Power Wave 450 Service Manual PDF

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INVERTEC POWER WAVE ™ 450

For use with machines having Code Numbers:
10105, 10106, 10194, 10195, 10196, 10344, 10345, 10346, 10347, 10365, 10366,
10391, 10392, 10405, 10406, 10431, 10432, 10433, 10434, 10449, 10511, 10512,
10513, 10514, 10515, 10516, 10520, 10607, 10608, 10609, 10610

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SERVICE MANUAL
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Need Help? Call 1.888.935.3877

to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:

Email: globalservice@lincolnelectric.com
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SVM112-B | Issue Date 01, Feb

© Lincoln Global, Inc. All Rights Reserved.
i i
Return to Master TOC SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline 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.
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 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
ii ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
5.a. Welding may produce fumes and gases
• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
iii iii
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc 8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: 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
a. Les circuits à l’électrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains. câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
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

PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
TRANSFORMATEUR ET À
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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

How To Use Troubleshooting Guide ...........................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.........................................................F-3
Troubleshooting Guide ................................................................................................................F-5
Test Procedures ........................................................................................................................F-27
Removal and Replacement Procedures .................................................................................F-155
Electrical Diagrams ..............................................................................................................Section G
Parts Manual................................................................................................................................P-261
POWER WAVE 450

Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications .............................................................................................................A-2

Safety Precautions......................................................................................................................A-3
Select Suitable Location .............................................................................................................A-3
Stacking................................................................................................................................A-3
Tilting .................................................................................................................................A-3
Lifting .................................................................................................................................A-3
High Frequency Precautions.......................................................................................................A-3
Input Connections.......................................................................................................................A-3
Ground Connections...................................................................................................................A-4
Input Power Connections ...........................................................................................................A-4

Input Fuse and Supply Wire Considerations .......................................................................A-4
Input Voltage Reconnect Procedure ....................................................................................A-4
Output Connections....................................................................................................................A-5
Work and Electrode Cable Connections ..............................................................................A-5
Size.................................................................................................................................A-5
Routing............. ..............................................................................................................A-5
Water Cooler Connections ...................................................................................................A-5
Wire Feeder Connections.....................................................................................................A-5
POWER WAVE 450

A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 450
Return to Section TOC
INPUT -THREE PHASE ONLY
Input Voltages: 200 230 400 460 575

Input Currents
@ 500A/40 VDC 87 76 44 38 32
@ 450A/38 VDC 75 65 38 32 28
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
60% Duty Cycle 500 40 VDC
100% Duty Cycle 450 38 VDC
Constant Open Continuous Process

Circuit Voltage Current Range Current Ranges

75 Volts 5-540 Amps GMAW 50-540 Amps
FCAW 40-540 Amps
STICK 30-540 Amps
Pulse Pulse Pulse and Background Pulse
Current Range Voltage Range Time Range Frequency
5-750 Amps 5-55 Volts 100 Microsec - 3.3 Sec 0.15 - 1000 Hz
RECOMMENDED INPUT WIRE AND FUSE SIZES

Type 75°C Type 75°C Type 75°C
Input Duty Input Ampere Copper Wire in Ground Wire in (Super Lag)
Voltage/ Cycle Rating on Conduit Conduit or Breaker
Freqency Nameplate AWG[IEC] AWG[IEC] Size (Amps)
Sizes (MM2) Sizes (MM2)
200/50-60 60% 87 4 (25) 8 (10) 120
230/50-60 60% 76 4 (25) 8 (10) 100

400/50-60 60% 44 8 (10) 10 (6) 50
460/50-60 60% 38 8 (10) 10 (6) 50
575/50-60 60% 32 8 (10) 10 (6) 50
200/50-60 100% 75 4 (25) 8 (10) 100
230/50-60 100% 65 4 (25) 8 (10) 100
400/50-60 100% 38 8 (10) 10 (6) 50
460/50-60 100% 32 8 (10) 10 (6) 50
575/50-60 100% 28 8 (10) 10 (6) 40
PHYSICAL DIMENSION
Height Width Depth Weight
905 mm 515 mm 1010 mm 137.9 kg
35.6 in. 20.3 in. 39.8 in. 303.5 lbs.
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° to 40°C -50° to 85°C
POWER WAVE 450

A-3 A-3
INSTALLATION
Read this entire installation section before you LIFTING

start installation.
Lift the machine by the lift bail only. Do not attempt to
lift the machine by the push handle.
SAFETY PRECAUTIONS HIGH FREQUENCY PRECAUTIONS

If possible, locate the Power Wave away from radio
WARNING controlled machinery. The normal operation of the
ELECTRIC SHOCK can kill. Power Wave may adversely affect the operation of RF
controlled equipment, which may result in bodily injury
• Only qualified personnel should
or damage to the equipment.
perform this installation.
• Turn the input power OFF at the INPUT CONNECTIONS
disconnect switch or fuse box Be sure the voltage, phase, and frequency of the input
before working on this equipment. power is as specified on the rating plate, located on
• Do not touch electrically hot parts. the rear of the machine. See Figure A.1 for the loca-
tion of the rating plate.

• Always connect the Power Wave grounding terminal
(located inside the reconnect input access doors). FIGURE A.1 - RATING PLATE LOCATION
SELECT SUITABLE LOCATION

Place the welder where clean cooling air can circulate
in through the rear louvers and out through the side
and front louvers. Dirt, dust, or any foreign material
that can be drawn into the welder should be kept at a
minimum. Using filters on the air intake to prevent dirt 2
1
from building up restricts air flow. Do not use such fil- 3
ters. Failure to observe these precautions can result in
excessive operating temperatures and nuisance shut-
downs.
The Power Wave may be used outdoors. Power Wave

power sources carry an IP23 enclosure rating. They
are rated for use in damp, dirty environments subject
to occasional falling water such as rain. However, the
best practice is to keep the machine in a dry, sheltered
area, since a wet environment speeds corrosion of
parts. Do not place the machine in puddles or other-
wise submerge parts of the machine in water. This
may cause improper operation and is a possible safe-
ty hazard. 1. RATING PLATE
2. RECONNECT/INPUT ACCESS DOOR
STACKING 3. INPUT CORD ACCESS HOLE
Power Wave machines cannot be stacked.

