-575V

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

INPUT CONNECTION
WARNING
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be made
in accordance with all local and national electrical codes
and the connection diagram located on the inside of the
reconnect/input access door of the machine. Failure to
do so may result in bodily injury or death.

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'A'

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380-415V

(K1761-2) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

VOLTAGE = 220-230V

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'A'

380-415V
440-460V

440-460V

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VOLTAGE=440-460V

S23847

WARNING

THE LINCOLN ELECTRIC CO.

INPUT SUPPLY CONNECTION DIAGRAM

CLEVELAND, OHIO U.S.A.

FIGURE A.1
(K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
XA
S25198

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A-5

Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door, or refer to Figure A.1.

Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called
“inverse time” or “thermal/magnetic” circuit breakers).
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.

POWER WAVE 455/R

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A-6

INSTALLATION

INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)

WELDING WITH MULTIPLE POWER
WAVES
CAUTION

Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram
located on the inside of the input access door. (Figure
A.1.) If the main reconnect switch or link position is
placed in the wrong position, the welder will not produce output power.

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.

If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in
a position higher than the applied line voltage, the
welder may not come on at all. If the auxiliary (A) lead
is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this occurs,
turn off the input voltage, properly connect the (A) lead,
reset the breakers, and try again.

Each power source requires a work lead from the work
terminal 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 in Figure A.2. 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.

FIGURE A.2 – MULTIPLE POWER WAVE CONNECTIONS
TWO POWER WAVES

I ON

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POWERWAVE 455/R

O OFF

SEN
SE L
EAD

ELECTRODE

VEL
TRAECTION
DIR

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SENSE LEAD
CONNECT ALL WORK
SENSE LEADS AT THE
END OF THE JOINT
WORK LEAD

WORK LEAD
CONNECT ALL WELDING
WORK LEADS AT THE
BEGINNING OF THE JOINT
POWER WAVE 455/R

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A-7

When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use, each gun must have
its own anti-spatter system. See Figure A.2.

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ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (per
Table A.1) 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. Do not tightly bundle the electrode and work cables together.
Use K1796 coaxial welding cables wherever possible.

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Minimum work and electrode cables sizes are as
follows:
TABLE A.1
(Current (60% Duty Cycle)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To 100 Ft. Length (30 m)
400 Amps
500 Amps
600 Amps

2/0 (67 mm )
3/0 (85 mm2)
3/0 (85 mm2)

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Most welding applications run with the electrode being
positive (+). For those applications, connect one end of
the electrode cable to the positive (+) output terminal
on the power source (located beneath the spring
loaded output cover near the bottom of the case front).
Connect the other end of the electrode cable to the
wire drive feed plate using the stud, lockwasher, and
nut provided on the wire drive feed plate. The electrode
cable lug must be against the feed plate. Be sure the
connection to the feed plate makes tight metal-to-metal
electrical contact. The electrode cable should be sized
according to the specifications given in Table A.1.
Connect a work lead from the negative (-) power
source output terminal to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.

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

When welding with the STT process, use the positive
output connection labeled (STT) for STT welding. (If
desired, other welding modes can be used on this terminal; however, their average output current will be limited to 325 amps.) For non-STT processes, use the
positive output connection labeled (Power Wave), so
that the full output range of the machine is available.

CAUTION

When using an inverter type power source like the
Power Wave, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not normally require it.

CAUTION
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A-7

INSTALLATION

When pulsing, the pulse current can reach very high
levels. Voltage drops can become excessive, leading
to poor welding characteristics, if undersized welding
cables are used.

Do not connect the STT and Power Wave terminals
together. Paralleling the terminals will bypass STT circuitry and severely deteriorate STT 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 (-) terminal, and work cable to the positive
(+) terminal).
When operating with electrode polarity negative, the
Dip switch 7 must be set to ON on the Wire Feed Head
PC Board. The default setting of the switch is OFF to
represent positive electrode polarity.
To set the Negative Polarity switch on Wire Feed Head
PC board, refer to the section DIP SWITCH
SETTINGS AND LOCATIONS.

POWER WAVE 455/R

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A-8

VOLTAGE SENSING

The sense leads connect to the Power Wave at the
four-pin connector located underneath the output terminal cover. Lead 67 senses electrode voltage. Lead
21 senses work voltage.

The best arc performance occurs when the Power
Wave has accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the voltage apparent at the terminals of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.

Enable the voltage sense leads as follows:
TABLE A.2

CAUTION

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If the voltage sensing is enabled but the sense leads
are missing or improperly connected, extremely high
welding outputs may occur.
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A-8

INSTALLATION

Do not tightly bundle the work sense lead to the work
lead.

Process

Electrode Voltage
Sensing 67 lead *

Work Voltage
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

STT

67 lead required

21 lead required

GTAW

Voltage sense at
terminals

SAW

67 lead required

21 lead optional

* The electrode voltage 67 sense lead is integral to the control cable to the wire feeder.

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FIGURE A.3 – DIP SWITCH LOCATION

5/R
45
E
AV
RW
WE
O
P

REMOVE
FRONT
COVER

IO
N
O

OF
F

PO
WE
RW
AV
E4
55
/R

WIRE FEED
HEAD BOARD
ON RIGHT

POWER WAVE 455/R

CONTROL
BOARD
ON LEFT

WORK VOLTAGE SENSING

CONTROL CABLE SPECIFICATIONS

The Power Wave is shipped from the factory with the
work sense lead enabled.

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.

For processes requiring work voltage sensing, connect
the (21) work voltage sense lead from the Power Wave
to the work. Attach the sense lead to the work as close
to the weld as practical. To enable the work voltage
sensing in the Power Wave, refer to the section DIP
SWITCH SETTINGS AND LOCATIONS.

Enabling or disabling electrode voltage sensing is automatically configured through software. Electrode sense
lead 67 must be connected at the wire feeder.

CAUTION
The use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration
(poor arc starting) and low wire driving force (wire feeding problems).

Lincoln control cables are copper 22 conductor cable in
a SO-type rubber jacket.

9 10 11 12

Reserved for future use

Shutdown2 input

Shutdown1 input

A work lead must be run from the negative (-) power
source output connection to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.

+15 for shutdown group

Output connections on some Power Waves are made
via 1/2-13 threaded output terminals located beneath
the spring-loaded output cover at the bottom of the
case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles,
also located beneath the spring-loaded output cover at
the bottom of the case front.

Gas Purge Input

The Shutdown Group is always enabled. Shutdown 2 is
used for signaling low flow in the water cooler. Unused
shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See
Figure A.4)
FIGURE A.4 – INPUT PORT CONNECTIONS

Cold Inch Reverse

For convenience sake, the electrode and control
cables can be routed behind the left or right strain
reliefs (under the spring loaded output cover), and
along the channels formed into the base of the Power
Wave, out the back of the channels, and then to the
wire feeder.

Cold Inch Forward

The Power Wave is equipped with a port for making simple input signal connections. The port is divided into
three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a “slave”
on the DeviceNet network, the Trigger and Cold Inch
Groups are disabled when the DeviceNet/Gateway is
active.

+15 VDC for Cold Inch Group

Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Wave is located under the spring loaded
output cover, near the bottom of the case front. The
control cable is keyed and polarized to prevent improper connection.

4 Step Input

EXTERNAL I/O CONNECTOR

Dual Procedure Input

POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS

Trigger Input

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ELECTRODE VOLTAGE SENSING

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A-9

INSTALLATION

+15 VDC for Trigger Group

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A-9

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CAUTION
Excessive voltage drops at the work piece connection
often result in unsatisfactory pulse welding performance.

D
B

E
C

POWER WAVE 455/R

G
H
F

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A-10

INSTALLATION

DIP SWITCH SETTINGS AND LOCATIONS

CONTROL BOARD DIP SWITCH:

DIP switches on the PC boards allow for custom configuration of the Power Wave. Access the DIP switches as follows:

switch
switch
switch
switch
switch
switch
switch
switch

WARNING
ELECTRIC SHOCK CAN KILL.

1
2
3
4
5
6
7
8

=
=
=
=
=
=
=
=

reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
work sense lead

use
use
use
use
use
use
use

• Do not touch electrically live parts or
electrodes with your skin or wet clothing.

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• Insulate yourself from the work and
ground.

switch 8

work sense lead

off

work sense lead not connected

work sense lead connected

• Always wear dry insulating gloves.

FEED HEAD BOARD DIP SWITCH:

• Turn off power at the disconnect switch.

switch
switch
switch
switch
switch
switch
switch
switch

• Remove the top four screws securing the front access
panel.
• Loosen, but do not completely remove, the bottom
two screws holding the access panel.

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• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.
• Adjust the DIP switches as necessary. Using a pencil or other small object, slide the switch left for the
ON position or to the right for the OFF position, as
appropriate.

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=
=
=
=
=
=
=
=

reserved for future use
reserved for future use
reserved for future use
reserved for future use
reserved for future use
reserved for future use
negative polarity switch
high speed gear

switch 7

electrode polarity

off

positive

negative

switch 8

wire drive gear

off

low speed gear

high speed gear

• Replace the panel and screws and restore power.
CONTROL BOARD
(LOCATED IN
CONTROL BOX
BEHIND CASE
FRONT)
DEVICENET/
GATEWAY
BOARD
(LOCATED
BEHIND
FRONT
COVER)
FRONT
COVER

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1
2
3
4
5
6
7
8

LEFT

BANK S1

FEED HEAD
BOARD
(LOCATED IN
CONTROL
BOX BEHIND
CASE FRONT)
CASE FRONT

BANK S2

OPENING IN
CASE FRONT
TO ACCESS
CONTROL
BOX

RIGHT

POWER WAVE 455/R

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A-11

INSTALLATION

DEVICENET/GATEWAY BOARD
DIP SWITCH, BANK (S2):
switch 1,2 = configure the baud rate
for DeviceNET
Prior to S24958-6 software
switch 1

switch 2

baud rate

off

-------

off

125K

off

250K

500

S24958-6 and later software
switch 1

switch 2

baud rate

off

125K

off

250K

off

500K

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Programmable value. Consult local Lincoln Technical
representative.

switch
switch
switch
switch

5
6
7
8

=
=
=
=

reserved
reserved
reserved
reserved

for
for
for
for

future
future
future
future

use
use
use
use

POWER WAVE 455/R

A-11

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A-12

NOTES

POWER WAVE 455/R

A-12

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Section B-1

TABLE OF CONTENTS
- OPERATION SECTION -

Section B-1

Operation...............................................................................................................................Section B
Safety Precautions ......................................................................................................................B-2
Graphic Symbols.........................................................................................................................B-3
General Description ....................................................................................................................B-4
Design Features and Advantages ........................................................................................B-4
Recommended Processes and Equipment.................................................................................B-5
Recommended Processes....................................................................................................B-5
Recommended Equipment ...................................................................................................B-5
Required Equipment .............................................................................................................B-5

Duty Cycle and Time Period.................................................................................................B-5
Case Front Controls ....................................................................................................................B-6
Welding Mode Descriptions ........................................................................................................B-7
Constant Voltage Welding ....................................................................................................B-7
Pulse Welding.......................................................................................................................B-8
STT Welding .........................................................................................................................B-9

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Limitations.............................................................................................................................B-5

POWER WAVE 455/R

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B-2

OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.

WARNING

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

FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.

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• 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.

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• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning
of this manual.

POWER WAVE 455/R

B-2

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B-3

OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

INPUT POWER

SMAW

GMAW

OFF

FCAW

HIGH TEMPERATURE

GTAW

MACHINE STATUS

OPEN CIRCUIT VOLTAGE

CIRCUIT BREAKER

INPUT VOLTAGE

WIRE FEEDER

OUTPUT VOLTAGE

POSITIVE OUTPUT

INPUT CURRENT

NEGATIVE OUTPUT

OUTPUT CURRENT

3 PHASE INVERTER

PROTECTIVE
GROUND

INPUT POWER
WARNING OR
CAUTION

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THREE PHASE

DIRECT CURRENT

POWER WAVE 455/R

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B-4

OPERATION

B-4

GENERAL DESCRIPTION

DESIGN FEATURES AND ADVANTAGES

The Power Wave 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, Surface Tension Transfer
and pulse welding modes.

• Designed to the IEC 974-1 Standard.

The Power Wave power source is designed to be used
with the 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,
electrical accessories) knows what the other is doing at
all times. The components communicate using ArcLink
protocol.
Robotic systems can communicate with other industrial machines via DeviceNET protocol. The result is a
highly intrigated and flexible welding cell.
The Power Wave 455/R 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,
GTAW and STT processes. It carries an output rating of
either 450 amps, 38 volts; or 400 amps, 36 volts (both
at 100% duty cycle), depending on input voltage and
frequency. The Surface Tension transfer process (STT)
is supported at currents up to 325 amps, at 100% duty
cycle.

• Power Wave 455 multiple process output ranges:
5 - 570 amps
• Easy access for input connections. Connections are
simple strip and clamp (no lugs required).
• F.A.N. (Fan As Needed). Cooling fan runs only when
necessary (above Code 10500 only, and all STT
machines).
• Modular construction for easy servicing.
• Thermostatically protected.
• Electronic over-current protection.
• Input over-voltage protection.
• Utilizes digital signal processing and microprocessor
control.
• Simple, reliable input voltage change over.
• All system components communicate and transfer
information.
• Auto device recognition simplifies accessory cable
connections.

If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.

POWER WAVE 455/R

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B-5

OPERATION

RECOMMENDED PROCESSES
AND EQUIPMENT

B-5

REQUIRED EQUIPMENT
• PF-10/R Wire Feeder, K1780-1
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,100

RECOMMENDED PROCESSES
The Power Wave 455/R can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW and STT
for a variety of materials, including mild steel, stainless
steel, cored wires, and aluminum. The STT process
supports mild steel and stainless steel welding.

• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 10 ft), K1804-1

The Power Wave 455/R is recommended only for
automatic or mechanized applications such as robotic
welding.

LIMITATIONS

RECOMMENDED EQUIPMENT

• Power Waves are not to be used in outdoor environments.

Automatic Operation
All welding programs and procedures are set through
software for the robotic Power Wave. FANUC robots
equipped with RJ-3 controllers may communicate
directly with the Power Wave. Other pieces of equipment such as PLCs or computers can communicate
with the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.

• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1804-2

• The Power Wave 455/R is not suitable for SMAW,
CAC-A or other processes not listed.

• Only ArcLink Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at
a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that 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.

POWER WAVE 455/R

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B-6

CASE FRONT CONTROLS
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled until
the machine cools down. When cool, the light
goes out and output is enabled.

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 system errors. Normal operation is a steady green
light. Error conditions are indicated, per Table B.1.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:
Protects 115 volt AC case front receptacle auxiliary supply.

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NOTE: The robotic Power Waves’ 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.

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6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1

TABLE B.1
Light
Condition

8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR

Meaning

Steady
Green

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

Blinking
Green

Normal for first 1-10 seconds
after power is turned on.

Alternating
Green
and Red

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B-6

OPERATION

Steady
Red

10. NEGATIVE OUTPUT TERMINAL
11. INTERFACE CONNECTOR S6
12. STT TERMINAL
13. POSITIVE OUTPUT TERMINAL
14. AUXILIARY OUTPUT

Non-recoverable system fault.
Must turn power source off, find
source of error, and turn power
back on to reset. See
Troubleshooting Guide.
See Troubleshooting Guide.

FIGURE B.1 – POWER WAVE CASE FRONT CONTROLS
2

I ON

POWERWAVE 455/R

O OFF

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8
9

12
13

POWER WAVE 455/R

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B-7

OPERATION

WELDING MODE DESCRIPTIONS
CONSTANT VOLTAGE WELDING
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed. With
synergic programs, when the wire feed speed changes,
the Power Wave will automatically adjust the corresponding voltage.

Wave control adjusts the inductance of the waveshape.
(This adjustment is often referred to as "pinch". Inductance is inversely proportional to pinch.) Increasing
wave control greater than 0 results in a harsher, colder
arc, while decreasing the wave control to less than 0
provides a softer, hotter arc. (See Figure B.2.)

FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS

Wave Control +10.0
Wave Control 0.00

Wave Control -10.0
Current

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Time

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B-7

POWER WAVE 455/R

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B-8

OPERATION

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, background current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting “trim.”

The Power Wave utilizes “adaptive control” to compensate for changes in electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip
to the work piece.) The Power Wave waveforms 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 the physical limitations of the welding process.

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.

Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave control
values less than 0 decrease the pulse frequency while
increasing the background current for a soft arc good
for out-of-position welding. (See Figure B.3.)

Most pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain
similar arc properties.

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FIGURE B.3 – PULSE WAVE CONTROL CHARACTERISTICS

Current

Wave Control -10.0
Wave Control 0.00
Wave Control +10.0

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Time

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B-8

POWER WAVE 455/R

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B-9

OPERATION

STT WELDING
The pictures illustrate the waveshape of current for the
process. They are not drawn to scale, and are intended only for the purpose of showing how the variables
affect the waveform.

Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater
than 1.0 add more energy to the weld and make the
weld puddle hotter; trim values less than 1.0 reduce
energy to weld. A nominal value of 1.0 will work for
most applications. (See Figure B.4.)

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FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS

Trim 1.50
Current

Trim 1.00
Time

Trim 0.50

For most programs, peak current is adjusted by wave
control values. A value of +10.0 maximizes the peak
current, while a wave control of -10.0 minimizes peak
current. In general, the peak current is proportional to
torch arc length. (See Figure B.5.)

NOTE: The ranges on Wave Control and Trim are
dependent on the weld programs. The values
shown are typical ranges.

FIGURE B.5 – STT WAVE CONTROL CHARACTERISTICS

Wave Control +10.0
Wave Control 0.00
Wave Control -10.0

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Current

Time

POWER WAVE 455/R

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B-10

NOTES

POWER WAVE 455/R

B-10

TABLE OF CONTENTS
- ACCESSORIES SECTION -

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

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Section C-1

Accessories ..........................................................................................................................Section C

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Section C-1

POWER WAVE 455/R

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C-2

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C-2

OPTIONAL EQUIPMENT
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave 455R.

The water cooler is designed to cool only one welding
gun and should be not used to cool multiple guns or
other devices.

FIELD INSTALLED
•

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ACCESSORIES

Gas Guard Regulator (K659-1)
The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive
unit. Install the 5/8-18 male outlet on the regulator
to the proper 5/8-18 female gas inlet on the back
panel of the wire drive. Secure the fitting with the
flow adjuster key at the top.

•

Voltage Sense Leads (K940-10, -25 or -50)
The voltage sense leads connect at the front of the
machine. (See Figure A.2.)

•

Power Wave Water Cooler (K1767-1)*
The K1767-1 is the recommended water cooler for
the Power Wave. Incorporated into the cooler is an
automatic flow sensor to detect low coolant flow. In
the event of a low flow condition, a fault signal is
sent to the Power Wave, and welding output automatically stops to protect the torch.

Water cooler manufacturers often specify additives
to the coolant such as fungicides or alkalies. Follow
the manufacturers’ recommendations to achieve
proper operation and long lifetime without clogging.
•

Water Flow Sensor (K1536-1)
Water cooled guns can be damaged very quickly if
they are used even momentarily without water flowing. Recommend practice is to install a water flow
sensor such as on the water return line of the torch.
When fully integrated into the welding system, the
sensor will prevent welding if no water flow is present.

•

Dual Cylinder Undercarriage, K1570-1*

•

Coaxial Welding Cable, K1796

*The Dual Cylinder Undercarriage, K1570-1, is not
compatible in combination with the Power Wave
Water Cooler K1767-1.

POWER WAVE 455/R

TABLE OF CONTENTS
- MAINTENANCE SECTION -

Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Main Assembly (Exploded View) ...............................................................................................D-3

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Section D-1

Maintenance ..........................................................................................................................Section D

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Section D-1

POWER WAVE 455/R

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D-2

MAINTENANCE
PERFORM THE FOLLOWING DAILY:

SAFETY PRECAUTIONS

1. Check that no combustible materials are in the
welding or cutting area or around the machine.

WARNING

2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.

ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

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•

D-2

Do not touch electrically hot parts.

3. Inspect the electrode cables for any slits or punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.

PERFORM PERIODICALLY:
Clean the inside of the machine with a low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
• Transformer and output rectifier assembly.

ROUTINE AND PERIODIC
MAINTENANCE

• Electrode and work cable connections.
• PC board connections..

1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.

• Intake and outlet louvers on the machine case.
• Any obvious accumulations of dirt within the
machine.
• Fan Assembly.

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NOTE: The fan motor has sealed bearings which
require no maintenance.

POWER WAVE 455/R

D-3

MAINTENANCE

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D-3

FIGURE D.1 – MAIN ASSEMBLY (EXPLODED VIEW)

7
7

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7
3

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5
1. CASE FRONT ASSEMBLY
2. TRANSFORMER AND OUTPUT
RECTIFIER ASSEMBLY
3. INPUT ASSEMBLY

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4. CONTROL BOX AND VERTICAL
DIVIDER ASSEMBLY

5. BASE, LIFT BAIL AND FAN
ASSEMBLY
6. SWITCH BOARD HEATSINK
ASSEMBLY
7. CASE PARTS

POWER WAVE 455/R

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D-4

NOTES

POWER WAVE 455/R

D-4

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Section E-1

TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -

Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Voltage and Precharge ......................................................................................................E-3
Switch Boards and Main Transformer.........................................................................................E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board ...........................................................................................................E-5
Control Board ..............................................................................................................................E-7
Output Rectifier, Output Choke and STT Chopper Board ..........................................................E-8

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Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection ............................................................................................E-9
General Description of STT (Surface Tension Transfer) Process.............................................E-10
Insulated Gate Bipolar Transistor (IGBT) Operation .................................................................E-11
Pulse Width Modulation ............................................................................................................E-12

FIGURE E.1 – BLOCK LOGIC DIAGRAM
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

INPUT
RECTIFIER

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+20 VDC FROM
POWER BOARD

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

CURRENT
TRANSDUCER

STT CHOPPER
BOARD

STT
ELECTRODE
TERMINAL

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

ELECTRODE
TERMINAL

LEFT
SWITCH
BOARD

RECONNECT
SWITCH

STT
DRIVE

CURRENT
TRANSDUCER

OUTPUT
CHOKE

WORK
TERMINAL

67A

INPUT
BOARD

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

AUX
RECONNECT

MAIN
TRANSFORMER
OUTPUT DIODES
D1 -D4

CAP. V/F
FEEDBACK

CR1

CT CURRENT
TO CONTROL
BOARD

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

DEVICE NET

GATEWAY
BOARD

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T
F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

52 VAC

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DC
BUS
BOARD

BUS BOARD
RECTIFIER

T1
230 VAC

WATER
COOLER

CONNECTION
TO WIRE
DRIVE

+5 V ARC LINK

POWER
BOARD

40 VDC

115 VAC

S2 WORK
SENSE

+15V SPI

40 VDC

S3
RS232

+5 V
+15 V
-15 V

40 VDC

115 VAC
RECP.

+5V SPI

THERMOSTATS

CONTROL
BOARD

ARC LINK
WIRE
FEEDER
RECP.

POWER WAVE 455/R

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

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E-2

FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

INPUT
RECTIFIER

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+20 VDC FROM
POWER BOARD

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

CURRENT
TRANSDUCER

STT CHOPPER
BOARD

STT
ELECTRODE
TERMINAL

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

ELECTRODE
TERMINAL

LEFT
SWITCH
BOARD

RECONNECT
SWITCH

STT
DRIVE

CURRENT
TRANSDUCER

OUTPUT
CHOKE

WORK
TERMINAL

67A

INPUT
BOARD

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

AUX
RECONNECT

MAIN
TRANSFORMER

CT CURRENT
TO CONTROL
BOARD

OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK

CR1

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E-2

THEORY OF OPERATION

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

DEVICE NET

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

GATEWAY
BOARD

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T
F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

52 VAC

230 VAC

DC
BUS
BOARD

BUS BOARD
RECTIFIER

CONNECTION
TO WIRE
DRIVE

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115 VAC

+5V SPI

THERMOSTATS

CONTROL
BOARD

S2 WORK
SENSE

+15V SPI

S3
RS232

+5 V
+15 V

40 VDC

-15 V

40 VDC

POWER
BOARD

40 VDC

WATER
COOLER

115 VAC
RECP.

+5 V ARC LINK

ARC LINK
WIRE
FEEDER
RECP.

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

GENERAL DESCRIPTION
The Power Wave 455/R power source is designed to
be a part of a modular, multi-process welding system.
It is a high performance, digitally controlled inverter
welding power source capable of complex, high-speed
waveform control. Depending upon configuration, it
can support constant current, constant voltage, surface
tension transfer and pulse welding modes. Each
machine is factory preprogrammed with multiple welding procedures. Typically these procedures include
GMAW, GMAW-P, FCAW, GTAW and STT (Surface

Tension Transfer) for a variety of materials such as
mild steel, stainless steel, cored wires and aluminum.
The STT process supports mild steel and stainless
steel welding.
The Power Wave 455/R has an output rating of either
450 amps at 38 volts or 400 amps at 36 volts. The two
output ratings are dependent upon input voltage and
frequency. Both have a duty cycle of 100%. The STT
process is rated at currents up to 325 amps at a 100%
duty cycle.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R

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E-3

THEORY OF OPERATION

E-3

INPUT VOLTAGE AND PRECHARGE
The Power Wave 455/R can be connected for a variety
of three-phase input voltages. Refer to Figure E.2.
The initial input power is applied to the Power Wave
455/R through a line switch located on the front of the
machine. Two phases of the three-phase input power
are applied to the Input Board and both auxiliary transformers. The various secondary voltages developed
by transformer T1 are applied to the Input Board, the
fan motor (via a control relay) and the Bus Board rectifier. The 65VDC produced from the Bus Board rectifier is used by the Bus Board to provide various DC voltages for the Power Board, the Feed Head Board and
the wire feeder receptacle. The 115/230VAC developed on the secondary of auxiliary transformer T2 is
applied to the 115VAC receptacle and to the water
cooler receptacle.

the precharge or "soft start" sequence, these two phases are current limited by the Input Board. The AC input
voltage is rectified, and the resultant DC voltage is
applied through the reconnect switches to the input
capacitors located on the right and left switch boards.
The Control Board monitors the voltage across the
capacitors. When the capacitors have charged to an
acceptable level, the Control Board signals the Input
Board to energize the main input contactor, making all
three phases of input power, without current limiting,
available to the input capacitors. At this point the
Power Wave 455/R is in the "Run Mode" of operation.
If the capacitors become undervoltaged, overvoltaged,
or unbalanced, the Control Board will signal the Input
Board to de-energize the main input contactor, and the
Power Wave 455/R will be disabled. See Figure E.2.

The two phases that are connected to the Input Board,
through the input line switch SW1, are connected to the
input rectifier through the CR1 precharge relay. During

POWER WAVE 455/R

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E-4

FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

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+20 VDC FROM
POWER BOARD

STT
DRIVE

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

DEVICE NET

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

GATEWAY
BOARD

OUTPUT
CHOKE

WORK
TERMINAL

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T
F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

52 VAC

DC
BUS
BOARD

BUS BOARD
RECTIFIER

CONNECTION
TO WIRE
DRIVE

+5 V ARC LINK

POWER
BOARD

115 VAC

115 VAC
RECP.

+5V SPI

THERMOSTATS

CONTROL
BOARD

S2 WORK
SENSE

+15V SPI

40 VDC

WATER
COOLER

S3
RS232

+5 V
+15 V

40 VDC

-15 V

40 VDC

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CURRENT
TRANSDUCER

230 VAC

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STT
ELECTRODE
TERMINAL

67A

INPUT
BOARD

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CURRENT
TRANSDUCER

STT CHOPPER
BOARD

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

ELECTRODE
TERMINAL

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

AUX
RECONNECT

MAIN
TRANSFORMER

LEFT
SWITCH
BOARD

INPUT
RECTIFIER

CR1

CT CURRENT
TO CONTROL
BOARD

OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK

RECONNECT
SWITCH

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E-4

THEORY OF OPERATION

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD

ARC LINK
WIRE
FEEDER
RECP.

LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

SWITCH BOARDS AND MAIN
TRANSFORMER
There are two switch boards in the Power Wave 455/R
machine. Each contains an input capacitor and insulated gate bipolar transistor (IGBT) switching circuitry.
Refer to Figure E.3. When the machine reconnect
switches are configured for a lower input voltage
(below 300VAC), the input capacitors are connected in
parallel. When the machine is configured for higher
input voltages (300VAC and above), the input capacitors are connected in series.
When the input capacitors are fully charged, they act
as power supplies for the IGBT switching circuits. The
insulated gate bipolar transistors switch the DC power
from the input capacitors "on and off," thus supplying
pulsed DC current to the main transformer primary
windings. See IGBT OPERATION DISCUSSION AND
DIAGRAMS in this section.

