SVM181-AJanuary, 2008Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safe
INSTALLATIONA-2 A-2POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
SNUBBER BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-56 F-56POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Re
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
POWER BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-58 F-58POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Retu
POWER BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-59 F-59POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Retu
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-62 F-62POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Ret
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-63 F-63POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Ret
INSTALLATIONA-3 A-3POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
DC BUS BOARD REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-64 F-64POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Ret
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-66 F-66POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-67 F-67POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)TROUBLESHOOTING AND REPAIRF-70 F-70POWER WAVE 355M/405MReturn to Section TOC Return to Section
OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (con’t)TROUBLESHOOTING AND REPAIRF-71 F-71POWER WAVE 355M/405MReturn to Section TOC Return to Section
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
INSTALLATIONA-4 A-4POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-74 F-74POWER WAVE 355M/405MReturn to Section TOC Return to Section T
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-75 F-75POWER WAVE 355M/405MReturn to Section TOC Return to Section T
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-76 F-76POWER WAVE 355M/405MReturn to Section TOC Return to Section T
CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-77 F-77POWER WAVE 355M/405MReturn to Section TOC Return to Section T
TROUBLESHOOTING AND REPAIRF-78 F-78POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M/405MElect
ELECTRICAL DIAGRAMSG-2POWER WAVE 355M/405MWIRING DIAGRAM - POWERWAVE 355/405 - G4131NOTES:N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDS-
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
INSTALLATIONA-5 A-5POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMSG-7POWER WAVE 355M/405MSCHEMATIC - DIGITAL CONTROL PC BOARD #4G-7NOTE: This diagram is for reference only. It may not be accurate f
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
ELECTRICAL DIAGRAMSG-9POWER WAVE 355M/405MSCHEMATIC - SWITCH PC BOARDG-9NOTE: This diagram is for reference only. It may not be accurate for all machi
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa
ELECTRICAL DIAGRAMSG-13POWER WAVE 355M/405MSCHEMATIC - 40 VDC BUSS PC BOARDG-13NOTE: This diagram is for reference only. It may not be accurate for al
INSTALLATIONA-6 A-6POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
INSTALLATIONA-7 A-7POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
INSTALLATIONA-8 A-8POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
INSTALLATIONA-9 A-9POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Ret
INSTALLATIONA-10 A-10POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R
INSTALLATIONA-11 A-11POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R
SAFETYi iReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINEpowered equipment.1.a. Turn the engine off befor
INSTALLATIONA-12 A-12POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R
INSTALLATIONA-13 A-13POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R
INSTALLATIONA-14 A-14POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R
TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M/405MOpe
SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kill.• Unless using cold fee
OPERATIONB-3 B-3POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
OPERATIONB-4 B-4POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
OPERATIONB-5 B-5POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
OPERATIONB-6 B-6POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
Power Mode™ is a method of high speed regulation ofthe output power whenever an arc is established. Itprovides a fast response to changes
SAFETYii iiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFUMES AND GASEScan be dangerous.5.a. Welding may produce
OPERATIONB-8 B-8POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
OPERATIONB-9 B-9POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
OPERATIONB-10 B-10POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu
TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M/405MA
ACCESSORIESC-2 C-2POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu
TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M/405MM
MAINTENANCED-2 D-2POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu
MAINTENANCED-3 D-3POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M
SAFETYiii iiiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar ‘95FOR ELECTRICALLYpowered equipment.8.a. Turn off
GENERAL DESCRIPTIONThe Power Wave semi-automatic power source isdesigned to be a part of a modular, multi-processwelding system. D
THEORY OF OPERATIONE-3 E-3POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
THEORY OF OPERATIONE-4 E-4POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
THEORY OF OPERATIONE-5 E-5POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
THEORY OF OPERATIONE-6 E-6POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
THEORY OF OPERATIONE-7 E-7POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
THEORY OF OPERATIONE-8 E-8POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIRF-1 F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355
TROUBLESHOOTING AND REPAIRF-2 F-2POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to
TROUBLESHOOTING AND REPAIRF-3 F-3POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to
SAFETYiv ivReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection
OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE
OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE
FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR
FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR
FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR
TROUBLESHOOTING AND REPAIRF-9 F-9POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to
ERROR CODES FOR THE POWER WAVEThe following is a list of possible error codes that the POWER WAVE 355M/405M can output via the status lightIf connect
TROUBLESHOOTING AND REPAIRF-11 F-11POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
SAFETYv vReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)ConformanceProducts dis
TROUBLESHOOTING AND REPAIRF-14 F-14POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-16 F-16POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-17 F-17POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-20 F-20POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
ABCABCABC207207207207A207A207A209209209TROUBLESHOOTING AND REPAIRF-21 F-21POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Se
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
SAFETYvi viReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)The size of the surro
TEST PROCEDURE1. Remove input power to the Power Wave355M/405M.2. Using the 3/8” nut driver, remove the casetop.3. Perform the Capac
TROUBLESHOOTING AND REPAIRF-25 F-25POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TEST PROCEDURE1. Remove input power to the machine. 2. Using the 3/8” nut driver, remove the wrap-around cover.3. Locate the DC Bus Board. Se
TROUBLESHOOTING AND REPAIRF-29 F-29POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-32 F-32POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-33 F-33POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I IPOWER WAVE 355M/405MRETURN TO MAIN INDEXPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING AND REPAIRF-34 F-34POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-36 F-36POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-37 F-37POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-40 F-40POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-41 F-41POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPOWER WAVE 355M/405M
FAN CONTROL AND MOTOR TEST (continued)TROUBLESHOOTING AND REPAIRF-44 F-44POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Sec
FAN CONTROL AND MOTOR TEST (continued)TROUBLESHOOTING AND REPAIRF-45 F-45POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Sec
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
TROUBLESHOOTING AND REPAIRF-48 F-48POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-49 F-49POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
TROUBLESHOOTING AND REPAIRF-50 F-50POWER WAVE 355M/405MReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn t
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-52 F-52POWER WAVE 355M/405MReturn to Section TOC Return to Section
MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-53 F-53POWER WAVE 355M/405MReturn to Section TOC Return to Section
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