WARNING
TILTING Only a qualified electrician should connect the input
Each machine must be placed on a secure, level sur- leads to the Power Wave. Connections should be
made in accordance with all local and national electri-
face. The machine may topple over if this procedure

is not followed. cal 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.
Use a three-phase supply line. The Power Wave has
a 1.375” (35mm) access hole for the input cord, but
the input cord is not supplied.
POWER WAVE 450
A-4 A-4
INSTALLATION
wire sizes. Fuse the input circuit with the recom-

CAUTION mended super lag fuses or delay type circuit breakers.
Choose an input and grounding wire size according to
Failure to follow these instructions can cause immedi- local or national electrical codes. Using fuses or cir-
ate failure of components within the welder. cuit 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.
GROUND CONNECTIONS
INPUT VOLTAGE RECONNECT
The frame of the welder must be grounded.
PROCEDURE
A ground terminal marked with the symbol
is located inside the reconnect/input Welders are shipped connected for the highest input
access door for this purpose. See your voltage listed on the rating plate. To change this con-
local and national electrical codes for proper ground- nection for a different input voltage, refer to reconnect
ing methods. See Figure A.2 for the location of the instructions in Figure A.2 and proceed according to
reconnect/input access door and related connection the steps that follow for the appropriate voltage.
diagram.
INPUT POWER CONNECTIONS

Connect L1, L2, L3 according to the Input Supply
Connection Diagram decal located on the reconnect/-
input access door. See Figure A.2.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
NOTE: Turn main input power to

mthe machine OFF before perform-

ing reconnect procedure. Failure to
do so will result in damage to the
machine. DO NOT switch the re-
connect bar with machine power
SA FE FIC
R EC
ON.
SP
E I
M R T DI
PL O A
E Y GR
O OU A
N
LY R
M
Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the mag-
nitude of the current increases.
POWER WAVE 450

A-5 A-5
INSTALLATION
FIGURE A.3 – FRONTPANEL/BACK PANEL
6
5 (IN)
4
(OUT)
1 3 2
1 WORK TERMINAL 4 WATER COOLING FITTINGS (ON BACK PANEL)
2 ELECTRODE TERMINAL 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)
3 REMOTE CONTROL AMPHENOL RECEPTACLE 6 ELECTRODE TERMINAL
To operate at 200-208 VAC: OUTPUT CONNECTIONS

1. Open the reconnect/input access door. See Figure A.3 for the location of the work terminal,
electrode terminal, remote control amphenol recepta-
2. Move the input voltage switch to Voltage = 200-
cle, water cooler fittings and wire feeder connections.
208V position.
WORK AND ELECTRODE CABLE
3. Move “A” lead to the 200-208V terminal.
CONNECTIONS
To operate at 220-230 VAC:
SIZE
1. Open the reconnect/input access door.
Use the largest welding (electrode and ground) cables
2. Move the input voltage switch to voltage = 220- possible — at least 70mm2 (#2/0) copper wire — even
230V position. if the output current does not require it. When pulsing,
the pulse current often exceeds 650 amps with the
3. Move “A” lead to the 220-230V terminal. Power Wave 450. Voltage drops can become exces-
To operate at 380-415 VAC: sive if undersized welding cables are used.
1. Open the reconnect/input access door. ROUTING
2. Move the input voltage switch to Voltage = 380- To avoid interference problems with other equipment
and to achieve the best possible operation, route all
415V position.
cables directly. Avoid excessive lengths, bundle the
3. Move “A” lead to the 380-415 VAC terminal. electrode and ground cables together where practical,
and do not coil excess cable.
To operate at 440-460 VAC: No setup required. The
machine is factory-connected to operate at 440 volts. WATER COOLER CONNECTIONS
To verify, do the following: The water cooler fittings are a quick-connect type.
Refer to the Accessories section of this manual for

1. Open the reconnect/input access door.
water cooler operation and antifreeze mixtures.
2. Check that the input voltage switch is set to WIRE FEEDER CONNECTIONS
Voltage = 440-460V position.
Refer to the Accessories section for Wire Feeder Con-
3. Check that the “A” lead is at the 440-460V. nections.
Refer to Setup overlay in Operation section for Wire
Feeder Configuration.
POWER WAVE 450
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES
POWER WAVE 450

Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
Quick Start Reference for Process Selection Overlay................................................................B-3
General Description ....................................................................................................................B-4
Synergic Welding..................................................................................................................B-4
Recommended Processes ...................................................................................................B-4
Operational Features and Controls ......................................................................................B-4
Design Features and Advantages ........................................................................................B-4
Welding Capability................................................................................................................B-4
Limitations ............................................................................................................................B-4
Controls and Settings .................................................................................................................B-5

Case Front Controls .............................................................................................................B-5
Operating Overlays .....................................................................................................................B-6
Overview...............................................................................................................................B-6
Installing an Overlay .............................................................................................................B-6
Overlay Types .......................................................................................................................B-7
Pulse, GMAW, FCAW, Stick Overlay ..........................................................................................B-8
Weld from Memory Overlay ......................................................................................................B-11
Weld from Memory, Dual Procedure Overlay ...........................................................................B-12
Dual Wire Feeders, Dual Procedure Overlay ............................................................................B-14
Limits Overlay ...........................................................................................................................B-15
Setup Overlay ...........................................................................................................................B-17

Wire Feeder Setup Description ................................................................................................B-18
Overview of Welding Procedures .............................................................................................B-20
FCAW and GMAW..............................................................................................................B-20
Pulse Procedures ...............................................................................................................B-20
Stick/TIG Procedures .........................................................................................................B-20
Wave Control......................................................................................................................B-20
Tables B.3, B.4, B.5, B.6 ....................................................................................................B-21
Pulse Welding.....................................................................................................................B-22
Overload Protection..................................................................................................................B-23
Thermal Protection .............................................................................................................B-23
Over Current Protection .....................................................................................................B-23
POWER WAVE 450

B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.
FUMES AND GASES can be

dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause

fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com-

bustibles.
ARC RAYS can burn.