Each switch board 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
switch boards induce an AC square wave output signal
at the secondary of the main transformer. Current
transformers located on the switch boards monitor the
primary currents. If the primary currents become
abnormally high, the Control Board will shut off the
IGBTs, thus disabling the machine’s 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 windings. The firing of
the two switch boards occurs during halves of a 50microsecond interval, creating a constant 20 KHZ output.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R

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E-5

FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

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STT
DRIVE

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

DEVICE NET

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

OUTPUT
CHOKE

GATEWAY
BOARD

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T

WORK
TERMINAL

F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

DC
BUS
BOARD

BUS BOARD
RECTIFIER

230 VAC

CONNECTION
TO WIRE
DRIVE

+5 V ARC LINK

POWER
BOARD

115 VAC

115 VAC
RECP.

+5V SPI

THERMOSTATS

CONTROL
BOARD

S2 WORK
SENSE

+15V SPI

40 VDC

WATER
COOLER

S3
RS232

+5 V
+15 V

40 VDC

-15 V

40 VDC

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CURRENT
TRANSDUCER

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STT
ELECTRODE
TERMINAL

67A

INPUT
BOARD

52 VAC

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CURRENT
TRANSDUCER

STT CHOPPER
BOARD

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

AUX
RECONNECT

+20 VDC FROM
POWER BOARD

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

ELECTRODE
TERMINAL

LEFT
SWITCH
BOARD

INPUT
RECTIFIER

CR1

MAIN
TRANSFORMER

CT CURRENT
TO CONTROL
BOARD

OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK

RECONNECT
SWITCH

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E-5

THEORY OF OPERATION

ARC LINK
WIRE
FEEDER
RECP.

DC BUS BOARD, POWER BOARD,
FEED HEAD BOARD, GATEWAY
BOARD AND VOLTAGE SENSE
BOARD
The DC Bus Board receives approximately 65VDC
from the Bus Board rectifier. The DC Bus Board regulates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Feed Head Board, the Power
Board, and the wire feeder receptacle.
The switching power supplies on the Power Board supply a variety of regulated DC voltages to the Control
Board and a +20VDC to the STT Chopper Board. The
Control Board uses these regulated voltages to power
the many circuits and communication functions incorporated within the Control Board.

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

When the Feed Head Board activates the Voltage
Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the voltage sense board to the Control Board.
The Power Wave 455R uses two digital communication
platforms. Internally the PC boards communicate via
ArcLink. Externally the Power Wave 455R communicates using the industry standard Device Net protocol.
The Gateway Board makes the translation between the
two platforms possible. The Power Wave 455R does
not have a dedicated interface device or board. The
robot (or other input device – PLC, etc.) acts as the
user interface, issuing commands through the Device
Net protocol that are translated by the Gateway Board
to ArcLink compatible messages. The following block
diagram (Figure E.5) depicts the flow of communication information.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 455/R

FIGURE E.5 – POWER WAVE 455/R COMMUNICATIONS

A
rc L
ink
Arc
Link
Control
Board

Gateway
Board
Translator

Feed
Head
Board

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Weld Controller /
Sequencer

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E-6

THEORY OF OPERATION

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E-6

PF-10R

PW-455R
D
evice N
et
Device
Net

Robot
Controller

POWER WAVE 455/R

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E-7

FIGURE E.6 – CONTROL BOARD
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

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STT
DRIVE

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

DEVICE NET

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

GATEWAY
BOARD

OUTPUT
CHOKE

WORK
TERMINAL

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T
F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

52 VAC

DC
BUS
BOARD

BUS BOARD
RECTIFIER

CONNECTION
TO WIRE
DRIVE

+5 V ARC LINK

POWER
BOARD

115 VAC

115 VAC
RECP.

+5V SPI

THERMOSTATS

CONTROL
BOARD

S2 WORK
SENSE

+15V SPI

40 VDC

WATER
COOLER

S3
RS232

+5 V
+15 V

40 VDC

-15 V

40 VDC

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CURRENT
TRANSDUCER

230 VAC

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STT
ELECTRODE
TERMINAL

67A

INPUT
BOARD

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CURRENT
TRANSDUCER

STT CHOPPER
BOARD

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

AUX
RECONNECT

+20 VDC FROM
POWER BOARD

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

ELECTRODE
TERMINAL

LEFT
SWITCH
BOARD

INPUT
RECTIFIER

CR1

MAIN
TRANSFORMER

CT CURRENT
TO CONTROL
BOARD

OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK

RECONNECT
SWITCH

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E-7

THEORY OF OPERATION

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD

ARC LINK
WIRE
FEEDER
RECP.

LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

CONTROL BOARD
The Control Board performs the primary interfacing
functions to establish and maintain output control of the
Power Wave 455R machine. The function generator
and weld files exist within the Control Board hardware
and software. Digital command signals and feedback
information is received and 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 IGBTs. In this manner, the digitally
controlled high-speed welding waveform is created.

The Control Board also monitors and controls the STT
(Surface Tension Transfer) circuitry incorporated in the
Power Wave 455R. STT output currents and arc voltages are monitored, and the appropriated gate firing
signals are applied (or removed) from the STT
Chopper Board and switch boards to create a low spatter, low fume MIG welding process. See GENERAL
DESCRIPTION OF STT (SURFACE TENSION
TRANSFER PROCESS) in this section.
In addition, the Control Board monitors the thermostats, the main transformer primary currents and
input filter capacitor voltages. Depending on the fault
condition, the Control Board will activate the thermal
and/or the status light and will disable or reduce the
machine output. In some conditions the input contactor will be de-energized.

POWER WAVE 455/R

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E-8

FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
IGBT DRIVE
FROM
CONTROL
BOARD

POWER WAVE 455/R

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STT
DRIVE

67B
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD

VOLT
SENSE
BOARD

VOLTAGE SENSE
OUTPUT

DEVICE NET

VOLTAGE SENSE SELECT
ARC LINK

2
4
V
A
C

FROM CONTROL
BOARD

FEED
HEAD
BOARD

40 VDC

115 VAC
FAN

RELAY

GATEWAY
BOARD

OUTPUT
CHOKE

WORK
TERMINAL

CONNECTION
TO
ROBOT

TO
LEFT
S.B.

TO
RIGHT
S.B.

C
U
R
R
E
N
T
F
B

S
T
T
F
B

40 VDC
TO FAN RELAY

IGBT
DRIVES

CONTACTOR AND
PRECHARGE
CONTROL SIGNALS

ARC LINK

115 VAC
+5V RS232
65 VDC

52 VAC

DC
BUS
BOARD

BUS BOARD
RECTIFIER

CONNECTION
TO WIRE
DRIVE

+5 V ARC LINK

POWER
BOARD

115 VAC

115 VAC
RECP.

+5V SPI

THERMOSTATS

CONTROL
BOARD

S2 WORK
SENSE

+15V SPI

40 VDC

WATER
COOLER

S3
RS232

+5 V
+15 V

40 VDC

-15 V

40 VDC

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CURRENT
TRANSDUCER

230 VAC

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STT
ELECTRODE
TERMINAL

67A

INPUT
BOARD

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CURRENT
TRANSDUCER

STT CHOPPER
BOARD

RIGHT
SWITCH
BOARD

CAP. V/F
FEEDBACK

AUX
RECONNECT

+20 VDC FROM
POWER BOARD

IGBT DRIVE
FROM
CONTROL CT CURRENT
TO CONTROL
BOARD
BOARD

SW1

ELECTRODE
TERMINAL

LEFT
SWITCH
BOARD

INPUT
RECTIFIER

CR1

MAIN
TRANSFORMER

CT CURRENT
TO CONTROL
BOARD

OUTPUT DIODES
D1 -D4
CAP. V/F
FEEDBACK

RECONNECT
SWITCH

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E-8

THEORY OF OPERATION

ARC LINK
WIRE
FEEDER
RECP.

LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F

+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB

RIGHT CT
CURRENT
FB

STATUS
LIGHT

THERMAL
LIGHT

OUTPUT RECTIFIER, OUTPUT
CHOKE AND STT CHOPPER
BOARD
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. The output choke is in series with the
negative leg of the output rectifier and also in series
with the welding load. Due to the current "smoothing"
capability of the output choke, a filtered DC output current is applied through machine output terminals to the
welding arc.

The STT Chopper Board is in series with the STT output terminal and is used to interrupt the welding current for very short periods of time during the short-arc
MIG welding process. The IGBT modules incorporated on this board receive their gate firing commands
from the Control Board.

POWER WAVE 455/R

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E-9

THEORY OF OPERATION

E-9

THERMAL PROTECTION

OVER CURRENT PROTECTION

Three normally closed (NC) thermostats protect the
machine from excessive operating temperatures.
These thermostats are wired in series and are connected to the control board. One of the thermostats is
located on the heat sink of the output rectifier, one on
the DC bus, and one on the output choke. Excessive
temperatures may be caused by a lack of cooling air or
by operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should
occur, the thermostats will prevent output from the
machine. The yellow thermal light, located on the front
of the machine, will be illuminated. The thermostats
are 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 turning or the intake air louvers are obstructed, the power
must be removed from the machine and the fan condition or air obstruction corrected. On later production
machines (above code 10500) the cooling fan runs
only when necessary. The F.A.N. (fan as needed) system is controlled by the Control Board via a solid state
relay.

If the average current exceeds 570 amps, the peak current will be limited to 100 amps until the average current decreases to under 50 amps or the system is retriggered.

PROTECTIVE CIRCUITS

3. Voltage across a capacitor is under 70 volts. (This
would be due to improper input voltage connections.)

Protective circuits are designed into the Power Wave
455/R to sense trouble and shut down the machine
before damage occurs to the machine’s internal components.

UNDER/OVER VOLTAGE
PROTECTION
A protective circuit is included on the Control Board to
monitor the voltage across the input capacitors. In the
event that a capacitor voltage is too high, too low, or
becomes unbalanced side-to-side, the protection circuit will de-energize the input contactor. Machine output will be disabled, and the "soft start" mode will be
repeated. The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required. (This may be
required if the machine has been off for a long period of time and is connected for high input voltage
operation.)
2. Voltage across a capacitor exceeds 390 volts. (This
could result from high line surges or improper input
voltage connections.)

4. Internal component damage.

POWER WAVE 455/R

E-10

THEORY OF OPERATION

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E-10

FIGURE E.8 – STT WAVEFORMS

Wave Control +10.0
Wave Control 0.00
Wave Control -10.0

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Current

Time

STT Wave control characteristics

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Trim 1.50
Current

Trim 1.00
Time

Trim 0.50

STT Trim control characteristics

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GENERAL DESCRIPTION OF
THE STT (SURFACE TENSION
TRANSFER) PROCESS
The STT process cannot be classified as either a constant current (CC) or a constant voltage (CV) application. The STT function produces current of a desired
waveform to reduce spatter and fumes. The STT
process is optimized for short-circuit GMAW welding
only.

POWER WAVE 455/R

FIGURE E.9 – IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
SOURCE

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E-11

THEORY OF OPERATION

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E-11

GATE

SOURCE

GATE

BODY REGION

DRAIN DRIFT REGION

BUFFER LAYER

INJECTING LAYER

DRAIN

B. ACTIVE

A. PASSIVE

INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and
high current applications.
Drawing A shows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction, the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.

Drawing 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
connected to the drain terminal will allow the IGBT to
conduct and supply current to 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.

POWER WAVE 455/R

THEORY OF OPERATION

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E-12

FIGURE E.10 – TYPICAL IGBT OUTPUTS

sec

sec
50

sec

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MINIMUM OUTPUT

24 sec
24 sec

1 sec

50 sec
MAXIMUM OUTPUT

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

MAXIMUM OUTPUT
MINIMUM OUTPUT

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

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The shaded portion of the signal represents one IGBT
group1, conducting for 1 microsecond. The negative portion is the other IGBT group. The dwell time (off time) is
48 microseconds (both IGBT groups off). Since only 2
microseconds of the 50-microsecond time period are
devoted to conducting, the output power is minimized.

By holding the gate signals on for 24 microseconds each
and allowing only 2 microseconds of dwell or off time
(one microsecond during each half cycle) during the 50
microsecond cycle, the output is maximized. The darkened area under the minimum output curve can be compared to the area under the maximum output curve. The
more darkened area, the more power is present.

An IGBT group consists of the sets of IGBT modules grouped onto
one switch board.

POWER WAVE 455/R

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Section F-1

TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -

Troubleshooting & Repair ...................................................................................................Section F
How to Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures.......................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ..........................................................................................................................F-9
Input Filter Capacitor Discharge Procedure .........................................................................F-9
Switch Board Test ...............................................................................................................F-11
Input Rectifier Test .............................................................................................................F-14
Input Contactor Test............................................................................................................F-17

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DC Bus Power Supply PC Board Test................................................................................F-20
Power Board Test ..............................................................................................................F-23
Input Board Test .................................................................................................................F-26
STT Chopper Board Test ....................................................................................................F-30
Power Wave Current Transducer Test ...............................................................................F-33
STT Current Transducer Test ............................................................................................F-37
Output Rectifier Test ..........................................................................................................F-41
Auxiliary Transformer No. 1 Test .......................................................................................F-43
Auxiliary Transformer No. 2 Test .......................................................................................F-46
Component Removal and Replacement Procedure..................................................................F-48
Input Rectifier Removal and Replacement ........................................................................F-48
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Input Contactor Removal and Replacement ......................................................................F-50
Auxiliary Transformer No. 1 Removal and Replacement Procedure..................................F-52
Auxiliary Transformer No. 2 Removal and Replacement Procedure..................................F-55
Control, Feed Head, or Voltage Sense PC Board Removal and Replacement .................F-58
Gateway PC Board Removal and Replacement ...............................................................F-62
STT Current Transducer Removal and Replacement ...................................................... F-64
Power Wave Current Transducer Removal and Replacement.......................................... F-67
Output Rectifier, STT Chopper Board and Rectifier Module Removal
and Replacement ........................................................................................................F-70
Switch Board and Filter Capacitor Removal and Replacement .........................................F-74

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Retest after Repair ...................................................................................................................F-77

POWER WAVE 455/R

Section F-1

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F-2

TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician 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.

This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunctions. Simply follow the three-step procedure
listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and
Function Problems.

Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case cover.

Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.

All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this section.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to 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.

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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.

POWER WAVE 455/R

F-2

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F-3

TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES

WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

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

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F-3

PC Board can be damaged by
static electricity.

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

• Remove your body’s static charge
before opening the 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 unpainted, grounded,
part of the equipment frame. Keep
touching the frame to prevent static build-up. Be sure not to touch
any electrically live parts at the
same time.

• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the staticshielding bag.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure symptom has been corrected by the replacement PC
board.
NOTE: 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
substitution of the original board, then
PC board was the problem. Reinstall
replacement PC board and test
machine.

the
the
the
the

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.

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

POWER WAVE 455/R

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F-4

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

Observe Safety Guidelines
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

F-4

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Major physical or electrical damage
is evident when the sheet metal
covers are removed.

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

Contact the Lincoln Electric Service
Department at 1-800-833-9353
(WELD).

The input fuses repeatedly fail or
the input circuit breakers keep tripping.

1. Make certain the fuses or breakers are properly sized.

1. Check the reconnect switches
and associated wiring. See the
Wiring Diagram.

2. Make certain the reconnect
panel is configured properly for
the applied voltage.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and /or reduce the duty
cycle.

2. Perform the Input Rectifier
Test.
3. Perform the Switch Board Test.
4. Perform the Input Contactor
Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.

POWER WAVE 455/R

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F-5

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

1. Make certain the input power
switch SW1 is in the ON position.
2. Check the main input fuses (or
breakers). If open, replace or
reset.

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RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
The machine is dead—no lights—
no output—the machine appears to
be off.

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F-5

TROUBLESHOOTING & REPAIR

3. Check the 6 amp CB4 breaker
located in the reconnect area.
Reset if tripped.
4. Make certain the reconnect
panel is configured correctly for
the applied input voltage.

1. Check the input power switch
SW1 for proper operation. Also
check the associated leads for
loose or faulty connections.
See the Wiring Diagram.
2. Check circuit breaker CB4 for
proper operation.
3. Perform the T1
Transformer Test.

Auxiliary

4. The power board rectifier may
be faulty. Check rectifier and
associated wiring. See the
Wiring Diagram.
5. Perform the DC Bus Board
Test.
6. Perform the Power Board Test.

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7. The Control Board may be
faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.

POWER WAVE 455/R

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F-6

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TROUBLESHOOTING GUIDE

Observe Safety Guidelines
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

1. Turn the input power off and
make certain the reconnect
panel is configured correctly for
the applied input voltage.
2. If the Thermal light is lit, the unit
may be overheated. Let the
machine cool and adjust welding load and /or duty cycle to
coincide with the output limits of
the machine.

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1. Perform the Input Contactor
Test.
2. Perform the Input Board Test.
3. Perform the T1
Transformer Test.

Auxiliary

4. Perform the Input Rectifier
Test.
5. Perform the Switch Board Test.
6. Perform the Power Board Test.
7. The Control Board may be faulty.

The thermal light is lit.
The
machine regularly "overheats."

1. The welding application may be
exceeding the recommended
duty cycle and/or current limits
of the machine.
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Maintenance Section of this manual.

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RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
The Power Wave 455R does not
have welding output. The main
input contactor CR1 is not activating.

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F-6

TROUBLESHOOTING & REPAIR

1. One of the thermostats may be
faulty. Also check associated
wiring for loose or faulty connections.
See the Wiring
Diagram.

3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around the
machine.
4. Make sure the fan is functioning
correctly. Machines above code
10500 are equipped with F.A.N.
(fan as needed) circuitry. The
fan runs whenever the output is
enabled, whether under load or
open circuit conditions. The fan
also runs for a period of time
(approximately 5 minutes) after
the output is disabled.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.

POWER WAVE 455/R

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F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS
The machine often "noodle welds"
when running a particular process.
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 570 amps, the
machine will "phase back" to
protect itself. Adjust the procedure or reduce the load to lower
the current draw from the Power
Wave 455R machine.

1. Perform
the
Transducer Test.

The Power Wave 455R will not produce full output.

1. The input voltage may be too
low, limiting the output capability
of the machine. Make certain
the input voltage is correct for
the machine and the reconnect
panel configuration.

1. Perform the Output Rectifier
Test.

2. Make sure all three phases of
input power are being applied to
the machine.

4. The Control Board may be
faulty.

3. If using the STT output terminal,
be aware that the STT output is
limited to 325 amps.

Current

2. The Control Board may be
faulty.

2. Perform the Current Transducer Test.
3. Perform the Power Board Test.

5. If using the STT output terminal,
the STT Chopper Board may be
faulty. See the Wiring Diagram.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.

POWER WAVE 455/R

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F-8

Observe Safety Guidelines
detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

RECOMMENDED
COURSE OF ACTION

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS

The Auxiliary Receptacle is "dead."
The 120VAC is not present at the
receptacle.

1. Check the 10 amp circuit breaker (CB2) located on the case
front. Reset if necessary.

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2. Check the 6 amp circuit breaker
(CB4) located in the reconnect
area. Reset if necessary.

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1. Check the receptacle and associated wiring for loose or faulty
connections. See the Wiring
Diagram.
2. Perform the T2
Transformer Test.

Auxiliary

3. Make sure all three phases of
input power are being applied to
the machine.

The Power Wave 455R is "triggered" for output but there is no
welding output.

1. Make sure that the triggering
method and device is correct
and operating properly.
2. Check circuit breaker CB4.
Reset if tripped.

When in the STT mode,
the spatter is higher than normal
and the arc is inconsistent.

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F-8

TROUBLESHOOTING & REPAIR

Use troubleshooting software to
find the problem. Contact Lincoln
Electric Service Department to
obtain software.

1. Make certain the work sense
lead (21) is connected properly.

1. Perform the STT Chopper
Board Test.

2. Make certain the electrode
cable is connected only to the
STT output terminal and NOT
the Power Wave positive output
terminal.

2. Perform
the
Current
Transducer (STT) Test.
3. The Control Board may be
faulty.

3. Make sure the welding parameters are correct for the process.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.

POWER WAVE 455/R

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F-9

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

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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair
procedures are attempted on the Power Wave 455/R. Capacitance normally discharges
within 2 minutes of removing input power. This procedure is used to check that the capacitors have properly discharged.

MATERIALS NEEDED

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3/8” Nut driver
Volt-ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers

This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-9

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F-10

TROUBLESHOOTING & REPAIR

F-10

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.1 – CAPACITOR DISCHARGE PROCEDURE

SWITCH
BOARD

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CAPACITOR
TERMINALS

TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the left and
right case sides.
3. Be careful not to make contact with the
capacitor terminals that are located in the
bottom center of the left and right side switch
boards. See Figure F.1.

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4. Carefully check for a DC voltage at the
capacitor terminals on both boards. Note
the polarity is marked on the PC board and
also lead #19 is positive.
5. If any voltage is present, proceed to Step #6.
If no voltage is present, the capacitors are
discharged.
NOTE: Normally the capacitors discharge in
about two minutes after input power is
removed.

6. Using the high wattage resistor (25-1000
ohms @ 25 watts (minimum), electrically
insulated gloves and pliers, connect the
resistor across the two capacitor terminals.
Hold the resistor in place for 10 seconds.
DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS. NEVER
USE A SHORTING STRAP FOR THIS
PROCEDURE.
7. Repeat procedure for the other capacitor.
8. Recheck the voltage across the capacitor
terminals. The voltage should be zero. If
any voltage remains, repeat the discharge
procedure.
NOTE: If the capacitor voltage is present after
the discharge has been performed, this
may indicate a faulty switch board.

POWER WAVE 455/R

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F-11

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

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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 these boards can be
damaged easily. In addition, it is dangerous to work on these boards with the machine
energized.

MATERIALS NEEDED

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3/8” Nut driver
3/8” Wrench
Analog volt-ohmmeter
Wiring Diagram

This procedure should take approximately 20 minutes to perform.

POWER WAVE 455/R

F-11

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F-12

TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (CONTINUED)
FIGURE F.2 – RECONNECT SWITCHES

19C
19D

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RECONNECT
SWITCHES

TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and sides.

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3. Perform
the
Procedure.

Capacitor

Discharge

4. Locate label and remove leads 19C and 19D
from the reconnect switches with the 3/8”
wrench. Note lead placement for reassembly. Clear leads. Refer to Figure F.2.

5. Using the Analog ohmmeter, perform the
resistance tests detailed in Table F.1. Refer
to Figure F.3 for the test points.
6. If any test fails replace both switch boards.
See Switch Board Removal and
Replacement.
7. If the switch board resistance tests are OK,
check the molex pin connections and associated wiring from the switch boards to the
control board. See the Wiring Diagram.

POWER WAVE 455/R

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F-13

SWITCH BOARD TEST (CONTINUED)
FIGURE F.3 – SWITCH BOARD TEST POINTS

13/14
OR
17/18

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SWITCH
BOARD

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F-13

TROUBLESHOOTING & REPAIR

-20 +19

11/12
OR
15/16

8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are
installed in the same location they were
removed from.

9. Install the right and left case sides and top
using the 3/8” nut driver.

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TABLE F.1 – SWITCH BOARD RESISTANCE TEST
APPLY POSITIVE TEST
PROBE TO TERMINAL

APPLY NEGATIVE TEST
NORMAL
PROBE TO TERMINAL

RESISTANCE READING

+19
+19
11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18

11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
+19

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

POWER WAVE 455/R

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F-14

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

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

MATERIALS NEEDED
Analog volt-ohmmeter
Phillips head screw driver
Wiring Diagram
3/8” Nut driver

This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-14

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F-15

INPUT RECTIFIER TEST (CONTINUED)
FIGURE F.4 – INPUT RECTIFIER TEST
INPUT
RECTIFIER

NEG (-)
POS (+)

TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.

3. Perform
the
Procedure.
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C
A

2. Using the 3/8” nut driver, remove the case
top.

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F-15

TROUBLESHOOTING & REPAIR

Capacitor

Discharge

NOTE: Some RTV sealant may have to be
removed from the input rectifier terminals. The RTV should be replaced
when test is complete.
5. With the phillips head screw driver remove
the positive and negative leads from the rectifier.

4. Locate the Input Rectifier and lead locations.
Refer to Figure F.4.

POWER WAVE 455/R

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F-16

INPUT RECTIFIER TEST (CONTINUED)
6. Use the analog ohmmeter to perform the
tests detailed in Table F.2.
7. If the input rectifier does not meet the
acceptable readings outlined in the table,
the component may be faulty. Replace.

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NOTE: Before replacing the input rectifier, perform the Switch Board Test and the
Input Contactor Test.

9. If the input rectifier is good, be sure to
reconnect the positive and negative leads
to the correct terminals and torque to 31
in.-lbs. See the Wiring Diagram.
10. Replace any RTV sealant previously
removed.
11. Install the case top.

8. When installing a new input rectifier, see
Input
Rectifier
Removal
and
Replacement procedure.

TABLE F.2 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
ANALOG METER X100
RANGE

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TEST POINT TERMINALS

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F-16

TROUBLESHOOTING & REPAIR

+ Probe

- Probe

Acceptable Meter Readings

A
B
C

NEG
NEG
NEG

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

A
B
C

POS
POS
POS

Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms

NEG
NEG
NEG

A
B
C

Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms

POS
POS
POS

A
B
C

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

POWER WAVE 455/R

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F-17

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

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TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.

MATERIALS NEEDED

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3/8” Nut driver
Volt-ohmmeter
External 24 VAC supply

This procedure should take approximately 17 minutes to perform.

POWER WAVE 455/R

F-17

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F-18

TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.5 – INPUT CONTACTOR COIL

INPUT
CONTACTOR
601

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TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the input
access panel and case top.

4. Using the external 24 VAC supply, apply 24
VAC to the terminals of the input contactor
coil. If the contactor does NOT activate, the
input contactor is faulty. Replace.

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3. Locate, mark, and remove the two leads
(601, X4) that are connected to the input
contactor coil. Refer to Figure F.5.

POWER WAVE 455/R

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F-19

TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (CONTINUED)
FIGURE F.6 – INPUT CONTACTOR TEST POINTS

5. With the input contactor activated, check the
continuity across the three sets of contacts.
(Zero ohms or very low resistance is normal.) Refer to Figure F.6. If the resistance
is high, the input contactor is faulty. Replace
the input contactor.

7. Reconnect the two leads (601, X4) to the
input contactor coil.
8. Install the input access door and case top
using the 3/8” nut driver.

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6. When the contactor is NOT activated, the
resistance should be infinite or very high
across the contacts. If the resistance is low,
the input contactor is faulty.

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F-19

POWER WAVE 455/R

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F-20

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

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

MATERIALS NEEDED

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3/8” Nut driver
Volt/ohmmeter
Wiring Diagram

This procedure should take approximately 30 minutes to perform.

POWER WAVE 455/R

F-20

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F-21

TROUBLESHOOTING & REPAIR

F-21

DC BUS POWER SUPPLY PC BOARD TEST (CONTINUED)
FIGURE F.7 – DC BUS POWER SUPPLY POWER SUPPLY PC BOARD

LED

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DC BUS
POWER
SUPPLY
PC BOARD

J47
J46
CAPACITOR
C3
CAUTION!

J46

J47

1 2

1 2 3 4

3 4

5 6 7 8

TEST PROCEDURE

WARNING

1. Remove input power to the machine.
ELECTRIC SHOCK can kill.

2. Using the 3/8” nut driver, remove the case
top.

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

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3. Locate the DC Bus Power Supply PC Board
and plugs P46 and P47. See Figure F.7.
4. Carefully apply input power to the Power
Wave 455/R.

5. Turn on the Power Wave 455/R. The LED
on the DC Bus Power Supply PC Board
should light.

POWER WAVE 455/R

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F-22

DC BUS POWER SUPPLY PC BOARD TEST(CONTINUED)
6. Check the DC Bus Power Supply PC Board
input and output voltages according to Table
F.3.
See Figure F.7 and the Wiring
Diagram.

WARNING
ELECTRIC SHOCK can kill.