• Wear eye, ear, and body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
HOT COOLANT can burn skin.

• Always be sure coolant is not hot before
doing any work on cooler parts.
POWER WAVE 450

B-3 B-3
OPERATION
QUICK START REFERENCE FOR Step 2: Adjust the wire feed to speed “WFS” and
voltage “V” or arc length “T” (if necessary).
USING THE PROCESS SELECTION
a. Press the DISPLAY RECALL key to
OVERLAY view additional procedure information.
Read and understand the “Controls and Settings” and
“Operating Overlays” sections of this manual before b. Adjust wire feed speed and voltage or arc
using the following Quick Start Reference procedure length trim through the controls on your wire
to operate the Power Wave. feeder. The new values appear on both the
wire feeder and the Power Wave display.
NOTE: Selection of certain options may limit the
selection of subsequent options. Step 3: Save process information (if desired).
Step 1: Select your process information: a. Press the SAVE TO MEMORY key SAVE .
a. Install the desired PROCESS OVERLAY. b. Press one of the MEMORY LOCATION keys
b. Turn the machine ON. (1-8).
c. Select the desired welding You can recall your procedure later by pressing the
PROCESS1.
RECALL FROM MEMORY key RECALL and the appro-

priate MEMORY LOCATION key.
1
The electrode class, electrode size, and electrode/
d. Select ELECTRODE CLASS. gas type you can select for your process will be
limited to the machine’s programmed recommenda-
tions. Therefore, selecting certain options may limit
other option selections.
2
The wave control scale displayed shows the default
setting. (The higher the setting, the softer the arc.) If
you change the setting, your new setting will be dis-
played.
e. Select ELECTRODE SIZE.
f. Select ELECTRODE/GAS TYPE.

g. Press the WAVE CONTROL

UP or DOWN keys to see
the present setting. Press
the WAVE CONTROL UP or
WAVE CONTROL DOWN
keys to adjust2.
POWER WAVE 450

B-4 B-4
OPERATION
GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES

The INVERTEC Power Wave power source is a high • Designed to NEMA Standards.
performance, digitally controlled inverter welding • Multiple process output ranges 5 - 540 amps.
power source capable of complex, high-speed wave-
form control. It uses three-phase input power only. • 2-line LCD display.
The Power Wave is designed to be used as a synergic • Easy access for input connections. Connections
welding system in conjunction with a wire feeder. are simple strip and clamp (no lugs required).
SYNERGIC WELDING • Modular construction for easy servicing.
The Power Wave system is designed primarily as a • Thermostatically protected.
synergic welding system. The word “synergic” comes
from the word “synergism,” which means “two or more • Electronic overcurrent protection.
things working together to achieve an effect which nei- • Overvoltage protection.
ther can achieve individually.”
• Digital signal processor and microprocessor control.
The Power Wave and wire feeder operate as a team.
Each “knows” what the other is doing at all times. • RS232 interface for future welding application
They each also know what process, wire type, wire updates.
size, and gas combination are being used. In a syner- • Simple, reliable reconnection for various input volt-
gic system, the wire feeder and power source must ages.
“talk” together. This means that only certain wire feed-
ers can work in a synergic setup. A synergic feeder • New accessories and wire feeders communicate
has special circuitry to “talk” with and “listen” to the using a digital current loop to transfer information.
Power Wave power source. • Auto device recognition simplifies accessory cable
Welding experts have preprogrammed the system for connections.
the best range of process settings according to wire • Direct support of two wire feeders.
type, wire size, and gas combination. When the wire
feed speed is changed, the system automatically • Auto-configurable for either metric or English mode.
adjusts the current and voltage waveforms to give the • Multi-process control: Stick, short arc, GMAW
best weld characteristics. This improves the sound- spray, GMAW pulse, and flux cored arc welding
ness, appearance, and repeatability of welds. (FCAW).
Refer to the Accessories section of this manual for • Simple control through use of overlays that limit
available wire feeders. access to only those keys required for a given appli-
cation.
RECOMMENDED PROCESSES
The Power Wave is designed to be used as a multiple
WELDING CAPABILITY
process machine. It comes preprogrammed with The Power Wave 450 is rated at 500 amps, 40 volts at
GMAW pulse, GMAW (short arc and spray) FCAW 60% duty cycle based on a ten minute time period. It
(Innershield™ and Outershield™), and stick proce- is capable of higher duty cycles at lower output cur-
dures. rents. If the duty cycles are exceeded, a thermostat
will shut off the output until the machine cools to a rea-
OPERATIONAL FEATURES AND sonable operating temperature.
CONTROLS
LIMITATIONS
The Power Wave, through use of a keypad overlay
system, provides various options and controls such as • The Power Wave is not recommended for process-
Multiple Process/Procedure Selection; Memory es other than those specified by available overlays.
Storage of Procedures; Weld from Memory Only oper- • The Power Wave is not recommended for pipe
ation; Dual Process/Dual Feeder capability. thawing.
POWER WAVE 450

B-5 B-5
OPERATION
CONTROLS AND SETTINGS CASE FRONT CONTROLS

All operator controls and adjustments are located on Refer to Figure B.1 for the location of the following
the case front of the Power Wave. Refer to Figure B.1 controls:
and corresponding explanations. 1. LCD DISPLAY: Provides welding procedure infor-
FIGURE B.1 – CASE FRONT CONTROLS mation and parameters such as wire type, gas
type, WFS, trim, etc.
6
2. POWER SWITCH: Controls input power to the
Power Wave. When the switch is turned to the ON
3
1
position, the connected wire feeder meters light
up and the LCD display on the Power Wave shows
the following:
LINCOLN ELECTRIC
Version X.X
2
This display is shown for a few seconds followed
by another display that depends on the overlay

placed on the machine. At this point, the machine
is ready for operation.
3. HIGH TEMPERATURE LIGHT (thermal overload): A
yellow light that comes on when an over tempera-
4 5 ture situation occurs. Output is disabled until the
1 LCD DISPLAY machine cools down. At that point the light goes
2 POWER SWITCH out and output is enabled again.
3 HIGH TEMPERATURE LIGHT
4 REMOTE CONTROL AMPHENOL RECEPTACLE 4. REMOTE CONTROL AMPHENOL RECEPTACLE:
5 5 AMP CIRCUIT BREAKER Allows remote current control during stick welding
6 LCD DISPLAY ADJUSTMENT
via a hand or foot Amptrol accessory.
5. 5 AMP CIRCUIT BREAKER: Protects two auxiliary
power circuits: the 24V supply used by the trigger
circuits and the 42V supply used by the internal
machine circuits and the wire feeders.
6. LCD DISPLAY ADJUSTMENT: Use a small flat

blade screw driver to adjust the viewing angle of
the LCD display.
POWER WAVE 450

B-6 B-6
OPERATION
OPERATING OVERLAYS INSTALLING AN OVERLAY

OVERVIEW 1. Open the ACCESS DOOR by grasping the provid-
ed indent on the door and pulling the door for-
The Power Wave is controlled by a panel of keys (key- ward. See Figure B.3 for door location.
pad) located on the front of the machine. The opera-
tor can access controls by placing an overlay over the
keys. FIGURE B.3 – OVERLAY ACCESS DOOR
An OVERLAY is a special plastic sheet with a number
of keys and symbols printed on one side and a bar 5 3 1
code printed on the other. See Figure B.2. The print-
ed keys allow the operator to communicate with the
machine for a specific set of functions. The bar code 2
allows the machine to identify the overlay.
4
FIGURE B.2 – TYPICAL POWER WAVE OVERLAY

C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
L9361-2 WELD FROM MEMORY
™
R
INVERTEC POWER WAVE 350 TM
WARNING
HIGH TEMP.
MEMORY RECALL PROGRAM LIST

M
1 M
2
1 2
M
3 M
4
3 4
M
5 M
6
5 6
DISPLAY
M
7 M
8 RECALL
7 8
Before the Power Wave is turned ON, the operator 1 OVERLAY ACCESS DOOR
2 OVERLAY FRAME
selects the desired overlay and mounts it in the over-
3 ACCESS DOOR INDENT
lay frame on the front of the machine. Then, when the 4 TRACKS
machine is turned ON, it reads the overlay bar code 5 LOCATING PINS
and configures the machine accordingly, allowing the
operator to access only certain keys. The machine
must be powered up each time an overlay is 2. Select the desired overlay from the storage com-
changed. partment located behind the access door.
3. Remove any overlay already in the overlay frame
and place it in the storage compartment.
4. Slide the new overlay into the overlay frame. Align
the overlay with the two tracks on the sides of the
frame. Be sure the overlay is seated in the bottom
lip of the frame and on the top two locating pins.
Close the access door securely.
POWER WAVE 450

B-7 B-7
OPERATION
OVERLAY TYPES Overlay Overlay Figure

Type Name No.
Four types of overlays can be used with the Power
Wave. 1 GMAW PULSE, GMAW
FCAW, STICK PROCESS
1. Process Overlays. These overlays are used to SELECTION OVERLAY B.4
create, save and recall specific welding proce-
dures by selecting and adjusting the various weld- 2 WELD FROM MEMORY
ing settings that have been programmed into the OVERLAY B.5
Power Wave at the factory. 2 WELD FROM MEMORY, DUAL
2. Weld From Memory Overlays. These overlays PROCEDURE OVERLAY B.6
(also called Shop Overlays) provide a simple way 2 *DUAL WIRE FEEDERS, DUAL
for operators to recall and use any of the welding PROCEDURES OVERLAY B.7
procedures that have been stored in the memory
of the Power Wave. 3 *LIMITS OVERLAY B.8
3. Setup Overlays. These overlays provide specific 3 SETUP OVERLAY B.9

machine setup information, such as operating lim- *These overlays are optional. See Accessories
its for the welding procedures stored in memory. Section for Order Numbers.
4. Special Purpose Overlays. These are custom
overlays for specific customer applications.
Detailed information on how to use currently available
Power Wave overlays follows.
POWER WAVE 450

B-8 B-8
OPERATION
PULSE, GMAW, FCAW, AND STICK/TIG

PROCESS SELECTION OVERLAY
An operator can use this overlay to create a new welding procedure, save a newly created welding procedure,
view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See
Figure B.4. The steps for performing each of these functions are given below.
FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY
1 11
10
2
8 6
3 4 5 7
1 LCD DISPLAY WINDOW 7 DISPLAY RECALL KEY
2 PROCESS SELECT KEY 8 SAVE TO MEMORY KEY

3 ELECTRODE CLASS UP/DOWN KEYS 9 MEMORY LOCATION NUMBER KEYS
4 ELECTRODE SIZE UP/DOWN KEYS 10 RECALL FROM MEMORY KEY
5 ELECTRODE/GAS TYPE UP/DOWN KEYS 11 HIGH TEMPERATURE LIGHT
6 WAVE CONTROL UP/DOWN KEYS
1. LCD DISPLAY WINDOW: Power up the machine NOTE: The following four selections should
with this overlay in place. When the Power Wave always be performed in this order: process, elec-
is turned on, the following message appears on trode class, electrode size, electrode/gas type.
the display for a few seconds: Selecting a setting for one component narrows
your choice of available settings in remaining com-
LINCOLN ELECTRIC
ponents. This is why the order of performing the
VERSION X.X
steps is important. However, if you make compo-
This display is followed by: nent selections out of order, the machine will
prompt you to make a new selection for any set-
OVERLAY ID
tings that do not apply.
NUMBER = 1
2. PROCESS SELECT KEY: Use the PROCESS