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

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F-22

TROUBLESHOOTING & REPAIR

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

TABLE F.3 – DC BUS POWER SUPPLY PC BOARD VOLTAGE TABLE

Positive Meter Probe
Test Point

Negative Meter Probe
Test Point

Approximate Voltage
Reading

Conditions/Comments

Plug P46 – Pin 1

Plug P46 – Pin 3

65 – 75 VDC

Should be same as the
Power PC Board
Rectifier

Plug P47 – Pin 7

Plug P47 – Pin 6

38.0 – 42.0 VDC

Supply to Power PC
Board

Plug P47 – Pin 8

Plug P47 – Pin 6

38.0 – 42.0 VDC

Supply to Power PC
Board

Plug P47 – Pin 4

Plug P47 – Pin 2

38.0 – 42.0 VDC

Supply to Feed Head PC
Board

Plug P47 – Pin 3

Plug P47 – Pin 1

38.0 – 42.0 VDC

Supply to S1 Wire
Feeder Receptacle

POWER WAVE 455/R

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F-23

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

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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
3/8” Nut driver
Volt-ohmmeter
Wiring Diagram

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This procedure should take approximately 30 minutes to perform.

POWER WAVE 455/R

F-23

TROUBLESHOOTING & REPAIR

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F-24

POWER BOARD TEST (CONTINUED)
FIGURE F.8 – POWER BOARD TEST

J41

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J42

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F-24

5 6
J42

J43

3 4

3 4
J41

9 10 11 12
J43

TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top.

6. Turn on the Power Wave 455/R. Carefully
test for the correct voltages at the Power
Board according to Table F.4.

Discharge

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.

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.

8. If any of the DC voltages are low or not present at plugs J42 and/or 43, the Power
Board may be faulty.

5. Carefully apply input power to the Power
Wave 455/R.

9. Install the case top using the 3/8” nut driver.

3. Perform
the
Procedure.

Capacitor

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

POWER WAVE 455/R

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F-25

TROUBLESHOOTING & REPAIR
POWER BOARD TEST (CONTINUED)
TABLE F.4 – POWER BOARD VOLTAGE CHECKS

CHECK POINT
LOCATION

TEST
DESCRIPTION

CONNECTOR
PLUG PIN NO.

LEAD NO. OR
IDENTITY

NORMAL
ACCEPTABLE
VOLTAGE
READING

POWER BOARD
CONNECTOR
PLUG J41

CHECK 40 VDC
INPUT FROM
DC BUS BOARD

2 (+)
1 (-)

477 (+)
475 (-)

38 – 42 VDC

POWER BOARD
CONNECTOR
PLUG J42

CHECK +15
VDC SUPPLY FROM
POWER BOARD

225 (+)
222 (-)

+15 VDC

221 (+)
222 (-)

+5 VDC

222 (+)
223 (-)

-15 VDC

274 (+)
273 (-)

+5 VDC

475

477

1 (+)
5 (-)

225

222

POWER BOARD
CONNECTOR
PLUG J42

CHECK +5 VDC
SUPPLY FROM
POWER BOARD

POWER BOARD
CONNECTOR
PLUG J42

CHECK -15 VDC
SUPPLY FROM
POWER BOARD

3 (+)
5 (-)

221

222

223

2 (+)
5 (-)

222

POWER BOARD
CONNECTOR
PLUG J43

CHECK +5 VDC
ARCLINK SUPPLY
FROM POWER BOARD

5 (+)
10 (-)

POWER BOARD
CONNECTOR
PLUG J43

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

4 (+)
9 (-)

226 (+)
228 (-)

+5 VDC

226

6 (+)
11 (-)

266 (+)
267 (-)

+15 VDC

266

478 (+)
476 (-)

38 – 42 VDC

268A (+)
262 (-)

+5 VDC

345 (+)
346 (-)

+20 VDC

274

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273

228

POWER BOARD
CONNECTOR
PLUG J43

CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD

267

POWER BOARD
CONNECTOR
PLUG J41

CHECK +40 VDC
INPUT FROM
DC BUS BOARD

4 (+)
3 (-)

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476

POWER BOARD
CONNECTOR
PLUG J43

CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD

268A

478

3 (+)
12 (-)

262

POWER BOARD
CONNECTOR
PLUG J43

CHECK +20 VDC STT
SUPPLY FROM
POWER BOARD

346

7 (+)
1 (-)

345

POWER WAVE 455/R

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F-26

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

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TEST DESCRIPTION
This test will help determine if the Input Board is sending the correct voltages and also if
the Input Board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

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3/8” Nut driver
Volt-ohmmeter
Wiring Diagram

This procedure should take approximately 30 minutes to perform.

POWER WAVE 455/R

F-26

INPUT BOARD TEST (CONTINUED)
FIGURE F.9 – INPUT CONTACTOR CR1

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J60

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J61

601
1

3 4

5
X4
INPUT
CONTACTOR

6 7
J60

8 9 10
J61

TEST PROCEDURE

WARNING

1. Remove input power to the Power Wave
455/R.

ELECTRIC SHOCK can kill.

2. Using the 3/8” nut driver, remove the case
top.

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

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3. Remove lead X4 from the coil terminal of
main input contactor CR1. Insulate lead X4.
Refer to Figure F.9.
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F-27

TROUBLESHOOTING & REPAIR

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F-27

4. Carefully apply input power to the Power
Wave 455/R.

5. Turn on the Power Wave 455/R. Carefully
test for the correct voltages according to
Table F.5.

POWER WAVE 455/R

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F-28

TROUBLESHOOTING & REPAIR
INPUT BOARD TEST(CONTINUED)
6. Remove input power to the Power Wave
455/R. If any of the voltages are low or not
present, perform the Input Contactor Test.
If that checks out, the Input Board may by
faulty.

9. Turn on the Power Wave 455/R. Check for
the presence of 24 VAC from lead X4 to
lead 601. See Figure F. 9. If the voltage
is not present, perform the Auxiliary
Transformer #1 Test.

7. Reconnect lead X4 to the main input contactor CR1 coil terminal.

9. This 24 VAC is the coil voltage for main
input contactor CR1. It will normally be
present approximately 12 seconds after
input line switch (SW1) is activated.

8. Carefully apply the correct input voltage to
the Power Wave 455/R.

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WARNING

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F-28

10. When the test is completed, remove input
power from the Power Wave 455/R.
11. Install the case top using the 3/8” nut driver.

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

POWER WAVE 455/R

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F-29

TROUBLESHOOTING & REPAIR
INPUT BOARD TEST(CONTINUED)
TABLE F.5 – INPUT BOARD VOLTAGE CHECKS

TEST POINTS

LEAD
NUMBERS

EXPECTED
VOLTAGE
READINGS

J61

SAME AS
INPUT
VOLTAGE

PLUG J61 PIN 8 (H1D)
TO
PLUG J61 PIN 2 (612)

COMMENTS

Present when Input
Switch SW1 is closed.

#612

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H1D

PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)

J61
T1

J60

#238

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This is Pre-Charge Voltage and
will normally be present 6 seconds after activating Input Switch
SW1. The Pre-Charge Voltage
should remain for approximately 6
seconds and then be removed.

13 – 15 VDC

This is the Coil Voltage for the
Pre-Charge Relay. Normally this
DC Voltage will be present 6 seconds after Input Switch SW1 is
activated. This 13 - 15 VDC will
remain for approximately 6 seconds and then be removed. The
Relay is controlled by the Control
Board. See the Wiring Diagram.

13 – 15 VDC

This is the DC Coil Voltage for the
Control Relay. Normally this DC
Voltage will be present approximately 12 seconds after Input
Switch SW1 is activated. The
Relay is controlled by the Control
PC Board. See the Wiring
Diagram.

PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)

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A LITTLE LESS
THAN INPUT
VOLTAGE

PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)

#604

J60

#238

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#232

POWER WAVE 455/R

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F-30

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

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TEST DESCRIPTION
This test will help determine if the STT Chopper Board is receiving the necessary voltages
to function and if the related circuitry is correct.

MATERIALS NEEDED

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3/8” Nut driver
Volt-ohmmeter
Wiring Diagram

This procedure should take approximately 30 minutes to perform.

POWER WAVE 455/R

F-30

F-31

TROUBLESHOOTING & REPAIR

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F-31

STT CHOPPER BOARD TEST (CONTINUED)
FIGURE F.10 – STT CHOPPER BOARD TEST DETAILS
CONTROL PC BOARD

POWER PC BOARD

J43

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346

9 10 11 12 13 14 15 16
4W 4R

3 4

9 10 11 12

345

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STT OUTPUT
TERMINAL
POWER WAVE
+ OUTPUT
TERMINAL

TEST PROCEDURE
1. Remove input power to the Power Wave
455/R.

+ probe on the Power Wave + output terminal

2. Using the 3/8” nut driver, remove the case
top and the control box cover. See Figure
F.10.

- probe on the STT output terminal

3. Perform the following resistance tests:
+ probe on the STT output terminal

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- probe on the Power Wave + output terminal
The reading should be approximately
300,000 ohms

POWER WAVE 455/R

The reading should be less than 500 ohms
If both the polarity resistance tests are low,
either the STT Chopper Module is faulty or
diode D6 is shorted. See the Wiring
Diagram.

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F-32

TROUBLESHOOTING & REPAIR
STT CHOPPER BOARD TEST (CONTINUED)
4. Carefully apply input power to the Power
Wave 455/R.

WARNING
ELECTRIC SHOCK can kill.

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

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F-32

For steps 5 and 6, see Figure F.10.

6. Measure the voltage from Control Board
plug J7 lead 4W pin 13 (-) to lead 4R pin 14
(+). The voltage should be 4 – 5 VDC. This
is the pulse width modulation signal to the
STT Chopper Board. If not correct, the
Control Board may be faulty.

7. When the test is completed, remove input
power from the Power Wave 455/R.

8. Install the case top using the 3/8” nut driver.

5. Turn on the Power Wave 455/R. Measure
the voltage from Power Board plug J43 lead
345 pin 7 (+) to lead 346 pin 1 (-). The voltage should be approximately 20 VDC. If not
correct, the Power Board may be faulty.

POWER WAVE 455/R

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F-33

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

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

MATERIALS NEEDED

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3/8” nut driver
Volt-Ohmmeter

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-33

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F-34

TROUBLESHOOTING & REPAIR

F-34

POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.11 – POWER WAVE CURRENT TRANSDUCER TEST
CONTROL BOARD

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J8
211 212 213
1

3 4

7 8

216
CURRENT
TRANSDUCER

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1234

P91

TEST PROCEDURE

WARNING

1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and the control box cover.

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3. Locate the Power Wave current transducer
leads at Control Board plug J8. See Figure
F.11.
4. Carefully apply input power to the Power
Wave 455/R.

POWER WAVE 455/R

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

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F-35

POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.12 – RECEPTACLE S7 TRIGGERED

RECEPTACLE
S7

POWER
WAVE

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STT

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F-35

TROUBLESHOOTING & REPAIR

5. Turn on the Power Wave 455/R. Check for
the correct DC supply voltage to the current
transducer at plug J8. See Figure F.11.

NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F.12.

A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read +15 VDC.

7. With the Power Wave 455/R triggered,
check the feedback voltage from the current
transducer. The current feedback voltage
can be read at plug J8 on the Control Board.

B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read -15 VDC.
If the DC supply voltages are not present,
the control board may be faulty.
6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P91 and the Control Board.

POWER WAVE 455/R

A. Pin 1 (lead 211) to pin 6 (lead 216)
should read 2.0 VDC (machine loaded
to 250 amps).

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F-36

TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER TEST (CONTINUED)

8. If for any reason the machine cannot be
loaded to 250 amps, Table F.6 shows what
feedback voltage is produced at various current loads.

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9. If the correct supply voltages are applied to
the current transducer, and with the machine
loaded, the feedback voltage is missing or

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F-36

not correct, the current transducer may be
faulty. Also make certain that lead 211
(plug J8 pin 1) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.
10. Install the right side case cover using the
3/8” nut driver.

TABLE F.6 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS
OUTPUT LOAD CURRENT

EXPECTED TRANSDUCER FEEDBACK
VOLTAGE

500
450
400
350
300
250
200
150
100
50

4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4

POWER WAVE 455/R

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F-37

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

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

MATERIALS NEEDED

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3/8” nut driver
Volt-Ohmmeter

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-37

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F-38

TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.13 – STT CURRENT TRANSDUCER TEST
CONTROL BOARD

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813
1

3 4

7 8

811

816 812
J8

1234
P90
CURRENT
TRANSDUCER

TEST PROCEDURE

WARNING

1. Remove input power to the Power Wave
455/R.

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2. Using the 3/8” nut driver, remove the case
top and the control box cover.
3. Locate the STT current transducer leads at
Control Board plug J8. See Figure F.13.
4. Carefully apply input power to the Power
Wave 455/R.

POWER WAVE 455/R

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

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F-39

STT CURRENT TRANSDUCER TEST (CONTINUED)
FIGURE F.14 – RECEPTACLE S7 TRIGGERED

POWER
WAVE

RECEPTACLE
S7

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STT

5. Turn on the Power Wave 455/R. Check for
the correct DC supply voltage to the current
transducer at plug J8.

NOTE: The machine can be triggered by
jumpering pin 1 to pin 2 at receptacle
S7. See Figure F. 14.

A. Pin 8 (lead 812+) to pin 7 (lead 816-)
should read +15 VDC.

7. With the Power Wave 455/R triggered,
check the feedback voltage from the current
transducer. The current feedback voltage
can be read at plug J8 on the Control Board.

B. Pin 4 (lead 813-) to pin 7 (lead 816+)
should read -15 VDC.
If the DC supply voltages are not present,
the control board may be faulty.

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6. If both of the supply voltages are low or
missing, check the associated leads
between plug J8 and current transducer plug
P90 and the Control Board.

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F-39

TROUBLESHOOTING & REPAIR

POWER WAVE 455/R

A. Pin 5 (lead 811) to pin 7 (lead 816)
should read 2.0 VDC (machine loaded
to 50 amps).

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TROUBLESHOOTING & REPAIR

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F-40

STT CURRENT TRANSDUCER TEST (CONTINUED)

8. If for any reason the machine cannot be
loaded to 50 amps, Table F.6 shows what
feedback voltage is produced at various current loads.

faulty. Also make certain that lead 811 (plug
J8 pin 5) has continuity (zero ohms)
between the current transducer and the
control board. See the Wiring Diagram.

9. 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

10. Install the right side case cover using the
3/8” nut driver.

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F-40

POWER WAVE 455/R

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F-41

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

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TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.

MATERIALS NEEDED
Analog Volt-Ohmmeter
3/8” Nut driver
5/16” Wrench

This procedure should take approximately 20 minutes to perform.

POWER WAVE 455/R

F-41

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F-42

TROUBLESHOOTING & REPAIR

F-42

OUTPUT RECTIFIER TEST (CONTINUED)
FIGURE F.15 – OUTPUT RECTIFIER TEST

I ON

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POWERWAVE 455/R

NEGATIVE (-)
OUTPUT
TERMINAL

STT OUTPUT
TERMINAL
POSITIVE (+)
OUTPUT
TERMINAL

TEST PROCEDURE
1. Remove main input supply power to the
Power Wave 455/R.
2. Remove the case top and sides and perform
the Input Filter Capacitor Discharge procedure.
3. Using the 5/16” wrench, remove and insulate lead 202A from the negative output terminal.

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4. Remove any output load that may be connected to the Power Wave 455/R.

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O OFF

5. With the analog ohmmeter, measure the
resistance between the positive and negative output terminals (NOT the STT terminal). Refer to Figure F.15.

IMPORTANT: The positive (+) meter probe
must be attached to the positive (+) output terminal and the negative (-) meter probe must be
attached to the negative (-) output terminal.
6. If the reading is more than 200 ohms, the
output rectifier modules are not shorted. If
the reading is less than 200 ohms, one or
more of the rectifier modules are shorted.
Refer to the Output Rectifier Module
Replacement procedure.
7. Reconnect lead 202A to the negative output
terminal.
8. Replace the case top and sides.

POWER WAVE 455/R

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F-43

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1 and also if the correct voltages are being induced on the secondary
windings of the transformer.

MATERIALS NEEDED

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Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram

This procedure should take approximately 30 minutes to perform.

POWER WAVE 455/R

F-43

F-44

TROUBLESHOOTING & REPAIR

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F-44

AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
FIGURE F.16 – AUXILIARY TRANSFORMER NO. 1 TEST
X3

X5
INPUT
CONTACTOR

601

FAN MOTOR
LEADS

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X4
-

POWER BOARD
RECTIFIER BRIDGE

TEST PROCEDURE
1. Remove the main input power to the Power
Wave 455/R machine.

5. Locate secondary leads X3 and X5 (fan
motor leads).

2. Using the 3/8” nut driver, remove the case
top and sides.

6. Locate secondary lead X4 (at main contactor).

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3. Perform the Capacitor Discharge procedure.
4. Locate secondary leads X1 and X2 (at
power board rectifier bridge). Refer to
Figure F.16.

POWER WAVE 455/R

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F-45

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (CONTINUED)
TABLE F.7 – SECONDARY VOLTAGES

LEAD IDENTIFICATION

NORMAL EXPECTED VOLTAGE

X1 to X2
X3 to X5
X3 to X4

52 VAC
115 VAC
24 VAC

7. Carefully apply the correct input voltage to
the Power Wave 455/R.

WARNING
ELECTRIC SHOCK can kill.
High voltage is present at primary of the Auxiliary Transformer.

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8. Check for the correct secondary voltages
according to Table F.7.

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F-45

NOTE: The secondary voltages will vary if the
input line voltage varies.

9. If the correct secondary voltages are present, the T1 auxiliary transformer is functioning properly. If any of the secondary
voltages are missing or low, check to make
certain the primary is configured correctly
for the input voltage applied. See the
Wiring Diagram.
10. If the correct input voltage is applied to the
primary, and the secondary voltage(s) are
not correct, the T1 transformer may be
faulty.
11. Replace any cables ties and insulation
removed earlier.
12. Install the case sides and top using the 3/8”
nut driver.

POWER WAVE 455/R

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F-46

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2 and also if the correct voltages are being induced on the secondary
windings of the transformer.

MATERIALS NEEDED

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Volt-ohmmeter (Multimeter)
3/8” Nut driver
Wiring Diagram

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-46

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F-47

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST (CONTINUED)
FIGURE F.17 – AUXILIARY TRANSFORMER NO. 2 TEST

H4 H3 H1
1

3
VIEWED FROM
TRANSFORMER
LEAD SIDE

H5 H6 H2
P50

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350 352
1

2
VIEWED FROM
TRANSFORMER
LEAD END

4
33A

P52

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TEST PROCEDURE
1. Remove the main input power to the Power
Wave 455/R machine.
2. Remove any load that may be connected to
the 115 VAC receptacle.
3. Using the 3/8” nut driver, remove the case
top.
4. Locate plugs P52 and P50 at the Auxiliary
Transformer No. 2. Refer to Figure F.17.
5. Carefully apply the correct input power.

WARNING

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ELECTRIC SHOCK can kill.
High voltage is present at both
plugs.

6. Check for 115 VAC at plug P52 pins 1 and
4 (leads 350 to 33A). Check for 230 VAC
at plug P52 pins 1 and 2 (leads 350 to
352).
7. If 115 VAC and 230 VAC are present,
Auxiliary Transformer No. 2 is good.
8. If 115 is not present between pins 1 and 4,
and 230 VAC is not present between pins 1
and 2, check the associated leads and
plugs for loose or faulty connections.
9. Carefully test for the correct AC input voltage applied to the primary windings at plug
P50. See the Wiring Diagram.
10. If the correct AC input voltage is applied to
the primary of the Auxiliary Transformer
No. 2 and the secondary voltage is NOT
correct, the transformer may be faulty.
Replace.
11. Replace any cables ties and insulation
removed earlier.
12. Install the case top using the 3/8” nut dri-

POWER WAVE 455/R

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F-48

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

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DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifier module.

MATERIALS NEEDED
3/8” nut driver
3/16” Allen wrench
Phillips head screwdriver

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This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-48

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F-49

TROUBLESHOOTING & REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.18 – INPUT RECTIFIER REMOVAL AND REPLACEMENT
INPUT
RECTIFIER

C
B
A

NEG (-)

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POS (+)

REMOVAL PROCEDURE

REPLACEMENT PROCEDURE

1. Remove input power to the Power Wave
455/R.

1. Clean heat sink surfaces.

2. Using the 3/8” nut driver, remove the case
top, sides, and input access panel.
3. Perform the Capacitor Discharge procedure.

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4. Locate and remove the RTV sealant from
the input rectifier connection terminals. See
Figure F. 18.
5. Label and, using the phillips head screwdriver, carefully remove the five leads from the
input rectifier terminals. Note placement for
reassembly. See Figure F.18.
6. Using the 3/16” allen wrench, remove the
two mounting screws and washers from the
rectifier module.

2. Apply an even coating of joint compound
(Penetrox A-13) to both the heat sink and
module mounting surfaces. The joint compound should be 0.002 - 0.005 in. thick per
surface.
3. Mount the module to the heat sink and evenly torque the mounting screws (with washers) to 44 in/lbs.
4. Assemble the leads to the correct module
terminals and torque to 26 in/lbs. See
Figure F.18.
5. Apply RTV sealant to the rectifier connection
terminals.
6. Install the case top, sides, and input access
panel using the 3/8” nut driver.

7. Carefully remove the input rectifier module.
POWER WAVE 455/R

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F-50

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

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input contactor.

MATERIALS NEEDED

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3/8” nut driver
5/16” nut driver
Phillips head screwdriver

This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-50

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F-51

TROUBLESHOOTING & REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.19 – INPUT CONTACTOR REMOVAL AND REPLACEMENT

INPUT
CONTACTOR
601

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REMOVAL PROCEDURE

REPLACEMENT PROCEDURE

1. Remove input power to the Power Wave
455/R.

1. Mount the contactor and tighten the mounting screws.

2. Using the 3/8” nut driver, remove the case
top, sides, and input access panel.

2. Assemble the leads to the correct terminals.
See Figure F.18.

3. Perform the Capacitor Discharge procedure

3. Install the case top, sides, and input access
panel using the 3/8” nut driver.

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4. Locate the input contactor. Label and,
using the phillips head screwdriver, carefully remove the leads from the input contactor terminals. Note placement for reassembly. See Figure F.19.
5. With the 5/16” nut driver, remove the three
mounting screws. See Figure F.19.
6. Carefully remove the input contactor.

POWER WAVE 455/R

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F-52

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 1.

MATERIALS NEEDED

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3/8” Nut driver
Wire cutters
Wire splicer or soldering equipment

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-52

AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.20 – AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT
X3

H1
CB4

RECONNECT
TERMINALS
H2
H3
H4
H5

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INPUT
CONTACTOR

601

FAN MOTOR
LEADS

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F-53

TROUBLESHOOTING & REPAIR

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F-53

POWER BOARD
RECTIFIER BRIDGE

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REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.

4. Using the 3/8” nut driver, remove the case
back.

2. Using the 3/8” nut driver, remove the case
top, sides and input access panel.

5. Remove lead X4 from the input contactor
coil terminal.

3. Perform the Capacitor Discharge procedure.

POWER WAVE 455/R

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F-54

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)

6. Remove leads X1 and X2 from the power
board rectifier bridge. Refer to Figure
F.20.

8. Cut the X3 lead that is connected to the
input board. Leave enough lead length to
splice in the new transformer lead.
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7. Cut X3 and X5 from the fan motor leads.
Leave enough lead length to splice in the
new transformer leads.

9. Locate, label, and remove primary lead H1
from circuit breaker CB4.
10. Label and remove primary leads H2, H3,
H4, and H5 from the reconnect terminals
on the reconnect panel. Note lead placement for reassembly.

6. Splice the new transformer fan leads to
the fan motor leads X3 and X5.
7. Connect lead X4 to the main contactor
coil terminal.
8. Connect leads X1 and X2 to the power
board rectifier bridge.
9. Reposition any wire leads and install
cable ties as necessary.
10. Install the case back using the 3/8” nut
driver.
11. Install the case top, sides, and input
access panel using the 3/8” nut driver.

11. Cut any necessary cable ties and clear the
leads.
12. Using the 3/8” nut driver, remove the two
mounting screws that hold the transformer
to the fan baffle and the machine base.

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13. Carefully remove the transformer from the
Power Wave 455/R.

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F-54

REPLACEMENT PROCEDURE
1.

Carefully place the transformer into the
Power Wave 455/R.

Install the two mounting screws that hold
the transformer to the fan baffle and the
machine base using the 3/8” nut driver.

Install the primary leads H2, H3, H4, and
H5 to the reconnect terminals on the
reconnect panel.

Connect primary lead H1 to circuit breaker
CB4.

Splice the new transformer lead with the
X3 lead connected to the input board.

POWER WAVE 455/R

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F-55

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary transformer No. 2.

MATERIALS NEEDED

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3/8” Nut driver
Wire cutters

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-55

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F-56

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.21 – AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT

INPUT
CONTACTOR

601

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X4
P52

P50

CB4 CIRCUIT
BREAKER &
115V RECEPTACLE
LEADS 33/32

REMOVAL PROCEDURE

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1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top, sides and input access panel.
3. Perform the Capacitor Discharge procedure.

5. Disconnect plugs P50 and P52.
6. Disconnect leads 33 and 32 to circuit breaker
CB2 and the 115 V receptacle.
7. Using the 3/8” nut driver, remove the two
transformer mounting screws.

4. Using the 3/8” nut driver, remove the case
back.

POWER WAVE 455/R

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F-57

TROUBLESHOOTING & REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (CONTINUED)

REPLACEMENT PROCEDURE
1. Carefully place the transformer into the
Power Wave 455/R.

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2. Install the two mounting screws that hold the
transformer to the machine base using the
3/8” nut driver.
3. Connect leads 33 and 32 to circuit breaker
CB4 and the 115 V receptacle.
4. Connect plugs P50 and P52.
5. Reposition any wire leads and install cable
ties as necessary.
6. Install the case back using the 3/8” nut driver.
7. Install the case top, sides, and input access
panel using the 3/8” nut driver.

POWER WAVE 455/R

F-57

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F-58

TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT
WARNING

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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 troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the
Control Board the Feed Head Board, or the Voltage Sense Board.

MATERIALS NEEDED

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3/8” Nut driver
Anti-static wrist strap

This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-58

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F-59

TROUBLESHOOTING & REPAIR

F-59

CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.22 – CONTROL OR FEED HEAD BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER

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CONTROL
BOARD

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POWER
BOARD

REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.

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2. Using the 3/8” nut driver, remove the case
top and sides.
3. Perform the Capacitor Discharge procedure.
4. Observe all static electricity precautions.

6. Using the 3/8” nut driver, remove the two
screws holding the rear of the Control Box in
place.
7. Clear the leads in the sleeving and the grommets on the sides of the control box.
8. Label and remove the molex plugs from the
Control Board and the Feed Head Board.

5. Using the 3/8” nut driver, remove the PC
board compartment cover. Refer to Figure
F.22.

POWER WAVE 455/R

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F-60

TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.23 – VOLTAGE SENSE BOARD REMOVAL AND REPLACEMENT
COMPARTMENT
COVER

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CONTROL
BOARD
VOLTAGE
SENSE
BOARD

POWER
BOARD

9. Tilt back the rear of the control box to
access the PC board mounting nuts. Using
the 3/8” nut driver, remove the self-locking
mounting nuts from the Control and Feed
Head Boards.
Carefully remove the
boards.

REPLACEMENT PROCEDURE
1. Install either the Control or the Feed Head
Board to the back of the control box with the
self-locking nuts. Use the 3/8” nut driver.

10. Remove plugs J1 and J2 from the Voltage
Sense Board. See Figure F.23.

2. Connect the molex plugs to the Control
Board and the Feed Head Board. Be sure
the lead harnesses are securely and properly positioned.

11. Using the needle-nose pliers, carefully
pinch the three plastic standoffs. Remove
the Voltage Sense Board.

3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.

POWER WAVE 455/R

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F-61

TROUBLESHOOTING & REPAIR
CONTROL, FEED HEAD, OR VOLTAGE SENSE PC BOARD
REMOVAL AND REPLACEMENT (CONTINUED)

3. Secure the rear of the control box in place
using two screws and the 3/8” nut driver.
4. Press the Voltage Sense Board onto its
standoffs. Make sure the board snaps into
place on all three standoffs.

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5. Connect the two molex plugs to the Voltage
Sense Board.
6. Install the PC board compartment cover
using the 3/8” nut driver.
7. Install the case top and sides using the 3/8”
nut driver.