A welding procedure is made up of seven compo-
SELECT key to select from the processes avail-
nents: process, material type, wire diameter, program,
able in the machine. Press the PROCESS
wire feed speed, voltage or arc length trim, and wave
SELECT key until the light by the desired process
control. A new welding procedure is created by
is lit.
selecting a combination of these components from the
ones that have been programmed into the Power
Wave. See Figure B.4 for key locations.
POWER WAVE 450
B-9 B-9
OPERATION
3. ELECTRODE CLASS UP/DOWN: Use the ELEC- 7. DISPLAY RECALL KEY: Since not all the informa-
TRODE CLASS UP or DOWN keys to select from tion about the procedure can be seen on the 2-line
the material types available for the selected LCD display window at the same time, use the
process. Press the ELECTRODE CLASS UP or DISPLAY RECALL key to display and verify all of
DOWN key until the desired material type is dis- the selected procedure information. The normal
played. default display window shows the Procedure
Description, WFS, and preset voltage or arc length
4. ELECTRODE SIZE UP/DOWN: Use the ELEC-
trim values. Press and hold the DISPLAY RECALL
TRODE SIZE UP or DOWN keys to select from the
key, and the window shows the procedure de-
wire diameters available for the selected process
scription and gas type for as long as the key is
and material type. Press the ELECTRODE SIZE
held depressed. Release the DISPLAY RECALL
UP or DOWN key until the desired wire diameter is
key, and the window shows wire size, material
displayed.
type, and process description. After a few sec-
5. ELECTRODE/GAS TYPE UP/DOWN KEYS: Use onds, the window changes back to the default dis-
the ELECTRODE/GAS TYPE UP or DOWN keys to play.
select from the programs available for the select-

8. SAVE TO MEMORY KEY: This key is used to save
ed process, material type, and wire diameter.
a newly created welding procedure. The Power
Press the ELECTRODE/GAS TYPE UP or DOWN
Wave has eight memory locations which can be
Key until the desired program is displayed.
used to store all the settings of up to eight welding
6. WAVE CONTROL UP/DOWN KEYS: Press one of procedures. Once stored in a memory location, a
the two WAVE CONTROL keys to display the pre- procedure can be recalled for later use with the
sent wave control. This is shown on a scale from RECALL FROM MEMORY key. To save a newly
LO to HI. Use the WAVE CONTROL UP or WAVE created welding procedure:
CONTROL DOWN key to change the wave control
Press the SAVE TO MEMORY key SAVE and then
to the desired level. When this scale is shown, the
one of the MEMORY LOCATION NUMBER keys.
WAVE CONTROL setting can also be changed
Keep a record of this number for future reference.
while welding (on the fly). Press the DISPLAY
RECALL key to exit the wave control function. For Any previously created welding procedure stored
a description of how the wave control setting in that location will be erased.
affects the welding procedure, refer to the
If you press the SAVE TO MEMORY key but
Overview of Welding Procedures sub-section of
decide not to save the procedure, you can exit this

the Operation section of this manual.

function by pressing the DISPLAY RECALL key.
The wire feed speed and voltage or arc length
9. MEMORY LOCATION NUMBER KEYS: To view
trim desired for the new procedure can be
information about any stored welding procedure,
changed from the wire feeder.
simply press its MEMORY LOCATION NUMBER
key.
As you hold down the selected key, the procedure
description and gas type of the procedure appear
in the display window. The process type is shown
by the indicating light opposite the appropriate
process symbol.
When you release the selected key, the wire size,
material type and process description appear for a
few seconds.
This function does not display the wire feed speed
and voltage or arc length trim settings. To view

these, you must recall the procedure from memo-
ry with the RECALL FROM MEMORY key.
POWER WAVE 450

B-10 B-10
OPERATION
10. RECALL FROM MEMORY KEY: This key is used

to recall an existing procedure from memory. You
can recall and use any of the previously created
welding procedures that are stored in one of the
eight memory locations. Simply press the
RECALL FROM MEMORY key RECALL and then the
appropriate MEMORY LOCATION NUMBER key.
If you press the RECALL FROM MEMORY key and
then change your mind, you can exit this function
by pressing the DISPLAY RECALL key. If the
memory location you select does not contain a
stored welding procedure, this will be indicated in
the display window. Select another memory loca-
tion. It is not necessary to save a procedure back
to memory after it is recalled from memory. When
a procedure is saved into a memory location, it
can be recalled from there until another procedure

is stored in that location or the location is cleared.
The RECALL FROM MEMORY and SAVE TO
MEMORY keys can be used to clear a memory
location.
SAVE
Press the SAVE TO MEMORY key and then
the RECALL FROM MEMORY key RECALL . (Do not
press both keys at the same time.) A message in
the display window will ask you to press the MEM-
ORY LOCATION NUMBER key of the memory
location you want to clear.
If you press the SAVE TO MEMORY and RECALL
FROM MEMORY keys and then change your
mind, you can exit this function by pressing the
DISPLAY RECALL key.
11. HIGH TEMPERATURE LIGHT: The high tempera-

ture light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
POWER WAVE 450

B-11 B-11
OPERATION
WELD FROM MEMORY OVERLAY
The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight mem-
ory locations. See Figure B.5.
FIGURE B.5 – WELD FROM MEMORY OVERLAY
1
1 LCD DISPLAY WINDOW 5
2 MEMORY RECALL KEYS
6
3 PROGRAM LIST
4 DISPLAY RECALL KEY
6 MEMORY LIGHTS
2
3 4
1. LCD DISPLAY WINDOW: Power up the machine With this overlay in place, the wire feed speed and
with this overlay in place. When the Power Wave the preset voltage or arc length trim can be
is turned on, the following message appears in the changed from the wire feeder. The new values will
display window for a few seconds: replace the previous values and become a perma-
nent part of the procedure.
LINCOLN ELECTRIC
Version X.X If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedure,
This display is followed by:
these limits will be active when this overlay is in
OVERLAY ID place. They cannot be overridden from this over-
NUMBER = 2 lay.
This message is then replaced by the following 3. PROGRAM LIST: The PROGRAM LIST block in
message: the center of this overlay provides a convenient
place to record a brief description of each welding
SELECT A MEMORY
procedure stored in memory. A “Dry Erase” mark-
LOCATION
er should be used for this purpose.
2. MEMORY RECALL NUMBERS: Select the mem-
4. DISPLAY RECALL KEY: To view other information
ory location of the desired welding procedure by
about the selected procedure, press the DISPLAY
pressing the appropriate MEMORY RECALL
RECALL key. The display window will show the
NUMBER key.
procedure description and gas type of the se-
If no procedure was saved in the selected memo- lected procedure for as long as the key is held
ry location, the following message appears: depressed. When the key is released, material
type, wire size, and process descriptions will be
MEMORY LOCATION
displayed for a few seconds.
# IS EMPTY
Select another memory location.
When a welding procedure is recalled from mem- temperature exceeds the allowed limit. Output is
ory, the display window will show the procedure disabled until the machine cools down and the
description, wire feed speed, and arc length trim high temperature light goes out.
or preset voltage.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory is active at any given time.
POWER WAVE 450

B-12 B-12
OPERATION
WELD FROM MEMORY, DUAL PROCEDURE OVERLAY

The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored
in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position
trigger. The switch or trigger selects which procedure will be active. See Figure B.6
FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY
1
6 5
3 4
1 LCD DISPLAY WINDOW 4 DISPLAY RECALL KEY
2 MEMORY RECALL KEYS 5 HIGH TEMPERATURE LIGHT
3 PROGRAM LIST 6 MEMORY LIGHTS
1. LCD DISPLAY WINDOW: Power up the machine Select a memory location PAIR for the two desired
with this overlay in place. When the Power Wave is welding procedures by pressing either of the two cor-
turned on, the following message appears in the responding MEMORY RECALL NUMBER keys.
display window for a few seconds:
If no procedure was saved to one of the memory pair
LINCOLN ELECTRIC locations, the following message appears:
Version X.X
MEMORY LOCATION
This display is followed by: # IS EMPTY
OVERLAY ID In this case select another memory pair.
NUMBER = 3
Set the dual procedure switch or gun trigger to the
This message is then replaced by the following position for PROCEDURE A or PROCEDURE B.
message: Position A activates the welding procedure from the
odd numbered memory locations (1, 3, 5 or 7).
SELECT A MEMORY
Position B activates the welding procedure from the
LOCATION
corresponding even numbered memory locations (2, 4,

2. MEMORY RECALL KEYS: The following four 6 or 8). For example, if memory location 3 was
memory pairs are available on this overlay: selected, Position A activates the procedure from
Memory 1 and Memory 2 memory location 3; Position B activates the proce-
Memory 3 and Memory 4 dure from memory location 4.
Memory 5 and Memory 6
Memory 7 and Memory 8
POWER WAVE 450

B-13 B-13
OPERATION
When a pair of welding procedures are recalled

from memory, the display window will show the
procedure description, wire feed speed, and the
preset voltage or arc length trim of the LAST pro-
cedure welded with.
With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values will
replace the previous values and become a perma-
If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedures,
place. They cannot be overridden from this over-
lay.
3. THE PROGRAM LIST: The PROGRAM LIST block

in the center of this overlay provides a convenient
place to record a brief description of each welding
procedure stored in memory. A “Dry Erase” mark-
er should be used for this purpose.
4. DISPLAY RECALL KEY: To view other information
about the active procedure, press the DISPLAY
RECALL key. The display window will show the
procedure description and gas type of the active
procedure for as long as the key is held
depressed. When the key is released, the wire
size, material type, and process descriptions dis-
play for a few seconds.

disabled until the machine cools down and the
what memory location is active at any given time.
POWER WAVE 450

B-14 B-14
OPERATION
DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY (OPTIONAL)

The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feed-
ers and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4
can be automatically recalled and used. See Figure B.7.
FIGURE B.7 – DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY
1 LCD DISPLAY WINDOW

2 WIRE FEEDERS MEMORY CHART 1
3 DISPLAY RECALL KEY
5 MEMORY LIGHTS 5 4
2 3
1. LCD DISPLAY WINDOW: Power up the machine With this overlay in place, the wire feed speed and
with this overlay in place. When the Power Wave is the preset voltage or arc length trim can be
turned on, the following message appears in the changed from the wire feeder. The new values
display window for a few seconds: replace the previous values and become a perma-
LINCOLN ELECTRIC
VERSION X.X If limits have been set on the wire feed speed, volt-
age or arc length trim of the selected procedures,

OVERLAY ID place. They cannot be overridden from this over-
NUMBER = 9 lay.
2. WIRE FEEDERS MEMORY CHART: The active 3. DISPLAY RECALL KEY:To view other information
welding procedure is determined by the active about the active welding procedure, press the
wire feeder and its gun switch position. The weld- DISPLAY RECALL key. The display window will
ing procedure recall from memory is as follows: show the procedure description and gas type of
the last active procedure for as long as the key is
Active Gun Trigger Memory Location
held depressed. When the key is released, the wire
Wire Feeder Position of Procedure
size, material type, and process descriptions will
#1 A 1 be displayed for a few seconds.
#1 B 2
#2 A 3
#2 B 4
Pull the trigger on either wire feeder. disabled until the machine cools down and the
Depending on the gun switch position, the corre-

sponding memory location is automatically 5. MEMORY LIGHTS: A memory light is on when its
recalled. The wire feeders memory chart has no corresponding memory is selected. This tells you
keys; it is simply a chart. what memory location is active at any given time.
The display window will show the procedure
description, wire feed speed, and the preset volt-
age or arc length trim of the last active welding
procedure.
POWER WAVE 450
B-15 B-15
OPERATION
LIMITS OVERLAY (OPTIONAL)
The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length
trim for any welding procedure stored in memory. See Figure B.8.
FIGURE B.8 – LIMITS OVERLAY
1
8
2
4 5 7
1 LCD DISPLAY WINDOW 5 LIMIT UP/DOWN KEYS

2 RECALL FROM MEMORY KEY 6 SAVE TO MEMORY KEY
3 MEMORY LOCATION NUMBER KEYS 7 DISPLAY RECALL KEY
4 SET LIMIT KEY 8 MEMORY LIGHTS
1. LCD DISPLAY WINDOW: Power up the machine Determine the memory location number of the
with this overlay in place. When the Power Wave is welding procedure for which you want to set lim-
turned on, the following message appears in the its.Then press the RECALL FROM MEMORY key
display window for a few seconds: RECALL followed by the MEMORY LOCATION NUM-
BER key for the selected procedure.