POWER WAVE 455/R

F-61

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F-62

TROUBLESHOOTING & REPAIR
GATEWAY PC BOARD REMOVAL AND REPLACEMENT

WARNING

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DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Gateway PC
Board.

MATERIALS NEEDED

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Phillips head screw driver
3/8” Nut driver
Anti-static wrist strap

This procedure should take approximately 15 minutes to perform.

POWER WAVE 455/R

F-62

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F-63

TROUBLESHOOTING & REPAIR

F-63

GATEWAY PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)

FIGURE F.24 – GATEWAY BOARD REMOVAL AND REPLACEMENT

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DEVICENET/
GATEWAY BOARD
(LOCATED BEHIND
FRONT COVER)

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PHILLIPS
SCREW

REMOVAL PROCEDURE

REPLACEMENT PROCEDURE

1. Remove input power to the Power Wave
455/R.

1. Install the Gateway Board to the case front
cover with the self-locking nuts. Use the 3/8”
nut driver.

2. Using the phillips head screw driver, remove
the six screws from the case front cover. Tilt
open the cover and support it. See Figure
F.24.

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3. Observe all static electricity precautions.

2. Connect the four molex plugs to the
Gateway Board.
3. Using the phillips head screw driver, attach
the cover to the case front.

4. Label and remove the four molex plugs from
the Gateway Board.
5. Using the 3/8” nut driver, remove the selflocking mounting nuts from the Gateway
Board. Carefully remove the board. Refer
to Figure F.24.

POWER WAVE 455/R

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F-64

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

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DESCRIPTION
This procedure will aid the technician in the removal and replacement of the STT Current
Transducer.

MATERIALS NEEDED
3/8” Nut driver
5/16” Open end wrench
5/16” Socket wrench with extension
Universal adapter
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-64

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F-65

TROUBLESHOOTING & REPAIR

F-65

STT CURRENT TRANSDUCER
REMOVAL AND PLACEMENT (CONTINUED)
FIGURE F.25 – STT CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE

RESISTOR
ASSEMBLY
1234
P90

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STT OUTPUT
TERMINAL
(TOP RIGHT)

CURRENT
TRANSDUCER

REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and right side.

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3. Perform the Capacitor Discharge procedure.
4. Using the wire cutters, cut all cable ties to
the transducer lead harness. Unplug the
harness and swing it aside.

5. Label and remove the leads to the resistor
assembly. See Figure F.25. Using the
5/16” socket wrench, extension and universal adapter, remove the resistor assembly.
It may be necessary to remove the glastic
high voltage protection shield. (Use the
3/8” nut driver.) It may also be necessary to
use a 5/16” open end wrench to remove the
inside screws. Carefully swing the resistor
assembly aside.

POWER WAVE 455/R

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F-66

TROUBLESHOOTING & REPAIR
STT CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)

6. With the 5/16” open end wrench, remove
the small screw from the STT output terminal. Label and remove the small leads.
See the Wiring Diagram.

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7. Using the 3/4” wrench, remove the bolt,
lock washer and flat washer from the STT
output terminal. Remove the double heavy
output leads. Cut any necessary cable
ties.
8. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
9. Remove the STT current transducer, carefully feeding the output leads through it.

3. Attach the double heavy leads to the STT
output terminal with the 3/4” bolt, lock washer and flat washer.
4. Attach the small leads to the STT output terminal with the 5/16” screw.
5. Install the resistor assembly using the 5/16”
socket wrench, extension and universal
adapter. Install the glastic high voltage protection shield with the 3/8” nut driver.
6. Replace all cable ties cut during removal.
7. Install the case top and right side using the
3/8” nut driver.

10. Remove the standoffs from the transducer
and save them for reassembly with the new
transducer.

REPLACEMENT PROCEDURE

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1. Attach the standoffs to the transducer.

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F-66

2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.

POWER WAVE 455/R

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F-67

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

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Power Wave
Current Transducer.

MATERIALS NEEDED

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3/8” Nut driver
5/16” Open end wrench
9/16” Wrench
3/4” Wrench
Phillips head screw driver
Wire cutters
Wiring Diagram

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-67

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F-68

TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)

FIGURE F.26 – POWER WAVE CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE

CURRENT
TRANSDUCER
HEAVY LEAD
BOLTED CONNECTION
(BEHIND CASE FRONT)

REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and sides and the control box cover.

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3. Perform the Capacitor Discharge procedure.
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F-68

4. Using the 3/8” socket wrench or nut driver,
remove the three screws along the bottom
case front. See Figure F.26.

6. Label all leads to all output terminals. Using
the 5/16” wrench and the 3/4” wrench,
remove all leads from the three output terminals. See the Wiring Diagram.
7. Cut any necessary cable ties. Then carefully swing the front panel aside.
8. Remove the insulating tape from the heavy
lead bolted connection. See Figure F.26.
Using the 9/16” wrenches, remove the bolt,
lock washer and nut.

5. Using the 3/8” socket wrench, remove the
four screws that hold the case front to the
machine.
POWER WAVE 455/R

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F-69

TROUBLESHOOTING & REPAIR
POWER WAVE CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT (CONTINUED)

9. Using the phillips head screw driver,
remove the screws and lock washers that
hold the transducer to the front panel.
10. Remove the Power Wave current transducer.

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11. Remove the standoffs from the transducer
and save them for reassembly with the
new transducer.

4. Using the 5/16” wrench and the 3/4” wrench,
attach all leads to the three output terminals.
See the Wiring Diagram.
5. Replace all cable ties cut during removal.
6. Install the case top and sides using the 3/8”
nut driver.

REPLACEMENT PROCEDURE
1. Attach the standoffs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two
phillips screws and lock washers. Feed the
output leads through the transducer.

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3. Run the heavy lead through transducer
and secure the bolted connection with the
9/16” bolt, lock washer and nut. Replace
the insulating tape around the connection.

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F-69

POWER WAVE 455/R

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F-70

TROUBLESHOOTING & REPAIR

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

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output rectifier assembly and individual rectifier module replacement.
This procedure takes approximately 35 minutes to remove and replace the output rectifier, 5 minutes to remove the STT Chopper Board and 5 minutes to remove and replace the
rectifier module.

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MATERIALS NEEDED

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F-70

3/8” Nut driver
7/16” Wrench
9/16” Wrench
9/64” Allen wrench
3/16” Allen wrench
Needle-nose pliers
Slot head screwdriver
Penetrox A13 Thermal Joint Compound
Wiring Diagram

This procedure should take approximately 45 minutes to perform.

POWER WAVE 455/R

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F-71

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.27 – OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT

LEAD 287
(SNUBBER
DIODE)

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F-71

PLUG J10

RECTIFIER
THERMOSTAT
(LEADS 291 & 292)
LEAD 289B
(STT SNUBBER
CAPACITOR)
TRANSFORMER
LEADS

STT LEAD

RECTIFIER
MODULE
HEATSINK
MOUNT
BOLTS (4X)

POSITIVE
OUTPUT
LEAD

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HEATSINK

RECTIFIER ASSEMBLY
REMOVAL PROCEDURE
1. Remove input power to the Power Wave
455/R.
2. Using the 3/8” nut driver, remove the case
top and sides.

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3. Perform the Capacitor Discharge procedure.
4. Using the 9/16” wrench, remove the Power
Wave positive output lead from the rectifier
heat sink. Note fastener hardware for
reassembly. Refer to Figure F.27.

5. Using the 7/16” wrench, remove the STT
output lead from the rectifier heat sink. Note
fastener hardware for reassembly. Refer to
Figure F.27.
6. Using the 7/16” wrench, remove the eight
transformer leads from the rectifier modules.
Label the leads and take note of lead placement for reassembly. Note that each screw
has two flat washers and one lock washer.

POWER WAVE 455/R

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F-72

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
7. Using the needle-nose pliers, remove
leads #292 and #291 from the rectifier thermostat.

4. Using the 3/16” allen wrench, remove the
four screws and lock washers holding the
board to the heat sink.

8. Disconnect plug J10 from the STT
Chopper Board.

5. Carefully remove the STT Chopper Board.

9. With the 7/16” wrench, remove lead #287
from the STT Snubber Diode D5.

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10. With the 7/16” wrench, remove lead #289B
from the STT Snubber Capacitor C10.
11. Using the 7/16” wrench, remove the four
nuts and associated washers from the heat
sink mounting bolts. The heat-sink assembly can be removed by carefully sliding the
assembly forward and removing the mounting bolts.

REPLACEMENT PROCEDURE
1. Position the new board on the heat sink,
using the standoffs for the slot head nylon
screws and the allen head screws.
2. Install the four 3/16” allen head screws and
lock washers.
3. Install the two nylon slot head screws.
4. Install the two 7/16” bolts, lock washers and
flat washers.

STT CHOPPER BOARD REMOVAL
AND REPLACEMENT PROCEDURE

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1. Place the output rectifier assembly on a
clean bench surface.

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F-72

2. Using a slot head screw driver, remove the
two nylon screws holding the board to the
heat sink. Save the standoffs for reassembly.
3. Using the 7/16” wrench, remove the two
bolts, lock washers and flat washers. Save
the standoffs for reassembly.

POWER WAVE 455/R

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F-73

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER, STT CHOPPER BOARD AND RECTIFIER MODULE
REMOVAL AND REPLACEMENT (CONTINUED)
RECTIFIER MODULE REMOVAL AND
REPLACEMENT PROCEDURE

RECTIFIER ASSEMBLY REPLACEMENT PROCEDURE

1. Using the 9/64” allen wrench, remove the
cap screw from the center of the rectifier
module that is to be replaced.

1. Position the assembly in place with the
mounting bolts.

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2. Using the 7/16” wrench, remove the two
mounting bolts and associated washers
from the rectifier module to be replaced.
3. Remove the faulty module.
4. This module requires special mounting considerations to prevent warping of the base
plate. The heat sink surfaces must be clean
and flat. Apply a thin, even coating of thermal compound, (Penetrox A13) 0.004 to
0.010 inches thick. Keep the compound
away from the area of the mounting holes.
5. Press the new module firmly against the
heat sink while aligning the mounting holes.
Start all three screws two to three turns by
hand.

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6. Tighten each of the outer screws to between
5 and 10 in-lbs.
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F-73

7. Tighten the center screw to between 12 and
18 in-lbs.
8. Tighten each of the outer screws again, this
time to between 30 and 40 in/lbs.

2. Assemble the nuts and associated washers to the mounting bolts.
3. Using the 7/16” wrench, tighten the four
nuts on the mounting bolts.
4. Replace leads #292 and #291 to the thermostat.
5. Connect plug J10 to the STT Chopper
Board.
6. With the 7/16” wrench, attach lead #287
from the STT Snubber Diode D5.
7. With the 7/16” wrench, attach lead #289B
from the STT Snubber Capacitor C10.
8. Connect the eight transformer leads to the
correct rectifier modules. Tighten the
screws (with two flat washers and one lock
washer) to between 30 and 40 in/lbs. Do
not stress the terminals when making
these connections.
9. Apply a thin coat of Penetrox A13 to the
heat sink where the Power Wave positive
output lead and the STT output lead attach.
10. Attach the Power Wave positive output
lead to the heat sink using the 9/16”
wrench.
11. Attach the STT output lead to the heat sink
using the 7/16” wrench.

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12. Install the case top and sides using the 3/8”
nut driver.

POWER WAVE 455/R

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F-74

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

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).

MATERIALS NEEDED

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3/8” Nut driver
7/16” Wrench
3/16” Allen wrench
Slot head screwdriver
Penetrox A13 thermal joint compound

This procedure should take approximately 25 minutes to perform.

POWER WAVE 455/R

F-74

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F-75

TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)
FIGURE F.28 – SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT

MOLEX PLUG
MOUNTING
SCREW (4X)
13/14
OR
17/18
SWITCH
BOARD
19+

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20-

11/12
OR
15/16

REMOVAL PROCEDURE
NOTE: Observe all static electricity precautions.
Lead and plug references below use a slash (/)
to indicate machine right side/left side wire
number differences.

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1. Remove input power to the Power Wave
455/R.
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NYLON
SCREW
(2X)

2. Using the 3/8” nut driver, remove the case
top and sides.

4. Using the 5/16” nut driver, remove the three
screws mounting the glastic high voltage
protective shield. Remove the shield.
5. Remove molex plug J40/J50 from the top of
the switch board. Refer to Figure F.28.
6. Remove the mylar insulating shield covering
leads 13/14 or 17/18. Cut the cable tie.

3. Perform the Capacitor Discharge procedure.

POWER WAVE 455/R

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F-76

TROUBLESHOOTING & REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (CONTINUED)

7. Using the 7/16” wrench, remove leads
13/14 or 17/18 from the switch board.
8. Using the 7/16” wrench, remove leads
11/12 or 15/16 from the switch board.

5. Mount the new switch board and tighten
the four cap head screws in the following
manner.
Tighten all until snug.
Tighten all from 24 to 28 in-lbs.

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9. Using the 7/16” wrench, remove leads
19C/D+ and 20C/D- from the switch board
capacitor connection bolts.
10. With the slot head screwdriver, remove the
two nylon mounting screws at the bottom of
the switch board. Note placement of the
shake-proof washers and fiber spacers.
11. Using the 3/16” allen wrench, carefully
remove the four cap screws that mount the
switch board to the heat sink.
12. Carefully remove the switch board from the
heat sink.
13. If the filter capacitor is to be removed, carefully slide it out of the mounting bracket.

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REPLACEMENT PROCEDURE
1. If the filter capacitor is to be replaced, carefully slide the new capacitor into the mounting bracket. Position the capacitor so the
correct polarity terminal is lined up with the
correct hole on the switch board.
2. All heat sink and IGBT mounting surfaces
must be clean.

Tighten all from 40 to 48 in-lbs.
6. Make sure the capacitor is positioned correctly. Connect leads 19C/D+ and 20C/Dto the correct terminals. Tighten to 55
in/lbs.
7. Position and mount the two nylon screws,
fiber spacers, and washers. Torque from 4
to 8 in-lbs.
8. Connect leads 11/12 or 15/16 to the correct
terminal.
9. Connect leads 13/14 or 17/18 to the correct
terminal.
10. Install the mylar insulating shield covering
leads 11/12 or 15/16. Replace the cable
tie.
11. Connect molex plug J40/J50 to the top of
the switch board.
12. Using the 5/16” nut driver, install the glastic
high voltage protective shield.
13. Install the case top and sides using the 3/8”
nut driver.

3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 to 0.010 inches thick
to the mating surfaces. Do not apply
around mounting holes.

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4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to apply
compound to screw threads or threaded
area of terminals.
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F-76

POWER WAVE 455/R

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F-77

TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR

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

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If you repair or replace any electrical components.

INPUT IDLE AMPS AND WATTS
Input Volts/Hertz

Maximum Idle Amps

Maximum Idle KW

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

4.0
3.3
2.1
2.0
1.8

0.45
0.45
0.45
0.45
0.45

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MAXIMUM OUTPUT VOLTAGES
Input Volts/Hertz

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

Output Terminals
- No load

50-70 VDC

X1 - X2

115 Volt Receptacles

OCV

10 Amp Load

115 - 123 VAC

111 - 119 VAC

48.5 - 55 VDC

POWER WAVE 455/R

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F-78

NOTES

POWER WAVE 455/R

F-78

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Section G-1

TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -

Section G-1

Electrical Diagrams ..............................................................................................................Section G
Wiring Diagram (Code 10675)....................................................................................................G-2
Wiring Diagram (Code 10676)....................................................................................................G-3
Schematic - Complete Machine (Code 10675) ..........................................................................G-4
Schematic - Complete Machine (Code 10676) ..........................................................................G-5
Schematic - Chopper PC Board .................................................................................................G-6
PC Board Assembly - Chopper PC Board ..................................................................................G-7
Schematic - DeviceNet/Gateway PC Board ...............................................................................G-8
PC Board Assembly - DeviceNet/Gateway PC Board ................................................................G-9

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Schematic - Control PC Board .................................................................................................G-10
PC Board Assembly - Control PC Board ..................................................................................G-11
Schematic - Digital Power Supply PC Board............................................................................G-12
PC Board Assembly - Digital Power Supply PC Board ............................................................G-13
Schematic - FeedHead PC Board #1 .......................................................................................G-14
Schematic - FeedHead PC Board #2 .......................................................................................G-15
Schematic - FeedHead PC Board #3 .......................................................................................G-16
PC Board Assembly - FeedHead PC Board .............................................................................G-17
Schematic - Input PC Board .....................................................................................................G-18
PC Board Assembly - Input PC Board......................................................................................G-19
Schematic - Switch PC Board ..................................................................................................G-20

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PC Board Assembly - Switch PC Board ...................................................................................G-21
Schematic - Voltage Sense PC Board......................................................................................G-22
PC Board Assembly - Voltage Sense PC Board ......................................................................G-23
Schematic - 40 VDC Bus PC Board .........................................................................................G-24
PC Board Assembly - 40 VDC Bus PC Board..........................................................................G-25

POWER WAVE 455/R

POWER WAVE

LEFT SIDE OF MACHINE

C1
.05/600V

J70

1
2

+24V

+24V GND 3

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CAN_H
CAN_L

4
5

A
B

TO
J75

S1
WIRE
FEEDER
RECEPTACLE

894
893
892
891

S6
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N

67A

TO
P73
J2VS
CB1
J47

J71
TO
S1

S2
VOLTAGE
SENSE
RECEPTACLE

841
844
842
843
845
846
847

3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE

67B
539
541

TO
J83
J84
J2VS

1
2
3
4

J72

TO
J9

21A

J73
1
2
3
4
5
6
7

S3
RS232
CONNECTOR

521

53
54

253
254

J74
TO
J2

J75

251

20
522

P
R
S
T
U
V
W
X

J76

CB1
10A CIRCUIT
BREAKER

GND-A

TO
L2
BUSS BD

743
741
800
840
53
54

TO
J81
TO
S1
J4

892
893

TO
S5

891
894
J5
830

TO
WORK
ELECTRODE

TP3

1
2
3
4
5
6
7
8
9
10
11
12

851
852
853
854
855
856
857
858
859
860
861
862

S4
115V
RECEPTACLE

TO
WORK
STT

TP6

TO
J85
31

32
TO
AUX 2
CB2

VOLTAGE SENSE
SELECT
BOARD
512

1
2
3
4
5
6

67
511

TO
J9
J85

1
2

67A
67B

TO
S1
S6 J8

GND-B
GND-A

202A
50Ω

TO
WORK
ELECTRODE

R
1
206A

CB2
10A CIRCUIT
BREAKER
1B

TO
S4
AUX 2

D6
+40VDC
DIODE

880

N.A.
STATUS LED (R/G)
TO J7

TO
J83
886

J10A
J10B

N.A.
THERMAL LED (Y)
TO J7

J11

TO J9
206

J82

J83

251
253
254

TO
S3

J84

267
266
268
228
226
227
221
222
223
225
224
220

TO
J42
J43
R5

J85

TO
RECT
THERM

231
232
J86
504
503
406
405
238
505

TO
J20
J40
J50

604
506
403
404
J87
1W
1B
2W
2B

4W
4R
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414
418
514
518
154
153
273
274

TO
SSR
J10CH

1
2
3
4

743
741
800
840

TO
J72

1
2
3
4

153
154
500
540

TO
J11
J47

1
2
3
4
5
6

539
541
521
522
886
880

TO
S6
D6

1
2
3
4
5
6
7
8

841
842
843
844
845
846
847

TO
S6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

851
852
853
854
855
856
857
858
859
860
861
862
512
511

1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12

J42

J41

J43

J47

TO
J1VS

216
211
213
212

220

TO AUX#1

224A
CHOKE
THERM

TO RECT
THERM

P91
4
3
2
1

291

H1A
TO AUX #2

H5A
H4A
TO
AUX #2
CB4
RECONNECT PANEL

H4
H3
(220-230)
H2
(200-208)
H1

H3A
H3

220A

POS
POS
NEG
NEG

H2A

H2
H1

TO SOLID STATE RELAY
444

FAN
X5
TO AUX#1

THIS AREA VIEWED FROM
REAR OF MACHINE

51
500
50
540
475
476
477
478

RECONNECT SWITCH

SEC
(TOP
LEFT)

PRI
(TOP
LEFT)

TO
SWITCH
BD #2

TO RECT
THERM

292

.022
SEC
800V (BOTTOM

TO D5

LEFT)

J40

NEG
TO
INPUT RECT

3500µF
500V

TO
20C 19C MAIN TRANSFORMER

289B
TO C10

TO
AUX #2

14
15 16 11 12

TP2

262
268
268A

TO
ROBOT
IFACE

TO
J4
J43

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ELECTRODE

289D
R2

TO TP3

Return to Section TOC

288D
TO R1
206A

TO RECONNECT PANEL
A
TO J61
H1D

(TOP)

288E

STT

LOAD LINE TO CONTACTOR
L3A

2Ω
R3

288F

2Ω
R4
2Ω
STT SNUBBER
RESISTOR BANK

SW1
POWER
TO CB3
612B

TO CONTACTOR
L1A

289E

POWER BD
RECTIFIER

TO
D6
J47
S1
J11

J60
F2

TO
C3
AUX. #1

TO
J40,J50

2.7 10W

SEC
(TOP
RIGHT)

PRI
(TOP
RIGHT)

POS
POS
POS

TO J46
POWER BD RECT

287

STT CURRENT
TRANSDUCER
P90
1
2
3
4

288B

J61

SWITCH BOARD
#2

STT SNUBBER
DIODE D5

289F

C10
20uF
400V

POS

NEG
T2
612
H1D

TO
CR1
SW1
CB4

AC
3

AC
2

AC
1

TO J61
TO J60

15 16

601
20D 19D

CR1
X4

TO
RECONNECT
SWITCH

TO
MAIN
TRANSFORMER

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 380-460V
OPERATION.

STT SNUBBER
CAPACITOR BANK

3500µF
500V

288A
TO C10
TO C8

INPUT POS
RECTIFIER

1
2
3
4
5
6
7
8
9
10

J50

RIGHT SIDE

NOTES:

20uF C8
400V

TO
RECONNECT
SWITCH

231

NEG
17

TO
SWITCH
BD #1

.022
800V

812
813
811
816

TO
CR1
J6
AUX #1

NEG
NEG
NEG

TO J8

TO
J43
J88

TO J6, J10B

TP7

2400µF
100V
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2

601
X3
238
604
232

NEG

TO
J73
TO
P90
P91

1
2
3
4
5
6
7
8

PRI
TO
(BOTTOM SWITCH
RIGHT) BD #2

289A
289C
288B
288C
288D
288E
289B
289C
289D
289E

3
4

INPUT BOARD

.022
800V

POS

TO
SSR, J10 CHOPPER BD.

288A
288C

33A

WATER
COOLER
RECEPTACLE

2.7 10W

SEC
(BOTTOM
RIGHT)

TO D5

TP5

1
2

TO RECONNECT SWITCH

TO AUX #1

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V
OPERATION.

RIGHT SIDE OF MACHINE

32
33

352

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

W
(115V) R

33A
4
2

TO
S4
CB2

350

P52
1
4
(230V)

H6A

H5A

H4A

H3A

COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS

J10,J2VS
J74
1

J2,J5,J11,
J41,J46,J72
J73,J76,J81
J82
1 2

TO SW1
L1A

H2A

H1A

TO SUPPLY LINES

TO
CB3
AUX #1

G
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.

AUXILIARY TRANSFORMER #2

ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE

TO SW1
L3A

P50

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.

C6
.05/600V

350
352

EMITTER

TO TP6
C2
.05/600V

20C

20D
TO
SWITCH BD #2

200-208V
220-230V
380-415V
440-460V

'A
'

11 12

TO C8
289A

TO AUX #1
H2
H3
H4
H5

TO
SWITCH BD #1

SWITCH BOARD
#1

PRI
TO
(BOTTOM SWITCH
LEFT)
BD #1

TO SW1

N.C.

TO
INPUT RECT

2.7 10W

287

RECONNECT
PANEL

TO
SWITCH BD #1

POS

220A

TO
SWITCH BD #2
19D

13
14

19C
291

TO
CB1
J41
J82
S1

N.B.

TO J6,J10B

292

CB4
6A
CIRCUIT
BREAKER

H1
TO AUX #1

X3A
TO SOLID STATE RELAY

CURRENT
TRANSDUCER

RECT
THERM

TO
CHOKE
THERM

TO J61
CB3
612A
612

TO FAN

TO
CR1
J60

MAIN
TRANSFORMER
LEFT SIDE

OUTPUT
RECT

224A

COLLECTOR
1
2
3
J10
4
5
6

4R
346

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

X3A

224

CHOPPER BD
345

TP4

TO POWER BD.
RECTIFIER
X3
W
X3
(24V) N
X4
(115V) R
X5

H6
H5

CB3
10A
CIRCUIT
BREAKER

TO CB4
612A

H6A

TO J5

1
2
3
4
1
2
3
4
5
6
7
8

TO
S7

TO J8

(51V)
U

MAIN CHOKE
L1

228
273
267
262

H6
(550-575)
H5
(440-460)
H4
(380-415)

TO FAN

TO
J4
J11
R5

444

346

TO C3

J46

TO
J47

TO SW1
612B

AUXILIARY TRANSFORMER #1

SOLID
STATE
RELAY

475
477
476
478

268A
226
274
266
345

TO
J4

DC BUS
BOARD

DC BUS
THERM

1
2
3
4
5
6
7
8
9
10

225
223
221
227
222

REAR OF MACHINE

FRONT OF MACHINE

S7
12 PIN
CONNECTOR

J81

DIGITAL POWER
SUPPLY BOARD

414
418
403
404
405
406

WORK

FEED HEAD
BOARD

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
1
2
1
2
3
4

TO
J7

514
518
503
504
505
506

TO
CB1
J47

1
2
3
4
5
6

DEVICE NET
GATEWAY
BOARD

TO TP3
202A
TO R1

CONTROL BOARD

TO J9

Return to Master TOC

455 / R WIRING DIAGRAM

TO TP6
202

DEVICENET
CONNECTOR

Return to Section TOC

Return to Master TOC

WIRING DIAGRAM - POWER WAVE 455/R CODE 10675

TP1

Return to Section TOC

G-2

ELECTRICAL DIAGRAMS

Return to Section TOC

G-2

J1VS,J9,J10CH,
J14,J40J42,
J50,J75,J83

J8,
J47,J60
J84

J3,
J61,J86

J4,J13,
J43,J71

J1,J6,J7
J10,J70,J85
J87
8

11-3-2000A
CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

G3792

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.

POWER WAVE 455/R

POWER WAVE

LEFT SIDE OF MACHINE

C1
.05/600V

J70

1
2

+24V

+24V GND 3

Return to Master TOC

CAN_H
CAN_L

4
5

A
B

TO
J75

S1
WIRE
FEEDER
RECEPTACLE

894
893
892
891

S6
ROBOTIC/
WIREDRIVE
INTERFACE
RECEPTACLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N

1
2
3
4

J72

TO
J9

21A

J73
1
2
3
4
5
6
7

S3
RS232
CONNECTOR

521

67A

TO
S1

3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE
TO
J83
J84
J2VS

67B
539
541

TO
P73
J2VS
CB1
J47

J71

S2
VOLTAGE
SENSE
RECEPTACLE

841
844
842
843
845
846
847

53
54

253
254

J74
TO
J2

J75

251

20
522

P
R
S
T
U
V
W
X

J76

CB1
10A CIRCUIT
BREAKER

GND-A

TO
L2
BUSS BD

743
741
800
840
53
54

TO
J81
TO
S1
J4

892
893

TO
S5

891
894
J5
830

TO
WORK
ELECTRODE

TP3

1
2
3
4
5
6
7
8
9
10
11
12

851
852
853
854
855
856
857
858
859
860
861
862

S4
115V
RECEPTACLE

TO
WORK
STT

TP6

TO
J85
31

32
TO
AUX 2
CB2

VOLTAGE SENSE
SELECT
BOARD
1
2
3
4
5
6

512

67
511

TO
J9
J85

1
2

67A
67B

TO
S1
S6 J8

GND-B
GND-A

202A
50Ω

TO
WORK
ELECTRODE

R
1
206A

CB2
10A CIRCUIT
BREAKER
1B

TO
S4
AUX 2

D6
+40VDC
DIODE

880

N.A.
STATUS LED (R/G)
TO J7

TO
J83
886

J10A
J10B

N.A.
THERMAL LED (Y)
TO J7

J11

TO J9
206

J82

J83

251
253
254

TO
S3

J84

267
266
268
228
226
227
221
222
223
225
224
220

TO
J42
J43
R5

J85

TO
RECT
THERM

231
232
J86
504
503
406
405
238
505

TO
J20
J40
J50

604
506
403
404
J87
1W
1B
2W
2B

4W
4R
3R
3W
211
212
213
813
811
216
816
812
206
202
67
21A
414
418
514
518
154
153
273
274

TO
SSR
J10CH

1
2
3
4

743
741
800
840

TO
J72

1
2
3
4

153
154
500
540

TO
J11
J47

1
2
3
4
5
6

539
541
521
522
886
880

1
2
3
4
5
6
7
8

841
842
843
844
845
846
847

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

851
852
853
854
855
856
857
858
859
860
861
862
512
511

1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12

J42

J41
TO
S6
D6

J43
TO
S6

J47

TO
J1VS

216
211
213
212

220

TO AUX#1

224A
CHOKE
THERM

TO RECT
THERM

P91
4
3
2
1

291

H1A
TO AUX #2

H5A
H4A
TO
AUX #2
CB4
RECONNECT PANEL

H4
H3
(220-230)
H2
(200-208)
H1

H3A
H3

220A

H2A

H2
H1

TO SOLID STATE RELAY
444

FAN

CURRENT
TRANSDUCER

X5
TO AUX#1

THIS AREA VIEWED FROM
REAR OF MACHINE

51
500
50
540
475
476
477
478

RECONNECT SWITCH

PRI
(TOP
LEFT)

TO
SWITCH
BD #2

TO RECT
THERM

292

.022
SEC
800V (BOTTOM

TO D5

LEFT)

J40

289B
TO C10

11 12
TO
AUX #2

TO
MAIN TRANSFORMER

14
15 16 11 12

TO RECONNECT SWITCH

TO
ROBOT
IFACE

TO
J4
J43

.022
800V

TO
SSR, J10 CHOPPER BD.