LINCOLN ELECTRIC
Version X.X If no procedure was saved in the selected memo-
ry location, the following message appears:
MEMORY LOCATION
OVERLAY ID
# IS EMPTY
NUMBER = 4
Select another memory location.
This message is then replaced by the following
message: 4. SET LIMIT KEY:
SELECT A MEMORY AND
LOCATION
5. LIMIT UP / DOWN KEYS:
2. RECALL FROM MEMORY KEY:

The SET LIMIT key and LIMIT UP / LIMIT DOWN
AND keys are used to set the maximum and minimum
allowed wire feed speed, and voltage trim or arc
3. MEMORY LOCATION NUMBERS:
length trim values of the procedure that was
The RECALL FROM MEMORY key RECALL is used recalled from memory.
to recall a welding procedure from memory.
POWER WAVE 450

B-16 B-16
OPERATION
Use the LIMIT UP and LIMIT DOWN keys to 7. DISPLAY RECALL KEY: To view other information
change the maximum wire feed speed to the about the active welding procedure, press the
desired value. DISPLAY RECALL key. The display window will
show the procedure description and gas type of
Press the SET LIMIT key again. The new maximum
the last active procedure for as long as the key is
and old minimum wire feed speeds will be dis-
held depressed. When the key is released, the wire
played.
size, material type, and process descriptions will
Use the LIMIT UP and LIMIT DOWN keys to be displayed for a few seconds.
change the minimum wire feed speed to the
desired value.
Press the SET LIMIT key. The present maximum what memory is active at any given time.
and minimum voltage trim or arc length trim will be
displayed. (Refer to Table B.3 to see how voltage
trim affects preset voltage. Refer to Table B.6 to
see how arc length trim affects preset arc length.)
Use the LIMIT UP and LIMIT DOWN keys to

change the maximum value. The maximum for
either type is 1.5.
Press the SET LIMIT key. The new maximum and
old minimum voltage trim or arc length trim will be
displayed.
Use the LIMIT UP and LIMIT DOWN keys to
change the minimum value. The minimum for
either type is 0.5.
6. SAVE TO MEMORY KEY: The SAVE TO MEMO-
RY KEY is used to save the procedure with the
newly set limits to memory. Press the SAVE TO
MEMORY key SAVE followed by the MEMORY
LOCATION NUMBER key of the desired memory
location. This does not have to be the original
location from which the procedure was recalled.

Step 6 can be performed any time during the limit-
setting process. You do not have to set all the
available limits. When you have set all the desired
limits, save the procedure to memory.
To clear any previously set limits, recall the proce-
dure from memory and change the limits to the
maximum range available. Then save the proce-
dure to memory.
POWER WAVE 450

B-17 B-17
OPERATION
SETUP OVERLAY
The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set
up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figure
B.9.
FIGURE B.9 – SETUP OVERLAY
C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9660 SETUP OVERLAY
WARNING
+POLARITY +POLARITY 1
ELECTRODE ELECTRODE
SENSE LEAD SENSE LEAD
ENABLED ENABLED
WORK SENSE WORK SENSE

WATER COOLER ENABLED
LEAD ENABLED LEAD ENABLED
3
5 WATER COOLER PRESSURE
WATER
2
+/ - +/ -
COOLER
POLARITY POLARITY
6
ENABLE
ELECTRODE ELECTRODE PRIME

SENSE SENSE WATER
LEAD LEAD COOLER
7 WORK WORK
WATER COOLER CAN ONLY BE
PRIMED WHEN IT IS ENABLED.
4
SENSE SENSE
LEAD LEAD PRIME THE WATER COOLER
UNTIL WATER COOLER PRESSURE
LIGHT TURNS ON.
WATER COOLER SETUP
WIRE WIRE
FEEDER 1 FEEDER 2
1 LCD DISPLAY WINDOW 5 WIRE FEEDER 1+/- POLARITY KEY

2 WATER COOLER ON/OFF KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY
3 WATER COOLER PRESSURE LIGHT 7 WIRE FEEDER 1 WORK SENSE LEAD KEY
4 PRIME WATER COOLER KEY
1. LCD DISPLAY WINDOW: Power up the machine 3. WATER COOLER PRESSURE LIGHT: This light
with this overlay in place. When the Power Wave indicates whether or not the coolant flow rate is
is turned on, the following message appears in the high enough for normal water cooler operation. If
display window for a few seconds: the water cooler loses the required flow rate it will
shut down within a couple of seconds, the water
LINCOLN ELECTRIC
cooler pressure light will turn off,and the machine
Version X.X
sounds a buzzer.
OVERLAY ID
4. PRIME WATER COOLER KEY: The water cooler
NUMBER = 0
may have to be primed if there is not enough
This message is then replaced by the following coolant in the system for proper operation. Make
message: sure that the water cooler has been turned on
before it is primed. (The “WATER COOLER ON”
POWER WAVE
light should be turned on.) Check reservoir for
SETUP
proper coolant level - See Water Cooler informa-

2. WATER COOLER ON/OFF KEY: Press this key to tion in ACCESSORIES section. To prime the water
toggle the water cooler between being enabled cooler, hold the PRIME WATER COOLER key
and disabled. The present status of the water down. While this key is pressed, the display will
cooler is indicated by the “WATER COOLER ON” show:
light.
PRIME WATER
COOLER
POWER WAVE 450