SEC
(BOTTOM
RIGHT)

TO
C3
AUX. #1

2400µF
100V
TO J1 VOLTAGE SENSE
WORK
ELECTRODE
S2
TO
J40,J50

INPUT BOARD

SEC
(TOP
RIGHT)

PRI
(TOP
RIGHT)

STT CURRENT
TRANSDUCER
P90
1
2
3
4

13
J50

288B

STT SNUBBER
DIODE D5

288A
TO C10
TO C8

J61

3500µF
500V

15 16
20D 19D

TP2

Return to Master TOC

ELECTRODE

289D
R2

TO TP3

Return to Section TOC

288D
TO R1
206A

TO RECONNECT PANEL
A
TO J61
H1D

(TOP)

288E

STT

LOAD LINE TO CONTACTOR
L3A

2Ω
R3

288F

2Ω
R4
2Ω
STT SNUBBER
RESISTOR BANK

SW1
POWER
TO CB3
612B

TO CONTACTOR
L1A

289E

289F

288A
288C

TO
MAIN
TRANSFORMER

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
OPERATION.

289A
289C
288B
288C
288D
288E
289B
289C
289D
289E

20uF C8
400V

C10
20uF
400V

STT SNUBBER
CAPACITOR BANK

POS

NEG
AC
3

231

AC
2

AC
1

T1
T2
612
H1D

TO
CR1
SW1
CB4

TO J61
TO J60

601
T3

CR1
X4

NOTES:

TO D5

TP5

INPUT
RECTIFIER
TO
CR1
J6
AUX #1

TO
RECONNECT
SWITCH

TO AUX #1

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION.

RIGHT SIDE OF MACHINE

32
33

P52
1

352

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

W
(115V) R

33A
4
2

TO
S4
CB2

350

4
(230V)

H6A

H5A

H4A

H3A

COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS

J10,J2VS
J74
1

J2,J5,J11,
J41,J46,J72
J73,J76,J81
J82
1 2

TO SW1
L1A

H2A

H1A

TO SUPPLY LINES

TO
CB3
AUX #1

G
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.

AUXILIARY TRANSFORMER #2

ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE

TO SW1
L3A

P50

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.

C6
.05/600V

601
X3
238
604
232

1
2
3
4
5
6
7
8
9
10

SWITCH BOARD
#2

RIGHT SIDE

1
2
3
4
5
6
7
8

18
J60

287

TO
SWITCH
BD #1

.022
800V

D1
POS
POS
POS

812
813
811
816

TO
J43
J88

2.7 10W

NEG
NEG
NEG

TO J8

POS

TO J6, J10B

TO J46
POWER BD RECT

TO
RECONNECT
SWITCH
19

TP7

3
4

NEG
17

NEG

TO
J73

33A

WATER
COOLER
RECEPTACLE

19D

20C
F2

TO
P90
P91

1
2

PRI
TO
(BOTTOM SWITCH
RIGHT) BD #2

POS
TO
D6
J47
S1
J11

350
352

2.7 10W

POWER BD
RECTIFIER

TO TP6
C2
.05/600V

HARMONIC
FILTER

268
268A

FILTER

20C 19C
F3

200-208V
220-230V
440-460V
550-575V

'A
'

HARMONIC

3500µF
500V

EMITTER

NEG

20D
TO
SWITCH BD #2
TO

TO C8
289A

262

TO AUX #1
H2
H3
H5
H6

TO
SWITCH BD #1

SWITCH BOARD
#1

TO
PRI
(BOTTOM SWITCH
LEFT)
BD #1

TO SW1

N.C.

TO
HARMONIC
FILTER

2.7 10W

287

RECONNECT
PANEL

TO
SWITCH BD #1

220A

TO
SWITCH BD #2
POS

13
14

19C

SEC
(TOP
LEFT)

291

TO
CB1
J41
J82
S1

N.B.

TO J6,J10B

292

CB4
6A
CIRCUIT
BREAKER

H1
TO AUX #1

X3A
TO SOLID STATE RELAY

RECT
THERM

TO
CHOKE
THERM

TO J61
CB3
612A
612

TO FAN

TO
CR1
J60

MAIN
TRANSFORMER
LEFT SIDE

OUTPUT
RECT

224A

POS
POS
NEG
NEG

COLLECTOR
1
2
3
J10
4
5
6

4R
346

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

X3A

224

CHOPPER BD
345

TP4

TO POWER BD.
RECTIFIER
X3
W
X3
(24V) N
X4
(115V) R
X5

H6
H5

CB3
10A
CIRCUIT
BREAKER

TO CB4
612A

H6A

TO J5

TO C3

TO
S7

TO J8

(51V)
U

TO FAN

228
273
267
262

H6
(550-575)
H5
(440-460)
H4
(380-415)

MAIN CHOKE
L1

TO
J4
J11
R5

444

346

1
2
3
4
1
2
3
4
5
6
7
8

J46

TO
J47

TO SW1
612B

AUXILIARY TRANSFORMER #1

SOLID
STATE
RELAY

475
477
476
478

268A
226
274
266
345

TO
J4

DC BUS
BOARD

DC BUS
THERM

1
2
3
4
5
6
7
8
9
10

225
223
221
227
222

REAR OF MACHINE

FRONT OF MACHINE

S7
12 PIN
CONNECTOR

J81

DIGITAL POWER
SUPPLY BOARD

414
418
403
404
405
406

WORK

FEED HEAD
BOARD

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
1
2
3
4
1
2
3
4
1
2
1
2
3
4
5
6
1
2
3
4

514
518
503
504
505
506

TO
CB1
J47

TO
J7

1
2
3
4
5
6

DEVICE NET
GATEWAY
BOARD

TO TP3
202A
TO R1

CONTROL BOARD

TO J9

Return to Master TOC

455 / R WIRING DIAGRAM

TO TP6
202

DEVICENET
CONNECTOR

Return to Section TOC

Return to Master TOC

WIRING DIAGRAM- POWER WAVE 455/R CODE 10676

TP1

Return to Section TOC

G-3

ELECTRICAL DIAGRAMS

Return to Section TOC

G-3

J1VS,J9,J10CH,
J14,J40J42,
J50,J75,J83

J8,
J47,J60
J84

J3,
J61,J86

J4,J13,
J43,J71

J1,J6,J7
J10,J70,J85
J87
8

5-11-2001F
CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

G4010

SCHEMATIC - COMPLETE MACHINE 10675
N.A.

.022u
800V

19C
POS

NEG

414

+
20C

418

521

3J83

SOLENOID +40VDC

522

4J83

SOLENOID INPUT

539

1J83

MOTOR "+"

541

2J83

MOTOR "-"

841

1J84

4J40

V/F (+)

405

5J40

V/F (-)

L1A

L3A

INPUT BOARD

1J60

SW1
POWER

+13V
232

5J60

OFF

2J61

4J84

844

+13V

AUX. RECONNECT
A

200-208V

220-230V

380-415V

440-460V

4J60

3J60

+13V

SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)

238

Return to Master TOC

A
B
C
D
E
F
G
I
J
K
N
P
T

5J84

TACH 2A DIFF. INPUT

846

6J84

TACH 2B DIFF. INPUT

847

7J84

SINGLE TACH INPUT

851

1J85

TRIGGER +15VDC

852

2J85

TRIGGER INPUT

514

1J50

CT CURRENT (-)

518

2J50

CT CURRENT (+)

503

3J50

IGBT DRIVE (+)

504

4J50

V/F (+)

505

5J50

V/F (-)

3J85

DUAL PROC. INPUT

854

4J85

4 STEP INPUT

841
844
842
843
845
846
847

855

5J85

COLD INCH +15VDC

856

6J85

COLD IN. FORWARD

857

7J85

COLD IN. REVERSE

67B
539
541
521
522
GND-A

858

8J85

GAS PURGE INPUT

859

9J85

860

10J85

11J85

861

S7 I/O
RECEPTACLE

12J85

862
851
852
853
854
855
856
857
858
859
860
861
862

C5
(CAP "B")
3500uF
500V

6J50

ARCLINK L

(380-415)

24V

(220-230)

H3A

6A
612

115V

3J10

5J83

886

2J82

154

1J73

ARCLINK -

2J73

ARCLINK +

ARCLINK H

2J81

741

2J72

ARCLINK H

ARCLINK L

1J81

743

1J72

ARCLINK L

Return to Master TOC

Return to Section TOC

612B

612A

H5A

H4A

H3A

COMMON

3J81

800

3J72

COMMON

+40VDC

4J81

840

4J72

+40VDC

COMMON

3J82

500

5J75

+24VDC

H2A

+40VDC

4J82

540

893

2J75

+24V GND

VOLTAGE SENSE SELECT (-)

14J85

511

892

1J75

CAN_H

891

4J75

512

13J85

2J2

67B

H1A

7J8

CONTROL BOARD COMMON

811

5J8

STT FEEDBACK

813

4J8

-15V

812

8J8

+15V

L4
WORK VOLTAGE SENSE

21A

6J9

GND

13J7

STT CHOPPER DRIVE (-)

14J7

STT CHOPPER DRIVE (+)

503

6J6

IGBT DRIVE (+)

504

5J6

V/F (+)

505

10J6

V/F (-)

506

14J6

IGBT DRIVE (-)

THERMAL LED

8J7

THERMAL LED

7J7

2B
YELLOW
THERMAL
LED
2W

3J7

RED/GREEN
STATUS
LED

1J10B

CT CURRENT (-)
STATUS LED (HI FOR GREEN)

518

2J10B

CT CURRENT (+)

403

15J6

404

16J6

V/F (+)

405

8J6

V/F (-)

406

7J6

414

1J10A

VOLTAGE SENSE SELECT (-)

4J1

511

1J1

512

220A
DCBUS
THERMOSTAT

262

418

2J10A

224

2J5

THERMOSTAT

220

3J5

THERMOSTAT

16J7

FAN CONTROL (-)

15J7

FAN CONTROL (+)

268

3J4

IGBT DRIVE (-)

CT CURRENT (+)

}

(NORMALLY CLOSED)

+5V SPI

238

9J6

604

12J6

PRECHARGE CONTROL

231

1J6

SINGLE PHASE DETECT
(LOW=1 PHASE)

232

2J6

MAIN CONTACTOR CONTROL

4J9

POWER BOARD
SPI COMMON

345

7J43

+13V

VOLTAGE SENSE

3J1

1J2

67A

346

1J43

262

12J43

268A

3J43

2J4

+15V SPI

11J43

267

1J4

SPI COMMON

4J42

227

7J4

1J42

225

12J4

221

3J42

8J4

A ARCLINK -

B ARCLINK +

67A

C ELECTRODE SENSE

D +40VDC

E 0VDC

POWER DOWN INTERUPT
+15V

SPI COMMON
+5V

DC BUS BD

266

STT COMMON
+15V

S1 WIRE FEEDER
RECEPTACLE

6J43

STT +20V
POWER DOWN INTERUPT

VOLTAGE SENSE OUTPUT
WIRE FEEDER VOLTAGE SENSE

CT CURRENT (-)

ROBOTIC VOLTAGE SENSE

VOLTAGE SENSE SELECT (+)

4J7

IGBT DRIVE (+)

268A

N.A.

514

R5
10

+15V SPI

352
230V

(440-460)

115V

352A

33A

S8 WATER COOLER
RECEPTACLE

500

2J47

540

4J47

CB2
10A

33
0V

+5V

SPI +5V
CONTROL BOARD COMMON

5J42

222

10J4

CONTROL BOARD COMMON

32
H2

3
1
32

S4
110V
RECEPTACLE

COMMON

-15V

2J42

223

11J4

-15V

ARCLINK +5V
+40V COMMON

5J43

274

4J11

+5V ARCLINK +5V

ARCLINK COMMON

10J43

273

3J11

ARCLINK COMMON

RS232 +5V

4J43

226

6J4

RS232 +5V

894

2 +24VDC

RS232 COMMON

9J43

228

5J4

RS232 COMMON

893

3 +24V GND

892

4 CAN_H

891

5 CAN_L

5J47

475

1J41

+40VDC POWER

7J47

477

2J41

+40V

COMMON

6J47

476

3J41

+40V COMMON

COMMON
+40VDC POWER

350

S2 VOLTAGE SENSE
RECEPTACLE

816

CAN_L

N.A.

24000uF/100V

(200-208)

10A

224A

CHOKE
THERMOSTAT

OUTPUT RECTIFIER
THERMOSTAT
894

VOLT SENSE BD

N.A.

NEG

(220-230)

CB3

+15

(550-575)
H5

(380-415)

-15V

3J76

P80
5

2J8

830

1J76

TRANSFORMER T2

H6A

4J90

GATEWAY BD

292

52V
H1

153

INPUT B

X5
X1

(200-208)

H2A

4J10

6J10

1J82

SHUTDOWN 2 INPUT

POS
65VDC

212

COMMON

SHUTDOWN 1 INPUT

FAN

-15V

+20V STT

N.A.

880

6J83

POWER BD. RECT.

CURRENT FEEDBACK

3J8

TP5
320V
160J

C6
.05uF
600V

291

444
X3

1J8

STATUS LED (HI FOR RED)

SHUTDOWN +15VDC

TP4

H4A

1J10

346

+40VDC

(440-460)

211
213

7
20

STT

IGBT DRIVE (-)

SOLID STATE RELAY

(550-575)

CONTROL BOARD COMMON

251

1J2

ARCLINK H

X3A

H5A

6J8

+40VDC

AUXILIARY
TRANSFORMER T1

CB4

VOLTAGE SENSE SELECT (+)

H6A

P90

345

506
853

TRIGGER +15VDC 1
TRIGGER INPUT 2
DUAL PROC. INPUT 3
4 STEP INPUT 4
COLD INCH +15VDC 5
COLD IN. FORWARD 6
COLD IN. REVERSE 7
GAS PURGE INPUT 8
SHUTDOWN +15VDC 9
SHUTDOWN 1 INPUT 10
SHUTDOWN 2 INPUT 11
INPUT B 12

216

231

S6 ROBOTIC
INTERFACE
RECEPTACLE
TACH +15VDC
TACH COMMON
TACH 1A DIFF SIGNAL
TACH 1B DIFF SIGNAL
TACH 2A DIFF SIGNAL
TACH 2B DIFF SIGNAL
SINGLE TACH INPUT
VOLTAGE SENSE
MOTOR "+"
MOTOR "-"
SOLENOID +40VDC
SOLENOID INPUT

845
604

PRECHARGE RELAY
4J61

TACH COMMON

CHOPPER BOARD

+15V

TACH 1B DIFF. INPUT

I OUT

3J84

3J90

843

2J90

842

811

6J61

153

RS232 COMMON

816

612

10J61

ARC LINK L

1J90

8J61

812

612B

TACH 1A DIFF. INPUT

- ELECTRODE VOLTAGE SENSE

N.C.

2J84

3J9

ARC LINK H

CURRENT
TRANSDUCER

813

MAIN CONTACTOR CONTROL

1J9

2J11

N.C.

C10

+15VDC TACH

1J11

TP1
320V
160J

R3
H1D

253
254

154

TP6
150V
80J

N.A.

SWITCH BOARD #2 (RIGHT)

3J2

4J2

ELECTRODE

C1
.05uF
600V

880

IGBT DRIVE (-)

6J40

MAIN
CHOKE
L1

886
P91

2J60

C4
(CAP "A")
3500uF
500V

GND

404

I OUT

IGBT DRIVE (+)

-15V

3J40

406

N.A.

601

202

202A

4J91

FEED HD BD

403

RS232 RECEIVE
RS232 TRANSMIT
+ELECTRODE VOLTAGE SENSE

CT CURRENT (+)

2J40

S3 RS232
CONNECTOR

TP2
320V
160J

TP3
150V
80J

CURRENT
TRANSDUCER

211

C2
.05uF
600V

20D

N.A.

R1
50

2.7
10W

+15V

NEG

206A

OUTPUT DIODES
D1-D4

CT CURRENT (-)

NEG

1J40

2.7
10W

212

AC1

Return to Master TOC

.022u
800V

CONTROL BOARD

ELECTRODE

206

19D
AC2

.022u
800V

POS

216

AC3

2.7
10W

2J91

Return to Section TOC

N.A.

208-230V

2.7
10W

3J91

380-460V

.022u
800V

1J91

CR1

MAIN TRANSFORMER T1

SWITCH BOARD #1 (LEFT)

RECONNECT
SWITCH

INPUT
RECTIFIER

CR1

Return to Section TOC

G-4

ELECTRICAL DIAGRAMS

213

Return to Master TOC

Return to Section TOC

G-4

POS

1J46

POS

2J46

+40VDC POWER

8J47

COMMON

1J47

478

4J41

+40V

S5 DEVICENET
CONNECTOR

NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
N.C. R2, R3 AND R4 ARE 2 /300.
C8 AND C10 ARE 20 mfd/400V.

NEG

3J46

NEG

4J46

+40VDC FEEDER

3J47

CB1
10A

ELECTRICAL SYMBOLS PER E1537

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.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056

"X" INFO.

ON 2 PLACE DECIMALS IS± .02

ON 3 PLACE DECIMALS IS ± .002

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

DO NOT SCALE THIS DRAWING

Chg. Sheet No.
XB
11-3-2000A

DESIGN INFORMATION

REFERENCE:

DRAWN BY: KJ

G3450

ENGINEER: KJ

SUPERSEDING:

APPROVED:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

INVERTER WELDERS
PW455/R MACHINE SCHEMATIC

DATE: 7/11/00

DRAWING No.:

G 3791

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

SCHEMATIC-COMPLETE MACHINE CODE 10676
N.A.

.022u
800V

INPUT
RECTIFIER

CR1

380-460V

208-230V

AC3

POS

U
AC2

HARMONIC
FILTER

POS

NEG

20C

1J40

418

NEG

2.7
10W

206A

OUTPUT DIODES
D1-D4

C2
.05uF
600V

R1
50

2.7
10W

1J9

TP3
150V
80J

CURRENT
TRANSDUCER

3J83

521

P91

N.A.

L1A

L3A

601

INPUT BOARD

1J60

SW1
POWER

4J83

SOLENOID INPUT

539

1J83

MOTOR "+"

541

2J83

MOTOR "-"

232

5J60

841

1J84

6J61

2J61

4J84

844

+13V

AUX. RECONNECT
A

200-208V

220-230V

440-460V

550-575V

4J60

3J60

+13V

SINGLE PHASE DETECT
8J60
(LOW=1 PHASE)

238

Return to Master TOC

A
B
C
D
E
F
G
I
J
K
N
P
T

5J84

TACH 2A DIFF. INPUT

846

6J84

TACH 2B DIFF. INPUT

847

7J84

SINGLE TACH INPUT

851

1J85

TRIGGER +15VDC

852

2J85

TRIGGER INPUT

514

1J50

CT CURRENT (-)

518

2J50

CT CURRENT (+)

503

3J50

IGBT DRIVE (+)

504

4J50

V/F (+)

505

5J50

V/F (-)

3J85

DUAL PROC. INPUT

854

4J85

4 STEP INPUT

841
844
842
843
845
846
847

855

5J85

COLD INCH +15VDC

856

6J85

COLD IN. FORWARD

857

7J85

COLD IN. REVERSE

67B
539
541
521
522
GND-A

858

8J85

GAS PURGE INPUT

859

9J85

860

10J85

11J85

861

S7 I/O
RECEPTACLE

12J85

862
851
852
853
854
855
856
857
858
859
860
861
862

C5
(CAP "B")
3500uF
500V

6J50

ARCLINK L

(380-415)

24V

(220-230)

H3A

6A
612

115V

3J10

5J83

886

2J82

154

GND

1J73

ARCLINK -

2J73

ARCLINK +

ARCLINK H

2J81

741

2J72

ARCLINK H

ARCLINK L

1J81

743

1J72

ARCLINK L

3J81

800

3J72

COMMON

+40VDC

4J81

840

4J72

+40VDC

COMMON

3J82

500

5J75

+24VDC

Return to Master TOC

Return to Section TOC

612B

612A

H5A

H4A

+40VDC

4J82

540

893

2J75

+24V GND

VOLTAGE SENSE SELECT (-)

14J85

511

892

1J75

CAN_H

891

4J75

512

13J85

VOLT SENSE BD

N.A.

2J2

67B

H3A

H2A

H1A

(440-460)

115V

352A

STT FEEDBACK

813

4J8

-15V

812

8J8

+15V

L4
WORK VOLTAGE SENSE

21A

6J9

GND

13J7

STT CHOPPER DRIVE (-)

14J7

STT CHOPPER DRIVE (+)

503

6J6

IGBT DRIVE (+)

504

5J6

V/F (+)

THERMAL LED

8J7

THERMAL LED

7J7

505

10J6

V/F (-)

506

14J6

IGBT DRIVE (-)

2B
YELLOW
THERMAL
LED
2W

3J7

RED/GREEN
STATUS
LED

VOLTAGE SENSE SELECT (-)

4J1

511

VOLTAGE SENSE SELECT (+)

1J1

512

220A
DCBUS
THERMOSTAT

262

1J10B

CT CURRENT (-)
STATUS LED (HI FOR GREEN)

518

2J10B

CT CURRENT (+)

403

15J6

404

16J6

V/F (+)

405

8J6

V/F (-)

7J43

7J6

414

1J10A

3J1

1J2

67A

1J43

418

2J10A

224

2J5

THERMOSTAT

220

3J5

THERMOSTAT

16J7

FAN CONTROL (-)

15J7

FAN CONTROL (+)

268

3J4

IGBT DRIVE (-)

CT CURRENT (+)

}

(NORMALLY CLOSED)

+5V SPI

238

9J6

604

12J6

PRECHARGE CONTROL

231

1J6

SINGLE PHASE DETECT
(LOW=1 PHASE)

232

2J6

MAIN CONTACTOR CONTROL

4J9

+13V

VOLTAGE SENSE

262

12J43

268A

3J43

DC BUS BD

266

2J4

+15V SPI

11J43

267

1J4

SPI COMMON

4J42

227

7J4

1J42

225

12J4

221

3J42

8J4

A ARCLINK -

B ARCLINK +

67A

C ELECTRODE SENSE

D +40VDC

E 0VDC

POWER DOWN INTERUPT
+15V

SPI COMMON
+5V

S1 WIRE FEEDER
RECEPTACLE

6J43

STT COMMON
+15V

CT CURRENT (-)

STT +20V
POWER DOWN INTERUPT

VOLTAGE SENSE OUTPUT
WIRE FEEDER VOLTAGE SENSE

4J7

IGBT DRIVE (+)

406

POWER BOARD
SPI COMMON

345

N.A.

514

ROBOTIC VOLTAGE SENSE

346

2
4

33A

S8 WATER COOLER
RECEPTACLE

500

2J47

540

4J47

CB2
10A

33
0V

+5V

SPI +5V
CONTROL BOARD COMMON

5J42

222

10J4

CONTROL BOARD COMMON

3
1
32

S4
110V
RECEPTACLE

COMMON

-15V

2J42

223

11J4

-15V

ARCLINK +5V
+40V COMMON

5J43

274

4J11

+5V ARCLINK +5V

ARCLINK COMMON

10J43

273

3J11

ARCLINK COMMON

RS232 +5V

4J43

226

6J4

RS232 +5V

894

2 +24VDC

RS232 COMMON

9J43

228

5J4

RS232 COMMON

893

3 +24V GND

892

4 CAN_H

891

5 CAN_L

5J47

475

1J41

+40VDC POWER

7J47

477

2J41

+40V

COMMON

6J47

476

3J41

+40V COMMON

COMMON
+40VDC POWER

350

CONTROL BOARD COMMON

5J8

268A

3W
-

352
230V

(200-208)

10A

7J8

811

CAN_L

N.A.

24000uF/100V

(220-230)

CB3

816

R5
10

+15V SPI

NEG

S2 VOLTAGE SENSE
RECEPTACLE

(550-575)
H5

(380-415)

224A

CHOKE
THERMOSTAT

OUTPUT RECTIFIER
THERMOSTAT
894

P80
5

-15V

3J76

COMMON

INPUT B

+15

830

1J76

153

TRANSFORMER T2

H6A

4J90

GATEWAY BD

292

52V
H1

1J82

SHUTDOWN 2 INPUT

POS
65VDC
X1

(200-208)

H2A

4J10

6J10

SHUTDOWN 1 INPUT

FAN

2J8

COMMON

N.A.

880

6J83

POWER BD. RECT.

212

+20V STT

291

444
X3

-15V

STATUS LED (HI FOR RED)

SHUTDOWN +15VDC

TP4

H4A

1J10

346

+40VDC

(440-460)

CURRENT FEEDBACK

3J8

TP5
320V
160J

C6
.05uF
600V

IGBT DRIVE (-)

SOLID STATE RELAY

(550-575)

1J8

7
20

ARCLINK H

X3A

H5A

211
213

251

1J2

STT

+40VDC

AUXILIARY
TRANSFORMER T1

CB4

VOLTAGE SENSE SELECT (+)

H6A

P90

345

506
853

CONTROL BOARD COMMON

231

845
604

PRECHARGE RELAY
4J61

TACH COMMON

CHOPPER BOARD

+15V

TACH 1B DIFF. INPUT

I OUT

3J84

3J90

TACH 1A DIFF. INPUT

843

2J90

842

1J90

6J8

RS232 COMMON

816

612

10J61

811

8J61

ARC LINK L

216

812

612B

2J84

813

MAIN CONTACTOR CONTROL

ARC LINK H

N.C.

- ELECTRODE VOLTAGE SENSE

153
TP1
320V
160J

R3
H1D

2J11

CURRENT
TRANSDUCER

C8
D5

+15VDC TACH

1J11

N.C.

C10

SWITCH BOARD #2 (RIGHT)

253
254

154

TP6
150V
80J

N.A.

2J60

+13V
OFF

522

IGBT DRIVE (-)

6J40

3J2

4J2

ELECTRODE

C1
.05uF
600V

880

SOLENOID +40VDC
406

I OUT

V/F (-)

-15V

5J40

4J91

405

MAIN
CHOKE
L1

886

216

FEED HD BD

212

N.A.

C4
(CAP "A")
3500uF
500V

+15V

V/F (+)

2J91

4J40

3J91

404

1J91

IGBT DRIVE (+)

20D

CR1

3J9

202

202A

211

3J40

RS232 RECEIVE
RS232 TRANSMIT
+ELECTRODE VOLTAGE SENSE

403

S3 RS232
CONNECTOR

TP2
320V
160J

CT CURRENT (+)

2J40

CONTROL BOARD

ELECTRODE

206

20
NEG

Return to Master TOC

CT CURRENT (-)

+
AC1

.022u
800V

11
414

2.7
10W

19D

.022u
800V

19C
L1

.022u
800V

2.7
10W

N.A.

Return to Section TOC

MAIN TRANSFORMER T1

SWITCH BOARD #1 (LEFT)

RECONNECT
SWITCH

Return to Section TOC

G-5

ELECTRICAL DIAGRAMS

213

Return to Master TOC

Return to Section TOC

G-5

POS

1J46

POS

2J46

+40VDC POWER

8J47

COMMON

1J47

478

4J41

+40V

S5 DEVICENET
CONNECTOR

NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR
REFERENCE ONLY. ALL COMPONENTS
ARE NOT SHOWN.
N.C. R2, R3 AND R4 ARE 2 /300.
C8 AND C10 ARE 20 mfd/400V.

NEG
NEG

3J46

4J46

+40VDC FEEDER

3J47

CB1
10A

ELECTRICAL SYMBOLS PER E1537

"X" INFO.

Chg. Sheet No.

DESIGN INFORMATION

REFERENCE:

ON 2 PLACE DECIMALS IS± .02

XB-S

5-11-2001F

DRAWN BY: LW

G3791

ENGINEER: TR

SUP
ERSEDING:

ON 3 PLACE DECIMALS IS ± .002

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

DO NOT SCALE THIS DRAWING

APPROVED:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

INVERTER WELDERS
PW455/R MACHINE SCHEMATIC

DATE: 9/11/00

DRAWING No.:

G 4009

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

L 11340

Return to Master TOC

Return to Section TOC

INPUT

PWM

.0047
C11
1

2
5

OCI1

50V
CNY17-3

6
4

C22
5

R4
1

3.32K
2

X3
3

C12
C13
12

820p
100p

50V
100V
X3
11

+15
11

A
T1
15

3.32K

J10

13
5

T1
1

T2
2

X3
4

332
RST

3
1

7
2

R27
8

3.32K
X3
10

C14

.0047

X2
VS

OUT

NC
OUT

GND
GND

C15
C16
C17

100p
100p

475

820p

100V
100V
50V

1.0A

30V

DZ1
D6

15V
1.0A

1W
30V

301

50V

C23
4.7

35V

com
D7

R11
19

301
16

R12
13

301
10

R13

301

R14

R18

301

R20

301

R21

301

MIC4451BN

1
G7

R19
13

301
10

301

301
G1

E1
21

E2
18

E3
15

E4
12

9
E6
6

E5
9

E6
6

DR.

J10

+15

301

From Bridge

R10

40N60B3

630Vdc

C18

.47

R15

E7
3

301

To STT Output

com
com

+15

RST

R16
301

From Bridge

40N60B3

R22

301

3-3-99

CHK.

K.J.

TYPE

EQUIP.

SUBJECT

DZ1

INVERTER WELDERS

EARTH GROUND CONNECTION

FRAME CONNECTION

COMMON CONNECTION

POWER SUPPLY SOURCE POINT

VOLTAGE NET

27
CD-

R-

SUPPLY

LABELS

LAST NO. USED

SHT.
NO.

ll340

SCHEMATIC, CHOPPER PCB
SUP'S'D'G.

DATE

NONE

CLEVELAND, OHIO U.S.A.

THE LINCOLN ELECTRIC CO.
SCALE

com

JLJ

(UNLESS OTHERWISE SPECIFIED)

WITH PUBLISHED STANDARDS

MATERIAL TOLERANCE ("t") TO AGREE

com

4093B

50V

2-11-2000

GND

ON HOLES SIZES PER E-2056

0.1

63V

ON 2 PLACE DECIMALS IS + .O2

com

1.0

ON 3 PLACE DECIMALS IS + .OO2

50V
UNLESS OTHERWISE SPECIFIED)

ON ALL ANGLES IS + .5 OF A DEGREE

0.1

FILENAME: L11340-1CA

GND

C10

THE LINCOLN ELECTRIC CO.

D4
X2

Ch'ge.Sht.No.

J10
MIC4451BN

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

50V

UNLESS OTHERWISE SPECIFIED TOLERANCE

0.1

63V

THE LINCOLN ELECTRIC CO.

1.0

NUMBER.

com
C8

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

J10

MC14538B

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

50V

1A, 400V

0.1

63V

DIODES =

1.0

50V

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

0.1

25V

C21

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

50V

C20

N.A.

500

1/4W

C1
1

UNLESS OTHERWISE SPECIFIED)

OUT

RESISTORS = Ohms (

MFD ( .022/50V

+15

CAPACITORS =

+15

NOTES :

.24

+15

ELECTRICAL SYMBOLS PER E1537

GENERAL INFORMATION

GND

4.75K

J10

14 to 22 Vac

47.5K

Return to Master TOC

Return to Section TOC

R26

332K

R23

Return to Master TOC

Return to Section TOC

+15

4.75K

Return to Master TOC

Return to Section TOC

G-6

ELECTRICAL DIAGRAMS
G-6

SCHEMATIC - CHOPPER PC BOARD

R17

630Vdc

C19

.47

E7
3

To STT Output

J10
150p

50V

R25

221K
com

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

PC BOARD ASSEMBLY -CHOPPER

5.50

±.04

B48

B49

C10

DZ1

R14
R26

X2
C9

C8
R13
C3

R12

C13
R27
C15

R11

R3
R4
C12

R19

R6
C14

R18

C16

R20

C23

C17

C20
A2

xxx x xx x x x
x
x
x
x
x
x
x
x
x
x
x C19
x
x
x
x
x
x
x
x
x
x
x
xxx x x x x x x xx

C21

R17

xx x x x x x x xx
x
x
x
x
x
x
x
x
x
x
x
C18
x
x
x
x
x
x
x
x
x
x
xx x x x x x x x xx

ITEM
C1
C2
C3,C7,C9,10,C21
C6,C8,C20
C11,C14
C12,C17
C13,C15,C16
C18,C19
C22
C23

REQ'D
1
1
5
3
2
2
3
2
1
1

PART NO.
T11577-49
S13490-8
S16668-11
S13490-173
S16668-10
S16668-7
S16668-3
S20500-2
S16668-9
S13490-25

IDENTIFICATION
500/50
50/25
.1/50
CAP.,MPF,1.0 uF,63VDC
4700pF/50
820pF/50
100pF/100
.47/630
150pF/100
4.7/35

D1,D2,D3,D4,D7
D5,D6

5
2

T12199-1
T12705-23

1N4004
1N5818

DZ1

T12702-29

1N4744A

J10

S20351-6

HEADER

OCI1

S15000-10

OPTO ISOLATOR

R1
R2
R3,R4,R27
R5
R6
R8,R23
R9,R10,R11,R12,R13,R14,
R15,R16,R17,R18,R19,R20,
R21,R22
R25
R26

1
1
3
1
1
2

S18380-5
S19400-3320
S19400-3321
S19400-4752
S19400-4750
S19400-4751

THERM.,PTC,.5-1.17 OHM, .5A
332 1/4W
3.32K 1/4W
47.5K 1/4W
475 1/4W
4.75K 1/4W

S19400-3010

301 1/4W

1
1

S19400-2213
S19400-3323

221K 1/4W
332K 1/4W

1
1
1
1

S15018-9
S15018-21
S15018-15
S15128-6

CMOS MC14538B
IC,DRIVER,12A MOSFET(SS)
14 PIN IC
VOLTAGE REGULATOR

X1
X2
X3
X4

CAPACITORS = MFD/VOLTS
RESISTORS = OHMS

R21

R10

R25

Return to Master TOC

R15

R23
R8

R16

Return to Section TOC

G-7

ELECTRICAL DIAGRAMS

STT CHOPPER G3339-1

Return to Master TOC

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G-7

OCI1
R2

C22
R22

Return to Master TOC

J10
B55

B53

.45
0

±.04
7.50

0
4.00

1.30

:
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.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056

Chg. Sheet No.
2-11-2000

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

8-4-2000J

DO NOT SCALE THIS DRAWING

NOTE:

"X" INFO.

ON 2 PLACE DECIMALS IS± .02

ON 3 PLACE DECIMALS IS ± .002

EN-170

Return to Master TOC

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1.30

9-22-2000A

DESIGN INFORMATION

REFERENCE:

DRAWN BY: JLV/RAS

G3135-1

ENGINEER: KJ

SUPERSEDING:

APPROVED:DRS

EQUIPMENT TYPE:
SUBJECT:
SCALE: 1:1

INVERTER WELDERS
CHOPPER P.C. BOARD ASSEMBLY

DATE: 2-23-98 DRAWING No.:

G 3339-1

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

SOLID EDGE

Return to Section TOC

C11

POWER WAVE 455/R

Return to Master TOC

ELECTRICAL DIAGRAMS

G-8

SCHEMATIC-DEVICENET/GATEWAY PC BOARD

Return to Master TOC
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Return to Section TOC
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G-8

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

Return to Master TOC

G-9

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY-DEVICENET/GATEWAY
ITEM

PART NO.
QTY
PC BOARD REFERENCE
DESCRIPTION
DESIGNATORS
1
G3820-D
1
GATEW AY PC BOARD BLANK
2
S24671
1
PLUG, KEYING PLUG
3
M19436-5
1
POTTING TRAY
4
S8025-80
2
SELF TAPPING SCREW
5
E2527
195g.
(6.87OZ) EPOXY ENCAPSULATING RESIN
6
E3539
AS REQ.
ELECTRICAL INSULATING COMPOUND
7
S24824-3
1
X11
SOFTW ARE CPLD
8
S24825-1
1
X13
SOFTW ARE, FLASH
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS

(5.84)

Return to Master TOC

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G-9

Return to Master TOC

Return to Section TOC

(6.34)

9
10
11
12
13
14
15

S25020-13SMT
S25024-8SMT
S13490-179
S25024-5SMT
S25024-6SMT
S25024-2SMT
S25020-3SMT

2
5
1
4
4
4
30

16
17
18
19
20
21
22
23

S25020-15SMT
S13490-182
S13490-181
S25040-10SMT
S25040-9SMT
S25040-2SMT
S25040-11SMT
S25040-4SMT

3
1
1
2
1
3
3
8

24
25
26
27
28
29

S25049-3SMT
S25049-4SMT
S25040-5SMT
S25046-1SMT
S25046-3SMT
S25044-9SMT

1
1
6
1
4
7

30
31
32
33
34
35

S18248-16
S18248-10
S24020-4
S24020-2
S24020-6
S25080-2SMT

1
1
3
1
1
6

36
37
38
39
40
41
42
43

S25080-1SMT
S15000-28SMT
S15000-32SMT
S25050-2SMT
S25051-4SMT
S25000-4750SMT
S25003-2000SMT
S25000-1002SMT

3
4
2
5
6
6
2
25

44
45
46
47
48
49
50
51

S25000-4751SMT
S25000-1001SMT
S25001-1002SMT
S25000-1501SMT
S25001-3320SMT
S25000-7500SMT
S25001-1211SMT
S25001-2670SMT

5
6
2
1
6
3
2
7

52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75

S25000-1000SMT
S25001-24R9SMT
S25001-2000SMT
S18380-5
S19869-8
S20375-8
S20353-1SMT
S15128-25SMT
S25068-6SMT
S15128-5SMT
S24841-1
S25068-7SMT
S25069-2SMT
M15101-14SMT
S25070-3SMT
S25069-3SMT
S17900-11SMT
S25069-4SMT
S20353-5SMT
S20353-4SMT
S25068-4SMT
S17900-24SMT
S25065-2SMT
S25082-1SMT

6
3
3
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1

C2,C7
C3,C4,C5,C6,C8
C9
C10,C13,C27,C30
C11,C12,C43,C60
C14,C16,C20,C25
C15,C17,C18,C19,C21,C22
C23,C24,C26,C28,C31,C32
C33,C35,C36,C37,C38,C41
C42,C44,C45,C46,C47,C48
C49,C50,C51,C53,C54,C58

CAPACITOR,SMD,CERAMIC,150pF,100V,5%,C
CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S
CAPACITOR,ALEL,1000,35V,20%
CAPACITOR,SMD,TANTALUM,4.7MF,35V,10%,
CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X

C29,C39,C40
C56
C59
D1,D5
D2
D3,D6,D21
D4,D16,D20
D7,D8,D9,D10,D12,D13,D14
D15
D17
D19
D22,D23,D24,D25,D26,D27
DZ1
DZ2,DZ3,DZ4,DZ5
DZ6,DZ7,DZ8,DZ10,DZ11,DZ12
DZ13
J70
J71
J72,J73,J76
J74
J75
LED1,LED2,LED3,LED5,LED7
LED9
LED4,LED6,LED8
O C I1, O C I2, O C I3, O C I4
O C I5,O C I6
Q2,Q4,Q5,Q12,Q13
Q6,Q7,Q8,Q9,Q10,Q11
R1,R2,R39,R40,R66,R67
R3,R4
R5,R8,R9,R10,R11,R12,R13
R14,R15,R16,R17,R19,R20
R21,R22,R23,R24,R25,R29
R34,R35,R42,R60,R61,R69

CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG
C A P ,A L E L , 3 3 0 0 , 6 3 V , 2 0 %
C A P ,A L E L , 2 2 , 6 3 V , 2 0 %
DIODE,SMD,3A,400V,D0-214AB
DIODE,SMD,3A,200V,D0-214AB,ULTRA-FAST
DIODE,SMD,1A,400V,DO-214BA/AC
DIODE,SMD,1A,600V,S403A,ULTRA-FAST RE
DIODE,SMD,DUAL,0.200A,70V,UFR

R6,R38,R43,R45,R101
R18,R37,R41,R65,R68,R100
R27,R28
R30
R31,R32,R33,R46,R47,R72
R36,R44,R76
R48,R49
R50,R51,R52,R53,R57,R58
R59
R54,R55,R56,R80,R81,R82
R73,R74,R75
R77,R78,R79
R83
S1,S2
T1
X2
X3
X4,X24
X5
X6
X7,X9
X8
X10
X11
X13
X14
X15
X16,X18
X17,X22
X20
X23
X31
Y1

DIODE,SMD,3A,40V,SCHOTTKY,CASE 403-3
DIODE,SMD,DUAL,200MA,30V,SCHOTTKY,SOT
DIODE,SMD,DUAL,0.200A,70V,UFR
ZENER DIODE,SMD,0.5W ,5.1V, 5%,SOD123
ZENER DIODE,SMD,0.5W ,18V, 5%,SOD123
ZENER DIODE,SMD,3W,6.2V,5%, SMB
C O N N E C T O R , M O L E X , M I N I,PCB,16-PIN
C O N N E C T O R , M O L E X , M I N I,PCB,10-PIN
C O N N E C T O R , M O L E X , M I N I,PCB,4-PIN,TIN
C O N N E C T O R , M O L E X , M I N I,PCB,2-PIN,TIN
C O N N E C T O R , M O L E X , M I N I,PCB,6-PIN,TIN
LED,SMD,GREEN,CLEAR,S1206
LED,SMD,RED,CLEAR,S1206
OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR
OPTOCOUPLER,SMD,CMOS,HIGH SPEED,HIGH
TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM
TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 4 7 5 O H M S
R E S IS T O R ,S M D , 1 W , 2 0 0 O H M S , 1 %
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 1 0 . 0 K , 1

R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 4 . 7 5 K , 1
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 1 . 0 0 K , 1
R E S IS T O R ,S M D , 1 0 K , 1 / 4 W , 1 2 0 6 , 1 % , T R
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 1 . 5 0 K , 1
R E S IS T O R ,S M D , 3 3 2 O H M S , 1 / 4 W , 1 2 0 6 , 1 % , T R
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 7 5 0 O H M S
R E S IS T O R ,S M D , 1 . 2 1 K , 1 / 4 W , 1 2 0 6 , 1 % , T R
R E S IS T O R ,S M D , 2 6 7 O H M S , 1 / 4 W , 1 2 0 6 , 1 % , T R
R E S IS T O R ,S M D ,M E T A L F I L M , 1 / 1 0 W , 1 0 0 O H M S
R E S IS T O R ,S M D , 2 4 . 9 O H M S , 1 / 4 W , 1 2 0 6 , 1 % , T R
R E S IS T O R ,S M D , 2 0 0 O H M S , 1 / 4 W , 1 2 0 6 , 1 % , T R
THERMISTOR,PTC,0.5-1.17 OHMS,0.5A
S W IT C H , D I P , S P S T , 8 - C I R C U I T S
TRANSFORMER,PCB,PW M ,FLYBACK
IC,SMD,CMOS,DRIVER,RECEIVER,EIA232,14
IC,SMD,VOLTAGE REGULATOR,FIXED,POSITI
IC,SMD,VOLT REG,FIXED,3-T,(+),0.1A,5V
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
IC,MODULE,CONVERTER,DC-DC,+5V/3A OUT
IC,SMD,CMOS,UNDERVOLT-SENSING,RESET,M
IC,SMD,CMOS,EEPROM,SERIAL,SPI,64Kx8,S
IC,SMD,CMOS,MCU,32-BIT,2K-RAM,TPU,25M
CPLD,PROGRAMMABLE,XC9536,44-PIN,VQFP(
IC,SMD,CMOS,EEPROM,FLASH,16-BIT,512K
IC,SMD,CMOS,TRANCEIVER,BUS,3-STATE,OC
RAM,STATIC,16-BIT,128K,44-PIN,TSOP
IC,CMOS,CONTROLLER,COMMUNICATION,SERI
IC,CMOS,SMD,XCVR,EIA485(SS)
IC,SMD,TRANSCEIVER,CAN,UC5350,S0IC-8
IC,SMD,CMOS,GATE,NAND,2-INPUT,QUAD,SC
IC,SMD,ACT,LATCH,OCTAL,3-STATE,TSSOPCRYSTAL,SMD,QUARTZ,16MHZ

Return to Master TOC

Return to Section TOC

UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS

.
11-3-2000A

L11046-1
NOTE:

POWER WAVE 455/R

D32

1SMB5931
1.5W
18V

100pF

/RES

(3)

2 BAV99
D78
3

R84

CAPA_OV

CAPAUV

R135

CAPA_UV

MMSZ5231
1/2W
5.1V

820pF

(2)
(1)
(4)
(4)

MMSZ5231
1/2W
5.1V

D8
MMSZ5231
1/2W
5.1V

820pF

C69

4700pF

(3)
820pF

+15V

R32

D17

10.0K

R99
MMSZ5231
1/2W
5.1V

R33

10.0K

C46

R100
475K

1uF
35V

J5
J5

47.5

1uF
35V

INT_1_3PH

(4)

C74

(4)

/BKPT

/DS

G1
V1 11
G2
V2 19
G3
V3 37
G4
V4 47
G5
V5 61
G6
V6 72
G7
V7 86
G8
V8 89
G9
G10 V9 109
G11 V10 121
G12 V11 135
G13 V12 144
G14

2
12
20
35
48
54
62
74
82
91
107
120
128
134

CRYSTAL 85
83
/RES 92
93
80
TSC
/BERR 94
FREEZE 81
/BKPT 79
FPGA_RESET 114
FPGA_DONE 113
LEVEL_IN 112
RMC 111
/AS 106
/DS 110
SOFTST 105
MN_CNT 104

RMC
/AS
/DS

OUTPUT_ON 102
SYS_RESET 101
PWRDN_INT 100
99
FAULT_INT
98
FPGA_INT
97
INT_CAN
96
FPGA_BAD
INT_100 95

FPGA_INT
INT_CAN
FPGA_BAD

(4)

+5V

C67

C73

C68

0.1uF

FAULT
SIGNAL
RED
D

LED7

R183
D

+5V

TPU0
TPU1
TPU2
TPU3
TPU4
TPU5
TPU6

750

+5V
+5V
+5V

X17
CLK_8
CLK
SCK7
CMP4

/RES
THERMOSTAT
SSOUT
OVR_CUR
FET_B
CAPA_OV
CAPA_UV
FET_A
MN_CNT
FAULT_INT
PRI_OC
PWRDN_INT
MN_OUT
SPI_LATCH7

43
44
1
36
34
33

J1
J1
J1
J1
J1

40
41
42
2
3
5
6
7
8
12
13
14
16
18

GCK1
GCK2
GCK3
GTS1
GTS2
GSR
IO1A
IO2A
IO4A
IO6A
IO8A
IO9A
IO10A
IO11A
IO12A
IO13A
IO14A
IO15A
IO16A
IO17A

TCK
TMS
CPLD TDI
TDO
IO1B
IO2B
IO4B
IO7B
IO8B
IO9B
IO10B
IO11B
IO12B
IO13B
IO14B
IO15B
IO16B
IO17B

8
9
11
10
9
24
39
38
37
32
31
30
29
28
27
23
22
21
20
19

11
10
MISO7
RESET_RAMP
STROBE_AD
CAPB_UV
CAPB_OV
CLR_CAP
CMP0
CMP2
CRYSTAL
OUTPUT_ON
SOFTST
DISABLE_455

R174

(4)
(3)
(3)

(2)

MISO
(4)
MOSI
(3,4)
SCK
(3,4) SPI_CS0
(4)
SPI_CS1
(4)
SPI_CS2
(4)
SPI_CS3
(4) RS232_TXD
(2) RS232_RXD
(2)

13
34
33
32
31
30
29
28
27
24
23
22
21
17
16
15
14
65
66
67
68
69
70
71
75
76

EXTAL
XTAL

XFC
CLKOUT
CSBOOT'
RESET'
BR' /CS0'
HALT'
BG' /CS1'
TSC
BGACK' /CS2'
IPIPE' /DSO
BERR'
FREEZE IFETCH' / DSI
BKPT'/DSCLK
R/W
DSACK0'
/PE0
A0
DSACK1'
/PE1
A1
AVEC'
/PE2
A2
RMC'
/PE3
A3
AS'/PE4
A4
DS'/PE5
A5
SIZ0 /PE6
A6
SIZ1 /PE7
A7
A8
PF0/ MODCLK
A9
PF1/ IRQ1'
A10
PF2/ IRQ2'
A11
PF3/ IRQ3'
A12
PF4/ IRQ4'
A13
PF5/ IRQ5'
A14
PF6/ IRQ6'
A15
PF7/ IRQ7'
A16
A17
T2CLK
TPUCH0 PC3/CS6' /A18
TPUCH1 PC4/CS7' /A19
TPUCH2 PC5/CS8' /A20
TPUCH3 PC6/CS9' /A21
A22
TPUCH4
CS10' /A23
TPUCH5
TPUCH6 PC0/CS3' /FC0
TPUCH7 PC1/CS4' /FC1
TPUCH8 PC2/CS5' /FC2
TPUCH9
TPUCH10
D0
TPUCH11
D1
TPUCH12
D2
TPUCH13
D3
TPUCH14
D4
TPUCH15
D5
D6
PQS0/MISO
D7
PQS1/MOSI
D8
PQS2/SCK
D9
PQS3/PCS0/ SS'
D10
PQS4/PCS1
D11
PQS5/PCS2
D12
PQS6/PCS3
D13
PQS7/TXD
D14
RXD
D15
MC68332PV

+5V

X30

14
12
25
24
23
22
21
20
19
18
8
7
6
5
4
3
2
1
48
17
16
26
11
28
47

/RES
ADDR1
ADDR2
ADDR3
ADDR4
ADDR5
ADDR6
ADDR7
ADDR8
ADDR9
ADDR10
ADDR11
ADDR12
ADDR13
ADDR14
ADDR15
ADDR16
ADDR17
ADDR18
ADDR19
/CSB
R/W

X25
WP' VPP
RP' VCC
A0
A1
A2
A3
A4
D0
A5
D1
A6
D2
A7
D3
A8
D4
A9
D5
A10
D6
A11
D7
A12
D8
A13
D9
A14 D10
A15 D11
A16 D12
A17 D13
A18 D14
CE' D15
WE' GND1
OE' GND2
BYTE'

0.1uF

29
31
33
35
38
40
42
44
30
32
34
36
39
41
43
45
46
27

+5V TE28F800B5-B90

C111

13
37

512Kx16
FLASH

ADDR[1:19]

MMBT4401

R/W

X24

2
Q20

(3)

10.0K
R254

OUTPUT_ON
(4) SYS_RESET
(2,3,4)

(4)
(2)
(4)

/RES

D
DATA0
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
DATA9
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15

87
90 CLK
(1,4)
140 /CSB
141 /CS0
142 /CS1
143 /CS2
77
/IPIPE
78
/IFETCH
103
R/W
115
39
ADDR1
40
ADDR2
41
ADDR3
42
ADDR4
43
ADDR5
44
ADDR6
45
ADDR7
46
ADDR8
49
ADDR9
50
ADDR10
51
ADDR11
52
ADDR12
56
ADDR13
57
ADDR14
58
ADDR15
60
ADDR16
63
ADDR17
64
ADDR18
6
ADDR19
7 DSP_RESET
8 VPP_CTRL
9 IACK
10 CAN_CS
3
4FPGA_CS
5 FUNCEN

12
4

J1
J1

+5V

(4)
(3)
(2)

ADDR1
ADDR2
ADDR3
ADDR4
ADDR5
ADDR6
ADDR7
ADDR8
ADDR9
ADDR10
ADDR11
ADDR12
ADDR13
ADDR14
ADDR15
ADDR16
ADDR17

(3)
(4)

139
138
137
136
133
132
131
130
127
125
124
122
119
118
117
116

DATA0
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
DATA9
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15

44
43
42
27
26
25
24
21
20
19
18
5
4
3
2
1
22

ADDR[1:19]
/CS2
R/W
/CS2
/CS0
/CS1

(3)
(4)
(4)

/CS0
/CS1

6
17
41
39
40

(4)
(4)

X27
A0 VCC1
A1 VCC2
A2
A3128KX16
A4 SRAM
A5
A6
D0
A7
D1
A8
D2
A9
D3
A10
D4
A11
D5
A12
D6
A13
D7
A14
D8
A15
D9
A16 D10
D11
D12
CE' D13
WE' D14
OE' D15
LB' GND1
UB' GND2
IS61C12816

BANK1

C113

11
33

7
8
9
10
13
14
15
16
29
30
31
32
35
36
37
38

0.1uF
D
DATA0
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
DATA9
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15

12
34

DATA[0:15]

820pF

(4)

D
NOISE_GND

(3)

FREEZE

+5V

47.5

D19

BAV99

NOISE_GND
SINGLE/THREE PHASE DETECT

R34
1.00K

2.21K

MMSZ5231
1/2W
5.1V

NOISE_GND

5
13

3.32K
2 X23
VDD
1
RES' 1
VSS
MMBT4401
3 S80746AN
4.6V/2%

3
1
Q19

R179

PWRDN_INT

FPGA_RESET
FPGA_DONE

CAPB_UV

C72

3 10A,100V

1.00K

/RES
3

Q10

NOISE_GND

22.1K

R169

CAPBUV

NOISE_GND

(4)

R203 CAPB_OV

1.00k
4

CAP0

X30

R168

FILTER CAPACITOR VOLTAGE MONITORING

Return to Master TOC

74AC14

22.1K

820pF

R37
CAPBOV

820pF

R39

BAV99
D79
1
3
1

R85

C71

475

NOISE_GND

22.1K

C70

3 10A,100V

2 IRLR120N

C142

0V = NORMAR
5V = FAULT

+5V

11
+15V

/RES

0.1uF

820pF

(4)
(4)
(4)
(4)
(4)

1.00K

CAPAOV

1.00k R136

/BERR

+5V

DATA0
DATA1
DATA2
DATA6
DATA7
DATA11
DATA3
DATA8

THERMOSTAT

D
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.
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
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

"X" INFO.
XM5626

Chg. Sheet No.

DESIGN INFORMATION

6-2-2000A

DRAWN BY: F.V.

DO NOT SCALE THIS DRAWING

ENGINEER: T. KOOKEN
APPROVED:

REFERENCE:

SUPERSEDING:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

INVERTER WELDERS
DIGITAL CONTROL SCHEMATIC

DATE: 12-15-99 DRAWING No.:

G 3789-1D0/1

SOLID EDGE

22.1K

MMSZ5231
1/2W
5.1V

1
1

/RES

X30

1uF
35V

10.0k R189

Return to Master TOC

R35

22.1K

NOISE_GND

475

C141
0.1uF

R38

26
15
35

74AC14

D25

26.7K

330pF

C104

D
9

2 IRLR120N

R187

MMSZ5231
1/2W
5.1V
0V = NORMAR
5V = FAULT

D3
S1G

+5V

475

+15V

D4
S1G

VCCIO
VCC1
VCC2

475

NOISE_GND

XC9536-15-VQ44I

LEVEL_IN

GND1
GND2
GND3

R41

0.1uF

4
17
25

+15V

R11

X30

1uF

J1
J1
J1
J1
J1
J1

19
18
17
16
15
14
13
12

R242

X10

74AC14

(4)

/RES

0.1uF

475
R36

NOISE_GND

C136 C11

Q
Q
Q
Q
Q
Q
Q
Q

10.0K

D86
BAV70LT1

R257

D81
1BAT54S

C27

10.0K

C123

BAT54S
D82

2
4.75K

R21

X10

DATA[0:15]
X21
X21
X21
X21
X21
X21
X21
X21

+5V

C143

+5V

J6
J6

LE
OE'
D
D
D
D
D
D
D
D

+5V

475

820pF

D18

NOISE_GND

D115

(4)

FAN_CONTROL

2
475

1
2

X2
1
VS1 8
VS2 6
OUTPUT1 7
OUTPUT2 4
GND1 5
GND2 3
NC 2
INPUT
MIC4451BM

1SMB5930
1.5W
16V

D85
BAV70LT1

BAV70LT1
D91

R51

R40 475

MMBT4401 3

NOISE_GND

0.1uF

D114

1uF

+5V

R/W

1SMB5931
1.5W
18V

/RES

0.1uF

C43

R87

MMBR130LT3MMBR130LT3

100pF

C135 C14

C99

3
VPP

(2,4)

0.1uF

D30

D80
BAT54S

R258

C122

CAP1

X10

4700pF

NOISE_GND

10.0K

J6
J6

C44

R88

R186 10.0K

C22

10.0K

10.0K R181

13
475
2

4.75K

1.00K

120uF
50V

D76

(4)

D77

R15

R46

STT_ON

475

NOISE_GND

MMBT4401 3

NOISE_GND

0.1uF

10.0K
R185

D31

1SMB5931
1.5W
18V

100pF

R90

22.1K

R81

C13 J4

4.7uF
35V

X3
1
VS1 8
VS2 6
OUTPUT1 7
OUTPUT2 4
GND1 5
GND2 3
NC 2
INPUT
MIC4451BM

MMBR130LT3MMBR130LT3

Return to Master TOC

PTC

D83
BAT54S

R259

C12
MF-R050

C25

10.0K

475

1.00K

C90

0.1uF

+15V

1SMB5930
1.5W
16V

Q15
MMBT4403

10.0K

C110 C120 C108
22uF
20V

D15

R47

THERMAL_LED
4.75K

C119

+15V

0.1uF

2
1

+5V

22uF
20V
8

R171

MC68332

R172

MMBT4401 3 R20
NOISE_GND
1
Q6

10.0K

+15V

74AC573
11
1
2
3
4
5
6
7
8
9

/RES

R170

MICRO_CONTROLLER

D84
BAV70LT1

BAV70LT1
D90

(4)

100pF

R17
475

D29

1SMB5931
1.5W
18V

C18

10.0K

C95

10.0K R200

0.1uF

10.0K R199

MISC1

475

0.1uF

10.0K R180

R43

0.1uF

R19
475

0.1uF

10.0K R164

R14

1uF
35V

10.0K

MMBT4401 3

NOISE_GND

R260

Return to Section TOC

R10
475
1

4.75K

Return to Section TOC

1uF
35V

VDDSYN 84
VDDE 25
VSSE 26

38 VSTDBY

74AC14

100pF

C105 C93 C109 C106

MMSZ5231
1/2W
5.1V

R261

+5V

X24

D44

10.0K

C94 C107

74AC14

C15

R18
475

74AC14

4.75K

R255
1K

1
MMBT4401

R256
1K

+5V

R16

475

MMSZ5231
1/2W
5.1V

R42
MISC0

(4)

+15V

74AC14

475

BAV70LT1
D89

D24

Return to Master TOC

SCHEMATIC - CONTROL PC BOARD

(4)

Return to Section TOC

G-10

ELECTRICAL DIAGRAMS

1SMB5931
1.5W
18V

Return to Section TOC

G-10

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

51
52
53
54

29
30
31
32
33

FOR ITEMS LISTED BELOW REFER TO ELECTRICAL DATABASE FOR COMPONENT
SPECIFICATIONS
C138 C134 C133 C125 C55 C96 C98 C100 C28
C82 C14 C11 C83 C103 C121 C101 C117 C115
C111 C113 C85 C90 C48 C93 C109 C120 C127
C106 C95 C105 C73 C68 C8 C114 C108 C99
S25020-3SMT
68
SCAP,0.1uF,0805,50V,X7R,10%,TR
C77 C76 C75 C84 C79 C67 C88 C80 C50 C78
C23 C21 C91 C51 C92 C58 C57 C52 C60 C59
C131 C123 C122 C124 C30 C129 C139 C140
C42 C137 C141 C142
S14390-173
2
CAP,1uF,RA,63V,10%,NP
C136 C135
S25020-2SMT
2
SCAP,0.022uF,0805,50V,X7R,10%,
C86 C7
S25020-10SMT
2
SCAP,4700pF,0805,50V,X7R,10%
C44 C69
S25020-5SMT
4
SCAP,22pF,0805,50V,COG,5%,TR,N
C118 C116 C128 C130
S25020-18SMT
1
SCAP,10pF,CER,0805,100V,5%
C32
S25020-13SMT
7
SCAP,150pF,0805,100V,COG,5%,TR,
C64 C89 C26 C35 C36 C38 C37
S25020-4SMT
11
SCAP,820pF,0805,50V,COG,5%,TR,
C43 C4 C74 C3 C71 C19 C70 C5 C72 C6 C17
S24833-1
2
CAP,0.27uF,MF,50V,5mm,5%,TR,NP
C56 C34
S25020-14SMT
2
SCAP,330pF,100V
C126 C143
S25025-5SMT
9
SCAP,4.7uF,7343,35V,10%,TR,NP
C12 C102 C1 C9 C10 C39 C40 C16 C61
S25024-2SMT
8
SCAP,1uF,TAN,3528,35V,TR,NP
C94 C97 C104 C107 C47 C81 C2 C46
S25024-8SMT
4
SCAP,10uF,TAN,6032,TR,NP
C66 C62 C65 C63
S25024-10SMT
4
SCAP,22uF,TAN,7343,25V,10%
C119 C110 C49 C54
S13490-179
1
CAP,1000uF,ALU,35V,20%,NP
C45
S13490-183
1
SCAP,120MF,50V,20%,RADIAL,AE
C13
D68 D67 D4 D3 D75 D63 D64 D65 D70 D72 D71
S25040-2SMT
13
SDIO,1A,400V,DO-214BA,GLS
D73 D74
D25 D45 D44 D17 D9 D6 D2 D5 D7 D8 D35 D36
S25046-1SMT
19
SDIO,MMSZ5231BT1,5.1V,NP
D38 D37 D42 D41 D40 D39 D69
S25044-9SMT
7
SDIO,1SMB5920BT3,6.2V,NP
D62 D61 D60 D13 D12 D1 D46
S25046-3SMT
4
SDIO,MMSZ5248B,18V,ZENER,TR,NP
D53 D52 D58 D59
S25044-10SMT
3
SDIO,B5930,16V,1.5W,ZENER,TR,N
D18 D15 D43
S25044-5SMT
9
SDIO,1SMB5931BT3,3W,18V,5%
D27 D32 D26 D30 D31 D29 D24 D14 D16
S25044-4SMT
2
SDIO,B5929,15V,1.5W,ZENER,TR,N
D10 D11

S25040-5SMT

SDIO,BAV99LT1,SOT23,DUAL SWITC

S25049-4SMT

SDIO,BAT54S,DUAL,30V,200mA

D34 D54 D28 D47 D80 D81 D82 D83

S25080-2SMT

SLED,GRN,1206,TR,NP

LED8 LED1 LED5 LED3 LED2 LED4 LED6
LED9

37
38
39
40

S25080-1SMT
S25083-1SMT
S25001-4752SMT
S25001-2211SMT

2
1
8
8

SLED,RED,1206,TR,NP
SIND,FERRITEBEAD,TR,NP
SRES,47.5K,1206,1%,1/8W,TR,NP
SRES,2.21K,1206,1%,1/8W,NP

S25001-1001SMT

SRES,1K,1206,1%,1/8W,TR(9X0056

S25001-1002SMT

SRES,10K,MF,1206,1%,1/8W

S25001-4750SMT

SRES,475,1206,1%,1/8W,TR,NP

S25001-4751SMT

SRES,4.75K,1206,1%,1/8W,SM100-

R190 R192 R182 R184 R137 R146 R209 R210
R222 R42 R43 R46 R47 R51 R67

45
46
47
48
49
50

S25003-2000SMT
S25001-1501SMT
S25001-7500SMT
S25001-5110SMT
S25001-1004SMT
S25001-2672SMT

2
7
1
2
2
4

SRES,200,2512,1%,1W,TR,NP
SRES,1.5K,1206,1%,1/8W,NP
SRES,750,1206,1%,1/8W,NP
SRES,511,MF,1206,1%,1/8W,TR
SRES,1M,1206,1%,1/8W,TR(9X0098
SRES,26.7K,THK,1206,1%,1/8W,10

R132 R133
R113 R118 R122 R74 R76 R80 R78
R183
R24 R23
R212 R211
R187 R114 R120 R72

12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

(6.34)

Return to Master TOC

Return to Section TOC

G-11

ELECTRICAL DIAGRAMS

Return to Master TOC

Return to Section TOC

G-11

COMPONENT SIDE

D66 D50 D33 D49 D19 D78 D79 D102 D103
D104 D105 D106 D107

LED7 LED10
E1
R230 R27 R28 R26 R53 R29 R110 R57
R25 R13 R12 R32 R1 R31 R134 R66
R171 R178 R177 R193 R231 R167 R61 R34
R89 R82 R163 R135 R136 R169 R131 R112
R60 R56 R126 R71 R54 R69 R68 R143 R144
R58 R206 R213 R214 R90 R168 R255 R256
R173 R191 R181 R164 R170 R172 R189 R186
R180 R91 R92 R93 R94 R95 R96 R97 R98 R22
R174 R201 R185 R104 R87 R33 R99 R260
R261 R139 R140 R121 R200 R107 R199 R103
R221 R229 R204 R242 R241 R216 R217 R218
R243 R246 R244 R245 R247 R248 R249 R250
R251 R252 R253 R254 R257 R258 R259
R195 R194 R41 R11 R83 R86 R166 R165 R21
R15 R20 R88 R81 R14 R9 R17 R19 R10 R18
R16 R141 R138 R119 R116 R85 R84 R40 R36

S25001-3321SMT
S25001-2212SMT
S25001-47R5SMT
S25001-4753SMT

4
6
2
1

S25001-1003SMT

56
57
58
59
60
61
62
63

S25001-1213SMT
S25001-3322SMT
S25001-1000SMT
S25001-2210SMT
S25001-2671SMT
S25001-1502SMT
S25001-6811SMT
S25001-1500SMT

1
3
4
5
1
2
2
2

S25006-10R0

65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113

S25050-2SMT
S25051-6SMT
S25050-1SMT
S25051-4SMT
S25051-7SMT
S24020-4
S24020-6
S24020-2
S18248-10
S18248-16
S24020-16
S24020-12
S24020-8
S20353-4SMT
S25065-2SMT
S25070-7SMT
S15000-28SMT
S20353-5
S25082-1SMT
S20353-1SMT
S25067-3SMT
S17900-1SMT
S15128-13SMT
S15128-18SMT
S25069-3SMT
S25069-4SMT
M15101-14SMT
S25068-8SM
S25065-3SMT
S25057-3SMT
M15105-9SMT
S15018-21SMT
S25067-2SMT
S25070-3SMT
S25069-2SMT
S15128-21SMT
S19869-8
S25066-2SMT
S25068-7SMT
S25070-4SMT
S20620-1003
S25040-12SMT
S25020-SMT
S25000-1000SMT
T12702-60
T12702-59
S25049-2SMT
S25001-3320SMT
S25040-6SMT

5
2
9
2
1
3
1
2
1
1
2
1
1
1
1
1
4
1
1
1
2
1
1
3
1
1
1
1
2
2
1
2
1
1
1
2
1
1
1
1
4
8
5
6
2
2
4
6
6

SRES,3.32K,1206,1%,1/8W,NP(AM2
SRES,22.1K,1206,1%,1/8W,TR,NP
SRES,47.5,1206,1%,1/8W,TR,NP
SRES,475K,1206,1%,1/8W,TR,NP

R123 R128 R129 R179
R37 R38 R35 R203 R8 R39
R3 R2
R100
R55 R111 R49 R108 R115 R124 R142 R208
SRES,100K,1206,1%,1/8W,200PPM,
R207 R106
SRES,121K,1206,MF,1%,1/4W
R70
SRES,33.2K,1206,1%,1/8W,TR,NP
R63 R65 R233
SRES,100,1206,1%,1/8W,TR,NP
R62 R44 R52 R30
SRES,221,1206,1%,1/8W,NP
R59 R48 R102 R197 R45
SRES,2.67K,1206,1%,1/8W,TR,NP
R109
SRES,150K,1206,1%,1/8W,NP
R117 R125
SRES,6.81K,1206,1%,1/8W,NP
R127 R130
SRES,150,1206,1%,1/8W,TR,NP
R196 R198
R151 R154 R157 R160 R148 R161 R158 R155
SRES,10,
R152 R149
STRA,2N4403,SO23,TR,(500475),N
Q17 Q16 Q15 Q13 Q14
STRA,IRLR120N,10A,100V,MOSFET,
Q9 Q10
STRA,MMBT4401LT,NPN,SOT-23
Q12 Q4 Q7 Q5 Q6 Q1 Q18 Q19 Q20
STRA,2N7002,TR,NP
Q3 Q2
SICS,IRF7103,NP
Q11
CON,4P,TIN,MINI,NP
J5 J11 J2
CON,6P,TIN,MINI,NP
J9
CON,2P,TIN,MINI,NP
J10A J10B
CON,10P,MINI,NP
J3
CON,16P,MINI,NP
J1
CON,16P,TIN,MINI,NP
J6 J7
CON,12P,TIN,MINI,NP
J4
CON,8P,TIN,MINI,NP (or TH600-265)
J8
SICS,MAX485ESA,NP
X29
SICS,74ACT573,OCTAL,TRANS.,LAT
X21
SICS,TMS320F240PQA,NP
X22
SICS,HCPL-0601,OPTOCOUPLER
OCI1 OCI2 OCI3 OCI4
SICS,AN82527
X28
SXTL,16MHZ,HC40,20PF,NP
Y1
SICS,MC145407,RECEIVER/DRVR,RS
X16
SICS,ADG417,SPST,CMOS,SWT,SO8
X13 X31
74HC245, NEW PACKAGE
X33
SICS,OP-27G,OPAMP,SO8,TR,NP
X1
SICS,MC33074,QUAD,OPAMP,SO14,T
X8 X14 X20
SICS,28F800B5-90,FLASH RO,90n
X25
SICS,128Kx16,20nS,TSOP
X27
SICS,MC68332
X24
SICS,MC79L05ABD
X4
SICS,74VHC14,NP
X10 X30
SICS,AD8403ARU10
X6 X32
SICS,7945
X
12
ICS,MIC4451BM
X2 X3
SICS,ADG409BR
X15
ICS,XC9536-15 VQ44
X17
SICS,25128,SERIAL EEPR,NP
X11
SICS,LT1016,COMPARATOR
X5 X7
SWT,78B08S,DIP,SPST,8P,NP
S1
SICS,AD7862,DUAL,12BIT,250kSPS
X19
SICS,4.6V,2%,VOLT. DETECTOR,SO
X23
SICS,XCS20,FPGA
X18
RES,100K,AX,5%,1/2W,HI VOLT,TR
R73 R79 R75 R77
SDIO,MURS320T3,3A,200V,ULTRAFA
D51 D55 D56 D57 D98 D99 D100 D101
SCAP,100pF,0805,COG,100V,5%
C15, C18, C22, C25, C27
SRES,100,0805,1%,1/10W
R223, R224, R240, R226, R227, R228
DIO,1N5358B
DZ3 DZ4
DIO,1N5333B
DZ1 DZ2
SDIO,MBRA130LT3,1A,30V,SCHOTKY
D76 D77 D114 D115
SRES,332,1206,1%,1/4W
R262 R263 R264 R265 R266 R267
SDIO,BAV70
D84 D85 D86 D89 D90 D91

Return to Master TOC

Return to Section TOC

(8.09)

Return to Master TOC

Return to Section TOC

CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

OTHER COMPONENT SIDE (BACKSIDE)

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

DO NOT SCALE THIS DRAWING

NOTE:

Chg. Sheet No.
5-25-2001F

"X" INFO.

DESIGN INFORMATION

REFERENCE:

DRAWN BY: F.V.
ENGINEER: T. O'DONNEL
APPROVED:

SUPERSEDING:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

INVERTER WELDERS
CONTROL
P.
C.ARD
BO AS'BLY

-99
DATE: 4-6

DRAWING No.:

L 11088-1D2

POWER WAVE 455/R

G-12

ELECTRICAL DIAGRAMS

SCHEMATIC - DIGITIAL POWER SUPPLY PC BOARD

R50

OUT

Vref 1

D3
1A
600V

VREF

VFB

RT/CT

COMP 1

GND

J41

10.0

100K

3A
600V

D21
1.0A
30V

OV1

C11
22
35V

T1
475

C14
0.1
50V

C47
1.0
35V

1.21K
.33W

Vfb1

R52

1.82K

221K

C7
0.1
50V

C6
4.7
35V

C8
820p
50V

R39

R12

56.2K

5.62K

C45
150p
100V
3W
0.05

C32
10p
100V

J41
3

R11

Return to Master TOC

C42

R13

2700p
50V

10.0K

DZ1
24V
3W

R36

30.1

R35

OCI2

2
G
2

RT/CT

COMP 1

R1
C26
1
200V

150p
100V

D20
1.0A
30V

Vfb2

75K

C53
.1

OV2

C4
820p
50V

R31

C2
0.1
50V

C3
4.7
35V

GND

R32
15.0

R29

Q2
21A
200V

J43

DZ7
18V
3W

R38

R28

56.2K

5.62K

15Volts, .250Amps
SPI

C28
10p
100V

249

3W
0.05

J43

R40

3
+t
.13
60V

D16
16A
200V
LED1

C35
100
16V

C34
0.1
50V

+5Volts, 3 Amps
150
.33W

150
.33W

SPI
Vref 2
332

C33
4.7
35V
5

OUT

1A
600V
C5
0.1
50V

C30
1.0
35V

R44

C1
4.7
35V

GND

150
.33W

+5Volts, .100 Amp

OCI3

CNY17-3

CAN

C17
4.7
35V

C18
4.7
35V

C21
0.1
50V

R19

.24

2.49K
.33W

R21

C46
150p
100V

4
7

.24

C10
4.7
35V

C9
0.1
50V

C29
1.0
35V

+5Volts, .100 Amp
150
.33W

T2
8

RS232

C20
4.7
35V

C19
4.7
35V

C22
0.1
50V

R23

GND

R25

OUT

C16

R22

2700p
50V

10.0K

7
+t

D6
1A
600V

2.49K
.33W

+20Volts
.200 Amps
Gate Drive

8
X2
TL431 REF
6

R18

1.82K
R20

J43

R24

J43

Vfb2
475K

J43

D12

1A
600V

+20Volts
.200 Amps
Gate Drive

J43

R17

D7
1A
600V

43.2K

R42

J43

D15

44.2K

C36
100
16V

R43

C37
100
16V

R41

D13

R63

D17
T2

Return to Master TOC

1.21K
.33W

OV1

DZ4
3.3V
3W

C23
1.0
35V

C25
0.1
50V

C24
4.7
35V

> 55 VDC

D14

OUT

ADJ

100K
C52
150p

D9
1A
600V

R30

221K

Overvoltage
Shutdown

5.62K

VFB

R33

gnd_mcps

OUT

VREF

C27
DZ3
27V
.5W

VCC

15.0K

R56

R34

R62

Vref 2
C49
.022

D10

D
4

DZ2
27V
.5W

R45

D25

CNY17-3
J42

C31
.0015
2000V

D23
1.0A
30V

J42

gnd_mcps

R37

D2
1A
600V

J42

D8
1A
600V

R64

R26

Operation
30-55 VDC

1.00K

J42

OUT

+5V

1.21K
.33W

-15Volts, .100Amp

ADJ

Undervoltage
Detect
<30VDC

R48

C40
1.0
35V

R49

C44
0.1
50V

C38
4.7
35V

OV2

8
X1
TL431 REF

GND

43.2K

J41

DC Input (-)

10.0K

Return to Section TOC

Machine Control
Shut Down
Capacitor

OCI1

CNY17-3
2

6.19K

OUT

ADJ

R15

R10

J42

D19

4
R55

.750 Amp

D24

DZ8
18V
3W

Vfb1

+15Volts

Q1
21A
200V

R14

J41
2

R16

D
G

DC Input (+)

Vref 1

R51

R60

VCC

33.2

10.0

R61

C13
1
200V

33.2
332

R53

D22
1.0A
30V

C39
0.1
50V

C41
100
16V

44.2K

10.0K

+5Volts, .750 Amp
C43
100
16V

R46

10.0K

R27

10.0K

+t
.13
60V

LED2

C12
.0015
2000V

10-55 VDC
Operation

J42
3

6A
200V

47.5

R58

R57

D4
6A
200V

10.0

Return to Section TOC

+5V

Machine Control Power Supply
D18

Return to Master TOC

Return to Section TOC

G-12

J43
11

J43

J43
9

J43
1

FILENAME: G3631-2D2
LAST NO. USED
R-

ELECTRICAL SYMBOLS PER E1537
MFD ( .022/50V
CAPACITORS =

NOTES :

RESISTORS = Ohms (
DIODES =
1A, 400V

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

UNLESS OTHERWISE SPECIFIED)
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)

C-

LABELS

D-

SUPPLY

VOLTAGE NET

POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION

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
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING

"X" INFO.

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

DESIGN INFORMATION

REFERENCE:

DRAWN BY: JP\TK
ENGINEER:
APPROVED:

SUPERSEDING:

EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE

Digital Systems
Schematic, Digital Power Supply

DATE: 11-30-98 DRAWING No.:

G 3631

SOLID EDGE

EN-170

Return to Master TOC

Return to Section TOC

GENERAL INFORMATION

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

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G-13
PC BOARD ASSEMBLY-DIGITAL POWER SUPPLY

ITEM
1
2
3
4
5

ITEM
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

(3.64)

Return to Master TOC

(6.14)

Return to Section TOC

G-13

ELECTRICAL DIAGRAMS

29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79

PART NUMBER
REQ'D.
DESCRIPTION
REFERENCE
DESIGNATOR
G3632-C
1
POWER PC BOARD BLANK
M19436-3
1
POTTING TRAY
S8025-80
2
SELF TAPPING SCREW
E2527
115g
EPOXY ENCAPSULATIOG RESIN
E2861
AS REQ'D ELECTRICAL INSULATING COMPOUND
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT
SPECIFICATIONS
PART NUMBER
QTY.
DESCRIPTION
REFERENCE
PCLIN-503-3
1
PCB,MTP,DC POWER ASSY,NP
N/A
707W04095
2
SDIO,MURS120T3,NO PRINT
D1 D15
A262564400
2
SRES,1.82K,1206,1%,1/8W,NP
R14 R20
A262566900
3
SRES,5.62K,1206,1%,1/8W,TR,NP
R12 R28 R45
A262569000
6
SRES,10K,1206,1%,1/4W,(09X-007
R4 R13 R22 R2 R27 R56
A262576200
2
SRES,56.2K,1206,1%,1/8W,NP(500
R38 R39
A262577900
4
SRES,100K,TKF,1206,1%,1/8W,TR,
R5 R10 R21 R29
SM100-035
2
SRES,330,1206,5%,1/4W
R41 R53
SM100-444
1
SRES,249,1206,1%,1/4W,TR,NP
R33
SM100-411
2
SRES,221K,1206,1%,1/8W,TR,NP
R34 R52
SM100-420
1
SRES,20,1206,1%,1/8W,TR,NP
R32
SM100-440
2
SRES,0.05,1%,2W,TR,NP
R11 R30
SM100-441
1
SRES,1K,5%,2W,TR,NP
R26
SM100-443
3
SRES,33.2,1206,1%,1/4W,TR,NP
R15 R16 R43
SM100-445
2
SRES,43.2K,1206,1%,1/4W,TR,NP
R18 R49
SM100-446
2
SRES,44.2K,1206,1%,1/4W,TR,NP
R42 R51
SM100-447
1
SRES,THERMISTOR,POS TEMP,TR,NP
R50
SM100-448
2
SRES,THERMISTOR,POS TEMP,TR,NP
R17 R24
C1 C10 C17 C18 C19 C20 C24
SM200-145
11
SCAP,4.7uF,TAN,35V,20%,TR,NP
C33 C38 C3 C6
SM200-183
3
SCAP,150pF,0805,50V,COG,5%,TR,
C27 C45 C46
SM200-188
5
SCAP,1uF,TAN,3528,35V,TR,NP
C23 C29 C30 C40 C47
SM200-192
2
SCAP,820pF,0805,50V,COG,5%,TR,
C4 C8
SM200-193
2
SCAP,2700pF,0805,5OV,X7R,5%,TR
C16 C42
C2 C5 C7 C9 C14 C21 C22 C25
SM200-194
11
SCAP,0.1uF,0805,50V,X7R,10%,TR
C34 C39 C44
SM200-200
2
SCAP,10pF,CER,0805,100V,5%,TR,
C28 C32
SM200-201
1
SCAP,33uF,TAN,7343,25V,10%,TR,LOW ESR C11
SM200-202
5
SCAP,100uF,TAN,7343,10V,20%,TR
C35 C36 C37 C41 C43
SM550-079
7
SDIO,1A,400V,DO-214BA,GLS,NP
D10 D12 D13 D14 D17 D24 D25
SM550-109
2
SLED,RED,1206,TR,NP
LED1 LED2
SM550-122
2
SDIO,MURD620CT,6A,200V,ULTRA-F
D4 D18 D16
SM550-123
4
SDIO,MBRA130LT3,1A,30V,SCHOTTK
D20 D21 D22 D23
SM550-148
1
SDIO,MURB1620CT,16A,200V
D16
SM550-149
1
SDIO,1SMB5934BT3,24V,3W
DZ1
SM550-125
2
SDIO,MMSZ5254BT1,0.5W,27V,5%,T
DZ2 DZ3
SM550-126
1
SDIO,1SMB5913BT3,3W,3.3V,5%,TR
DZ4

SM550-128
703W31526
A262567400
SM550-104
A287245100
SM800-299
SM800-297
707W03410
HW900-379
TH100-160
TH100-161
TH200-132
TH300-023-A
TH300-024-A
TH400-053
TH600-263
TH600-264
TH600-266
PPW-11110-1
PPW-11160-1
707W04224
TH200-219
SM200-220
SM200-221
SM200-522
703W01044
SM100-523
SM400-057
SM400-058
SM400-059
SM100-524
SM100-525
SM100-526
SM100-409
SM900-001
9P7951
SM200-194
A262577600
SM100-526

2
1
1
6
2
2
2
3
2
1
1
2
1
1
2
1
1
1
2
2
1
2
1
1
4
3
2
1
1
1
2
3
2
1
2
AS REQ'D
1
1
1

SDIO,1SMB5931BT3,3W,18V,5%,TR,
SRES,15K,FXD,1206,1%,1/8W,TR
SRES,6.19K,1206,1%,1/8W,TR,NP
SDIO,MURS160,1A,600V,FAST RECO
SICS,TL4311D,LIN,V-REF,36V,-40
SICS,PWM CONTROLLER,I-MODE,NP
SICS,MC78M05,V-REG,100mA,5V,NP
TRA,CNY17-3,NP
HSS,MTP,VERT MOUNT,TO220,NP
RES,THERMISTOR,PTC,POS TEMP,TR
RES,THERMISTOR,NTC,NEG TEMP,NP
CAP,1uF,PEMF,200V,10%,NP
TFM,L-5763-3,FLYBACK,NP
TFM,L-5764-3,FLYBACK,NP
TRA,BUZ30A,NMF,21A,200V,T0220,
CON,4P,TIN,MINI,NP
CON,6P,TIN,MINI,NP
CON,12P,TIN,MINI,NP
SCREW
WASHER
SDIO,MURS360T3,NP
CAP, 1500pF,200V,MET POLYPROP
SCAP,0.022uF,50v, X7R
SCAP,330pF,0805,50V,5%, COG
SRES,47.5,1210,5%,1/2W,TR,NP
SRES,10,TKF,0805,1%,1/10W
SRES,30.1,FXD,1210,5%,1/2W,TR
STRA,78M15C,DPACK
STRA,7815C,DPACK
STRA,79M15C,DPACK
SRES,2.49K,1210,5%,1/2W,T/R
SRES,1.21K,1210,5%,1/2W,TR,NP
SRES,150,1210,5%,1/2W,TR,NP
SRES,475,1206
SHSS,MTP,D2PACK,TO263
THERMAL JOINT COMPOUND
SCAP,0.1uF,0805,50V,X7R,10%,TR
SRES,75K,TKF,1206,1%,1/8W,TR,
SRES,150,1210,5%,1/2W,TR,NP

DZ7 DZ8
R1
R3
D2 D3 D6 D7 D8 D9
X1 X2
X4 X5
X6 X7
OCI1 OCI2 OCI3
Q1,Q2 HEATSINKS
R40
R55
C13 C26
T1
T2
Q1 Q2
J41
J42
J43
N/A
N/A
D19
C12,31
C49
C52
R6 R7 R57 R58
R9 R60 R61
R35 R36
X3
X8
X9
R19 R23
R46 R48 R37
R25 R44
R8
X8,D16 HEATSINKS
N/A
C53
R31
R62, R63, R64

CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS

INVERTER WELDERS
DIGITAL POWER P.C. BOARD AS'BLY
6-2-2000A

G3632-1

NOTE:

POWER WAVE 455/R

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G-14

ELECTRICAL DIAGRAMS

SCHEMATIC - FEEDHEAD PC BOARD #1

Return to Master TOC
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G-14

XA
11-3-2000A

1 OF 3
LRW

COMMON DIGITAL CONTROLS
FEEDHEAD PC BOARD SCHEMATIC
07/17/2000

3823-1C1/1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

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G-15

ELECTRICAL DIAGRAMS

SCHEMATIC- FEEDHEAD PC BOARD #2

TPD

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TPE

COMMON DIGITAL CONTROLS
XA
11-3-2000A

2 OF 3
LRW

FEEDHEAD PC BOARD SCHEMATIC
07/17/2000

3823-1C1/2

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

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G-16

ELECTRICAL DIAGRAMS

SCHEMATIC- FEEDHEAD PC BOARD #3

Return to Master TOC
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G-16

XA
11-3-2000A

3 OF 3
LRW

COMMON DIGITAL CONTROLS
FEEDHEAD PC BOARD SCHEMATIC
07/17/2000

3823-1C1/3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

PC BOARD ASSEMBLY-FEEDHEAD

Return to Master TOC

G-17

ELECTRICAL DIAGRAMS
74
75
76

S25001-3320SMT
S25005-1SMT
S25001-4751SMT

6
2
4

S25000-4751SMT

78
79
80

S25001-1503SMT
S25000-1211SMT
S25000-2002SMT

1
1
3

S25000-1002SMT

82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107

S19869-8
S20375-8
S25068-7SMT
M15101-14SMT
S25069-2SMT
S20353-1SMT
S25070-6SMT
S17900-24SMT
S25069-3SMT
S25066-2SMT
S25057-3SMT
M15105-9SMT
S15128-21SMT
S15128-18SMT
S15128-16SMT
S15018-20SMT
S25069-4SMT
S20353-5
S25065-2SMT
S20353-4SMT
S25068-8SMT
S25068-6SMT
S15128-25SMT
S17900-11SMT
S24841-1
S25082-1SMT

1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
2
1
1
1
1

R139,R140,R141,R142,R143,R144
R97,R98
R99,R114,R132,R137
R101,R104,R125,R126,R127,
R128,R129,R130,R131,R133,
R134,R145,R90,R109
R115
R135
R146,R147,R76
R2,R3,R4,R5,R6,R7,R9,R16,R17,
R18,R19,R20,R21,R22,R23,R53,
R54,R77,R80,R106,R116,R138,
R148,R149
S1
T1
X1
X2
X3
X4
X5
X7,X29
X9
X10
X11
X12
X13
X14,X20
X15
X16
X17
X18
X19
X21,X26,X27
X22
X23,X24
X25
X28
X30
Y1

RESISTOR,SMD,332ohms,1/4W,1206,1%
SRES,0.05,3W,1%,TR,NP
SRES,4.75K,1206,1%,1/8W,NP,(SM

ITEM

SRES,4.75K,0805,1%,TR,NP
SRES,150K,1206,1%,1/8W,NP
SRES,1.21K,0805,1%,1/10W,TR,NP
SRES,20K,TKF,0805,1%,01/10W,TR
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%
SWT,78B08S,DIP,SPST,8P,NP
TFM,L5936,Noreast,Switching Pwr
SICS,4.6V,2%,VOLT. DETECTOR
SICS,MC68332,MICRCONTROLLER,TQ
SICS,25128,SERIAL EEPR,NP
SICS,MC145407,RECEIVER/DRVR,RS
SICS,XC9572-15,CPLD,TQ100,NP
SICS,74HC132,NP
SICS,28F800B5B90,FLASH ROM,90n
SICS,AD7862,DUAL,12BIT,250kSPS
SICS,AD8403ARU10,DIGITAL POT,NP
SICS,AD7945,12BIT,PARALLEL,DAC
SICS,LT1016,COMPARATOR,NP
SICS,MC33074,QUAD,OPAMP,S014,T
ICS,SMD,OP-AMP,QUAD,HIGH PERFORMANCE 1014
SICS,HIP4082,H-BRIDGE,FET DRIVE
SICS,128Kx16,20nS,TSOP(II)
SICS,AN82527,CAN CONTROLLER,PL
SICS,74ACT573,OCTAL,TRANS. LAT
SICS,MAX485,TRANSCEIVER,NP
SICS,79L05,V-REG,-5V,SO8
SICS,78L05,V-REG,+5V,SO8
SICS,LM2576HVS-5.0,VREG,60V,SWI
SICS,74HC245,SOL20,HCMOS,NP
ICS,DC/DC,5V 3A OUT,36-75V IN
SXTL,16MHz,HC40,20pF,NP

(6.34)

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G-17

(5.84)

N.D.
N.E.

PART NO.

1
2
3

G3822-D
M19436-5
S8025-80

PC BOARD REFERENCE
DESIGNATORS

QTY
1
1
2
195g
6.88 OZ.
AS REQ.
1
1

E2527

5
6
7

E3539
S24822-2
S24823-2

S25024-2SMT

S25020-3SMT

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

S25024-8SMT
S25020-13SMT
S25024-5SMT
S25024-10SMT
S25020-2SMT
S25020-10SMT
S25020-9SMT
S25020-15SMT
S24833-1
S13490-179
S13490-182
S13490-184
S25020-4SMT
S25040-12SMT
S25040-2SMT

5
2
6
3
1
3
2
3
2
1
1
1
2
2
4

S25040-5SMT

26
27
28
29
30
31
32
33

S25049-4SMT
S25040-4SMT
S25040-11SMT
S25040-9SMT
S25040-10SMT
S25046-3SMT
S25046-1SMT
S25044-9SMT

4
5
4
1
1
4
3
6

S25044-1SMT

35
36

S25046-2SMT
S18380-5

4
2

S18380-14

38
39
40
41
42
43
44
45
46
47

S24020-4
S24020-6
S24020-8
S24020-16
S18248-10
S18248-16
S15000-28SMT
S15000-26SMT
S25051-4SMT
S25050-2SMT

2
1
1
1
1
1
4
1
5
5

DESCRIPTION
FEED HEAD PC BOARD BLANK
POTTING TRAY
SELF TAPPING SCREW
EPOXY ENCAPSULATING RESIN
ELECTRICAL INSULATING COMPOUND
SOFTWARE,CPLD
SOFTWARE,FLASH

X5
X9

FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS

S25050-1SMT

49
50

S25051-5SMT
S23060-1SMT

4
1

S25000-1002SMT

52
53
54

S25001-1002SMT
S25001-4752
S25003-2000SMT

6
4
2

S25001-4750SMT

S25000-1001SMT

S25000-4750SMT

S25004-2430SMT

S25000-3320SMT

S25000-2210SMT

S25001-2000SMT

62
63
64
65
66
67
68
69
70
71
72
73

S25001-7500SMT
S25000-2213SMT
S25000-4752SMT
S25000-1003SMT
S25001-1001SMT
S25000-9092SMT
S25000-3921SMT
S25001-4753SMT
S25001-4752SMT
S25001-1000SMT
S25001-15R0SMT
S25001-1500SMT

1
1
2
6
1
2
1
2
2
9
2
4

C1,C2,C7,C50
SCAP,1uF,TAN,3528,35V,TR,NP
C3,C4,C5,C6,C8,C9,C12,C14,
C15,C19,C20,C22,C25,
C26,C27,C28,C29,C30,C31,
C32,C34,C35,C38,C39,C41,
SCAP,0.1uF,0805,50V,X7R,10%,TR
C43,C45,C46,C47,C48,C49,
C51,C54,C56,C57,C59,C60,
C64,C65,C69,C72,C75,C76,
C77,C78,C81,C82
C10,C11,C17,C18,C80
SCAP,10uF,TAN,6032,16V,10%,TR,NP
C13,C16
SCAP,150pF,CER,0805,100V,COG,5%,TR,NP
C23,C63,C66,C67,C68,C71
SCAP,4.7uF,TAN,7343,35V,10%,TR,NP
C24,C36,C73
SCAP,22uF,TAN,7343,25V,10%,POLAR,TR
C37
SCAP,0.022uF,0805,50V,X7R,10%,
C40,C42,C44
SCAP,4700pF,0805,50V,X7R,10%,T
C52,C79
SCAP,47pF,0805,50V,COG,5%,TR,N
C55,C58,C83
SCAP,22pF,0805,50V,COG,5%,TR,N
C61,C62
CAP,0.27uF,PCF,63V,5%,TR,NP
C70
CAP,1000uF,ALU,35V,20%,NP
C74
CAP,3300uF,ALU,63V,20%,NP
C84
CAP,330uF,100V
C85,C86
CAPACITOR ,SMD CERAMIC,820PF,50V,5%COG,S0805
D1,D12
SDIO,MURS320T3,3A,200V,ULTRAFA
D2,D17,D20,D27
SDIO,400V,0.8A,NP
D3,D4,D5,D6,D9,D18,D21,D28,D29,
SDIO,BAV99LT1,SOT23,DUAL SWITC
D31
D7,D8,D10,D19
SDIO,BAT54S,DUAL/SERIES,30V,20
D11,D13,D14,D15,D16
SDIO,BAW56LT1,SOT23,DUAL SWT,T
D22,D23,D24,D25
SDIO,MURS160,1A,600V,FAST RECO
D26
SDIO,3A,200V,D0-214AB,UFR
D30
DIODE,SMD,3A,400V
DZ1,DZ2,DZ3,DZ4
SDIO,MMSZ5248B,18V,ZENER,TR,NP
DZ5,DZ28,DZ29
SDIO,MMSZ5231BT1,5.1V,NP
DZ6,DZ7,DZ8,DZ9,DZ26,DZ27
SDIO,1SMB5920BT3,6.2V,NP
DZ10,DZ11,DZ12,DZ13,DZ14,
SDIO,1SMB5918BT3,3W,5.1V,5%,TR,NP
DZ15,DZ16,DZ17,DZ18
DZ20,DZ21,DZ22,DZ23
SDIO,MMSZ5240BT1,10V,500mW,ZEN
F1,F2
RES,50,VAR,PTC,NP
F3,F4,F5,F6,F7,F8,F9,F10,
RES,500,PTC,265V
F11,F12,F13,F14
J81,J82
CON,MOLEX,15-97-7042,MINI,PCB,4 PIN,TIN
J83
CON,MOLEX,15-97-7062,MINI,PCB,6 PIN,TIN
J84
CON,MOLEX,15-97-7082,MINI,PCB,8 PIN,TIN
J85
CON,MOLEX,15-97-7162,MINI,PCB,16 PIN,TIN
J86
CON,10P,MINI,NP
J87
CON,MOLEX,39-28-1163,PCB,16 PIN,TIN
OCI1,OCI2,OCI3,OCI4
SICS,Optocoupler, HCPL-0601 (SO-8)
OCI5
SICS,HCPL-0201,OPTOCOUPLE
Q1,Q12,Q13,Q15,Q16
STRA,2N7002,TR,NP, (SM400-020)
Q2,Q3,Q7,Q14,Q17
STRA,2N4403,SO23,TR,(500475),N
Q4,Q5,Q6,Q19,Q20,Q21,Q22,Q23,Q2
STRA,2N4401,SOT-23,NPN,TR,
4
Q8,Q9,Q10,Q11
Q18
R2,R3,R4,R5,R6,R7,R9,R16,
R17,R18,R19,R20,R21,R22,
R23,R53,R54,R77,R80,R106,
R116,R138,R148,R149
R8,R10,R13,R83,R100,R118
R84,R85,R86,R152
R11,R12
R14,R15,R62,R68,R78,R102,
R103,R107,R112
R24,R25,R55,R105,R113,
R136,R153,R154
R26,R27
R28,R29,R30,R31,R32,R33,
R34,R35,R36,R37,R38,R39
R41,R42,R48,R49,R50,R51,
R52,R121,R123
R43,R44,R45,R46,R47,R65,
R108,R122,R124
R56,R57,R58,R61,R64,R66,
R110,R111
R1
R63
R67,R72
R69,R71,R73,R75,R82,R117
R70
R74,R81
R79
R87,R120
R88,R119
R89,R93,R96,R155,R156,R157,
R91,R92
R94,R95,R150,R151

STRA,75A,55V,0.007 OHM FET,N-CHAN
IC,SMD,SWITCH,LO-SIDE,2.2A60V,
SRES,10K,0805,1%,1/10W,TR,NP
SRES,10K,MF,1206,1%,1/8W,TR
RESISTOR,SMD,47.5K,1/4W,1206,1%
SRES,200,2512,5%,1W,TR,NP
SRES,475,1206,1%,1/8W,TR,NP
SRES,1K,0805,1%,1/10W,TR,NP
SRES,475,0805,1%,TR,NP
SRES,243,WSC-1,1%,1W,TR,NP
SRES,332,0805,1%,1/10W,TR,NP
SRES,221,TKF,0805,1%,1/10W,TR
SRES,200,1206,1%,1/8W,TR,NP

RESISTOR,SMD,750ohms,1/4W,1206,1%
SRES,221K,TKF,0805,1%,01/10W,TR
SRES,47.5K,TKF,0805,1%,01/10W,TR
SRES,100K,TKF,0805,1%,01/10W,TR
SRES,1K,1206,1%,1/8W,TR,NP,(09
SRES,90.9K,TKF,0805,1%,1/10W
SRES,3.92K,TKF,0805,1%,1/10W,TR
SRES,475K,1206,1%,1/8W,TR,NP
SRES,47.5K,1206,1%,1/8W,TR,NP
SRES,100,1206,1%,1/8W,TR,NP
SRES,15,1206,1%,1/8W,TR,NP
SRES,150,1206,1%,1/8W,TR,NP

Return to Master TOC

Return to Section TOC

UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS

COMMON DIGITAL CONTROLS
FEED HEAD PC BOARD ASSEMBLY
4-20-2001C

L11087-2
NOTE:

POWER WAVE 455/R

Return to Master TOC

G-18

ELECTRICAL DIAGRAMS

SCHEMATIC - INPUT PC BOARD
M 19528

Return to Section TOC

G-18

PRE-CHARGE CONNECTIONS

CONTACTOR OUTPUT
2
10

J60

CONTACTOR

J61
J61

J61

COIL CONNECT

CR1
4

TP1

TP3
1

660V

250J

100

10W

100

10W

660V

CR2

R22

660V
250J

R11

3.01K

R12

3.01K

R13

3.01K

R14

3.01K

R15

3.01K

R16

3.01K

R17

3.01K

R18

3.01K

R19

3.01K

+13V

R20

10W

PRE-CHARGE CONTROL

J60

3.01K

100

10W

R24

100

3.01K

R25

10W

3.01K

100

10W

R23

100

+13V FROM CONTROL BOARD

CR2

3.01K

R10

R21

J60

J61
8

CONTACTOR CONTROL

+13V

CR1

TP4

Input

J60

250J

3.01K

475

OCI1

CNY17-3V

1500V
2

SINGLE PHASE DETECT

J60

CENTER LEG TO OUTSIDE LEG OF INPUT
267K

C1
.022

Return to Master TOC

100

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Return to Section TOC
Return to Section TOC

VAC

250J

TP2

3.01K

J61
6

J60

50V

GENERAL INFORMATION

UNUSED PINS

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537

J61

J60
6

J61

RESISTORS = Ohms (

J60
7

MFD ( .022/50V

CAPACITORS =

NOTES :
N.A.

DIODES =

1A, 400V

1/4W

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

Return to Master TOC

Return to Section TOC

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

UNLESS OTHERWISE SPECIFIED TOLERANCE

ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE

Ch’ge.Sht.No.

EQUIP.

THE LINCOLN ELECTRIC CO.

TYPE

CLEVELAND, OHIO U.S.A.

11-3-2000A

SCALE

MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

TP- 4

VOLTAGE NET

EARTH GROUND CONNECTION

FILENAME: M19528-1AA

THE LINCOLN ELECTRIC CO.

ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2

COMMON CONNECTION

THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

J61

CR- 2

D-

FRAME CONNECTION

J61
7

OCI- 1

POWER SUPPLY SOURCE POINT

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.

C-

SUPPLY

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

J61

R-

DR.

MAB

DATE

SUBJECT

INVERTEC 450 - 650
INPUT P.C. BOARD SCHEMATIC

NONE
5-25-99

CHK.

SUP’S’D’G.

SHT.
NO.

M 19528

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

Return to Master TOC

Return to Section TOC

G-19

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY-INPUT
ITEM

REQ’D

PART NO.

IDENTIFICATION

2.80
RESISTORS = OHMS/WATTS
CAPACITORS = MFD/VOLTS

Return to Master TOC

4.50

xxxxx

4.25

xxxxx

INVERTEC 455-655 INPUT

J61

J60

R24

R25
R23

TP2

R21
R20

x
x
x
x
x
R9
x
x
x
x
x
x
xxx x
x

Return to Master TOC

Return to Section TOC

xxx

TP1

.25

R19
R18

R10

TP3

TP4

R22

Return to Section TOC

~.04

OCI1

R11
R12
R13
R14
R15
R16
R17

x
x
x
x
x
x
x
x
x
x
x
x
x

CR1

CR2

x
x
x
x
x

L11396-1

~.04

6.00

Return to Master TOC

Return to Section TOC

0
.25

3.00

5.75
INVERTER WELDERS
INPUT P.C. BOARD ASSEMBLY

11-3-2000A

L11396-1
NOTE:

POWER WAVE 455/R

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Return to Master TOC

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Return to Master TOC

Return to Section TOC

G-20

ELECTRICAL DIAGRAMS

SCHEMATIC -SWITCH PC BOARD

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

G-20

Return to Master TOC

G-21

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY-SWITCH
ITEM

6.00 ±.04
C5

C10

C11

B11

C12

C1
X2

R11

R12

R15

Return to Master TOC

DZ3

OCI1

DZ2

REQ'D

C1
1
C2
1
C3
1
C4,C6,C7
3
C5
1
C8,C9,C10,C11,C12,C13,C14
10
C15,C16,C17
D1,D2
2
D3,D4,D5,D6,D7,D8,D9,D10
10
D11,D12
DZ1
1
DZ2,DZ3,DZ5,DZ6
4
DZ4,DZ7
2
J40
1
L1,L2,L3,L4,L5,L6,L7,L8,L9
10
L10
OCI1
1
R1
1
R2
1
R3,R8
2
R4,R13,R14,R17,R18,R19,R20 13
R21,R23,R24,R25,R26,R27
R5,R9
2
R6
1
R7
1
R10,R12,R15
3
R11
1
R16,R22
2
R28,R29,R30,R31,R32
5
T1
1
T2
1
X1
1
X2
1

PART NO
S2 0500-14
S16668-11
S16668-5
S16668-6
S13490-93
S20500-1

IDENTIFICATION
CAPACITOR,PPMF,.022,100V,BOX,5%
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,.022, 50V,20%
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,TAEL,27,35V,10%
CAPACITOR,PPMF,0.1,1000V,10%,BOX

T12705-44
T12705-32

DIODE,AXLDS,1A,1000V,FR, 818
DIODE,T220,15A,600V,FR,MUR1560

T12702-4
T12702-29
T12702-40
S24020-6
T 12218-15

ZENER DIODE, 1W,20V,5% 1N4747A
ZENER DIODE, 1W,15V,5% 1N4744A
ZENER DIODE, 1W,6.2V,5% 1N4735A
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CHOKE,RF,FERRITE BEAD,180 OHM

S15000-22
S16296-5
S19400-6811
S19400-1002
S19400-10R0

OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
TRIMMER,MT,1/2W,10K, 10%,LINEAR
RESISTOR,MF,1/4W,6.81K,1%
RESISTOR,MF,1/4W,10.0K,1%
RESISTOR,MF,1/4W,10.0,1%

S19400-2001
S19400-2213
S19400-1000
S19400-1003
S19400-6191
S19400-1001
T14648-9
T12737-7
M19612
M13552-3
S15128-10

RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,6.19K,1%
RESISTOR,MF,1/4W,1.00K,1%
RESISTOR,WW,5W,2.5K,5%,SQ
TRANSFORMER,PULSE,3-WINDING
CURRENT-TRANSDUCER,125-TURN
IC,CONVERTER,V/F,654
VOLTAGE REF,ADJ, PECISION,431I

DZ4
L4

R18

R13

R17

R19

R16

R20

R21

DZ1

B20

DZ5

R 1.62

3.00

R30

R29

DZ6

R28

R14
DZ7

R31

B19

R27

R26

R25

R24

L10

J40

R23
L6

R22

D2
B14

Return to Section TOC

.30 +.12
-.00

R9
R10

SH1

Return to Section TOC

G-21

Return to Master TOC

.00

1.20

1.38 +.12
-.00
N.T.,N.U.,N.V.

11.15 ±.04

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056

ON 2 PLACE DECIMALS IS± .02

ON 3 PLACE DECIMALS IS ± .002

NOTE:

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

DO NOT SCALE THIS DRAWING

"X" INFO.
XD-RW

Chg. Sheet No.
5-11-2001F

DESIGN INFORMATION

REFERENCE:

DRAWN BY: F.V
.

G3734-1

ENGINEER: L. C.

SUPERSEDING:

APPROVED:

EQUIPMENT TYPE:
SUBJECT:
SCALE: 1:1

INVERTER WELDERS
SWITCH P.C. BOARD AS'BLY

DATE: 10-3-2000 DRAWING No.:

G 3734-2

SOLID EDGE

EN-170

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2.00 ±.12

Return to Section TOC

C13

C14

C15

C16

C17

Return to Section TOC

B13

D10

D11

D12

R32

.30 +.12
-.00

POWER WAVE 455/R

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ELECTRICAL DIAGRAMS

G-22

SCHEMATIC - VOLTAGE SENSE PC BOARD

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Return to Section TOC
Return to Section TOC

Return to Section TOC

G-22

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

Return to Master TOC

Return to Section TOC

G-23

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY-VOLTAGE SENSE

.20

.
.

1.80
M19540-1

.20
0

Return to Master TOC

Return to Section TOC

R1
R2

T12199-1

J1
J2
L1

1
1
1

S24020-6
S24020-2G
T12218-7

OCI1,OCI2
R1,R2
R3
TP1,TP2

2
2
1
2

S15000-20
S19400-4750
S18380-1
T13640-18

PART NO.

IDENTIFICATION
1N4004
HEADER
HEADER
330uH
PHOTO FET
475 1/4W
THERMISTOR,PTC
160J

OCI2

REQD

CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
INDUCTANCE = HENRYS

OCI1

VOLTAGE SENSE SELECT

Return to Master TOC

1.75
1.55

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±.04

ITEM

TP2
TP1

A RA
±.04

1.00

2.00

COMMON DIGITAL CONTROLS
VOLTAGE SENSE SELECT P.C. BD AS'BLY
1-3-2000A

M19540-1
NOTE:

POWER WAVE 455/R

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ELECTRICAL DIAGRAMS

G-24

SCHEMATIC - 40 VDC BUS PC BOARD

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Return to Section TOC
Return to Section TOC

Return to Section TOC

G-24

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/R

Return to Master TOC

Return to Section TOC

G-25
PC BOARD ASSEMBLY-40 VDC BUS

ITEM

PART NO

M15458-4

IDENTIFICATION

IC,PWM-CONTROLLER,IMODE,2842A

C2,C3,C5

S13490-25

CAPACITOR,TAEL,4.7,35V 10%

C16

S13490-42

CAPACITOR,TAEL,1.0,35V,10%

S13490-66

CAPACITOR,TAEL,47,35V 10%

S13490-93

CAPACITOR,TAEL,27,35V,10%

C15

S13490-174

CAPACITOR,ALEL,470,100V,+50/-10%

S15018-16

IC,CMOS,DRIVER,MOSFET,2110(SS)

C14

S16668-3

C11,C17

S16668-10

CAPACITOR,CEMO,4700P, 50V,2%

C7,C8,C9,C10

S16668-11

CAPACITOR,CEMO,0.1, 50V,10%

R15,R16

S19400-47R5

RESISTOR,MF,1/4W,47.5,1%

R12,R13

S19400-1000

RESISTOR,MF,1/4W,100,1%

R3,R4,R5,R7,R8

S19400-1002

RESISTOR,MF,1/4W,10.0K,1%

R14,R22

S19400-1821

RESISTOR,MF,1/4W,1.82K,1%

R23

S19400-2213

RESISTOR,MF,1/4W,221K,1%

R20,R21

S19400-2672

RESISTOR,MF,1/4W,26.7K,1%

R29

S19400-3323

RESISTOR,MF,1/4W,332K,1%

R28

S19400-4752

RESISTOR,MF,1/4W,47.5K ,1%

R19

S19400-5622

RESISTOR,MF,1/4W,56.2K,1%

R9,R10,R11

S19400-8251

RESISTOR,MF,1/4W,8.25K,1%

CAPACITOR,CEMO,100P, 100V,5%

C13

S20500-2

CAPACITOR,PPMF,0.47,630V,10%,BOX

S24020-4

CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN

J47

S24020-8

CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN

T12199-1

T12199-2

T12218-16

CHOKE,HIGH-CURRENT,100UH,10A,10%, LOW

R26,R27

T12300-86

RESISTOR,WW,3W,0.05,1%

DZ4

T12702-25

ZENER DIODE,5W,20V,5% 1N5357B

DZ5,DZ6

T12702-45

ZENER DIODE, 1W,18V,5% 1N4746A

T12705-23

DIODE,AXLDS,1A,30V,SCHOTTKY,1N5818

T12705-34

DIODE,AXLDS,1A,400V,FR,1N4936

T12705-59

DIODE,AXLDS,3A,600V,UFR

MOV1

T13640-15

MOV,50VRMS,15J,14MM

MOV2

T13640-24

MOV,175VRMS,120J,20MM

LED1

T13657-2

LED,T-1,3/4,RED,HLMP-3003

T14648-17

RESISTOR,WW,5W,270,5%,SQ

3.65
MOV2

J47

J46

LED1

DIODE,AXLDS,1A,400V
DIODE,AXLDS,1A,1000V

C13

R26

C15

MOV1

R25

CAPACITORS = MFD/VOLTS

R11

RESISTORS = OHMS, 1/4 WATT (UNLESS OTHERWISE SPECIFIED)

R20

R19

R22

D1
R3

Return to Master TOC

REQ’D

J46

3.85~.04

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Return to Section TOC

4.30

R27

C16
DZ5

R15

R16

C8
C9

X2
C10

R14

R29

R13

C6
D2

C11

R25

DZ4

X1
C17

R21

D3
R23

.20

DZ6

R10

D5
C3

R12

R28

C14

Return to Section TOC

G-25

ELECTRICAL DIAGRAMS

.20

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Return to Section TOC

4.50~.04

MULTI-WELD 350
40V DC BUS P.C. BOARD ASSEMBLY
9-22-2000

L11078-1
NOTE:

POWER WAVE 455/R

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We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.

Thank You,
Technical Services Group
Lincoln Electric Co.
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199

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Return to Section TOC

SVM ERROR REPORTING FORM

FAX 216-481-2309

SVM Number ___________________________
Page Number if necessary__________________

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Your Company__________________________
Your Name_____________________________

Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

SD287 01/99

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Lincoln Electric Power Wave Svm156 A Users Manual

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