B-18 B-18
OPERATION
When the “WATER COOLER PRESSURE” light +/- POLARITY KEY

turns on, release the key. If this key has been
A. Positive Voltage Sensing Polarity:
pressed for 30 seconds and the ‘WATER COOLER
PRESSURE’ light still did not turn on, check the In most welding applications the electrode cable is
water cooler for adequate fluid level. connected to the + output terminal and the work
cable is connected to the - output terminal of the
5. WIRE FEEDER 1 +/- POLARITY KEY: Press this
power source. This is the positive voltage sensing
key to change the present voltage sensing polari-
polarity, illustrated by Figure B.10. When the
ty of wire feeder 1. The present polarity of wire
Power Wave and the wire feeder(s) are connected
feeder 1 is indicated by the “WIRE FEEDER 1+
in this manner, the arc voltage can be measured in
POLARITY” light. If wire feeder 1 is set for positive
one of four ways. These four ways are shown in
voltage sensing polarity, this light is turned on.
Table B.1.
6. WIRE FEEDER 1 ELECTRODE SENSE LEAD
Table B.1: Positive Voltage Sensing Options
KEY: Press this key to enable or disable the elec-
trode sense lead (lead #67) of wire feeder 1. When Positive Voltage Reference Negative Voltage Reference
enabled, voltage sensing is done by the electrode + Output Terminal - Output Terminal
sense lead. When disabled, voltage sensing is

+ Output Terminal Work Sense (21) Lead*
done at the Power Wave output terminal. When
enabled, the “WIRE FEEDER 1 ELECTRODE Electrode Sense (67) Lead - Output Terminal
SENSE LEAD ENABLED” light will be illuminated. Electrode Sense (67) Lead Work Sense (21) Lead*
7. WIRE FEEDER 1 WORK SENSE LEAD KEY: * Consult the factory before using this option.
Press this key to enable or disable the work sense Use the ELECTRODE SENSE LEAD KEY to
lead (lead #21) of wire feeder 1. When enabled, select either the + output terminal or the electrode
voltage sensing is done by the work sense lead. sense (67) lead for the positive voltage reference.
When disabled, voltage sensing is done at the
Power Wave output terminal. When enabled, the The work sense (21) lead is used only in rare cir-
“WIRE FEEDER 1 WORK SENSE LEAD cumstances. For most installations, use the
ENABLED” light will be illuminated. WORK SENSE LEAD KEY to select the - output
terminal for negative voltage reference. Consult
WIRE FEEDER SETUP DESCRIPTION the factory if use of the work sense (21) lead is
The Power Wave may be set up for either positive desired.
or negative arc voltage sensing using any two of
the following places:

B. Negative Voltage Sensing Polarity:
1. the positive output terminal of the Power Wave
In some welding applications (such as Inner-
2. the negative output terminal of the Power Wave shield®) the electrode cable is connected to the -
3. the electrode sense lead (67 lead) of the wire output terminal and the work cable is connected
feeder to the + output terminal of the power source. This
is the negative voltage sensing polarity, illustrated
4. the work sense lead (21 lead) of the wire feeder by Figure B.11. When the Power Wave and the
The SETUP Overlay allows you to select between wire feeder(s) are connected in this manner, the
which two places arc voltage will be sensed. arc voltage can be measured in one of four ways.
Once the selection is made it is not necessary to These four ways are shown in Table B.2.
reconfirm the selection every time a new overlay is
used or a wire feeder is replaced with another one.
The selection will remain until it is changed with Table B.2: Negative Voltage Sensing Options
the SETUP Overlay. Positive Voltage Reference Negative Voltage Reference
When welding with a stick procedure, the arc volt- – Output Terminal + Output Terminal
age is automatically measured between the Power – Output Terminal Work Sense (21) Lead*
Wave’s output studs. Electrode Sense (67) Lead + Output Terminal
I. Select arc voltage sensing polarity first. Electrode Sense (67) Lead Work Sense (21) Lead*
* Consult the factory before using this option.
11/96
POWER WAVE 450
B-19 B-19
OPERATION
Use the ELECTRODE SENSE LEAD KEY to select

either the - output terminal or the electrode sense (67)
lead for the positive voltage reference.
The two wire feeders can only be connected in the
The work sense (21) lead is used only in rare circum-
same manner, either by the Positive Polarity or the
stances. For most installations, use the WORK
Negative Polarity setup.
SENSE LEAD KEY to select the - output terminal for
negative voltage reference. Consult the factory if use
of the work sense (21) lead is desired.
FIGURE B.10
POSITIVE VOLTAGE SENSING POLARITY

Power Control Cable (includes 67 lead)

Wave
Electrode Sense Lead
67
- + Wire Feeder
Block
Electrode Cable
Work Cable
FIGURE 11B
FIGURE B.11
NEGATIVE VOLTAGE SENSING POLARITY
Power Control Cable (includes 67 lead)

Wave
Electrode Sense Lead
67
- + Wire Feeder
Block
Electrode
Cable
Work Cable
FIGURE 11C
POWER WAVE 450
B-20 B-20
OPERATION
OVERVIEW OF WELDING Increasing the arc length by 10 percent at a given wire

feed speed also increases all the other arc length set-
PROCEDURES tings of the procedure by 10 percent. In the GMAW
Pulse process, the display shows the Procedure
FLUX CORED ARC WELDING (FCAW)
Description, WFS and Arc Length Trim. Arc length trim
AND GMAW PROCEDURES is programmed to a default at the factory and may be
For each wire feed speed, a corresponding voltage adjusted on the wire feeder. When the trigger is
has been preprogrammed into the machine by welding pulled, the WFS, Actual Arc Voltage and Actual Arc
experts. This preprogrammed voltage is the best Current are displayed.
average voltage for the procedure at the given wire
STICK/TIG
feed speed. If the wire feed speed is changed on the
wire feeder, the voltage automatically changes with it. PROCEDURES
In some cases, the operator may want to change the Stick welding can be performed with the Power Wave
preprogrammed voltages; for example, to compensate by attaching a remote control kit to the 6-pin amphe-
for cable and fixture voltage drops. The preset volt- nol on the front of the machine. The K941-1 remote
ages can be adjusted on the wire feeder’s Voltage dis- control kit is recommended. Select the stick process
play. When a change is made to the voltage at one from either the GMAW Pulse, GMAW FCAW, stick
wire-feed speed, this change is applied to all other process selection overlay, or recall it from a previously
wire feed speed settings. For example, if the operator stored memory location with a Weld From Memory
turns up the voltage by 10 percent, the machine auto- overlay. When this process is selected, the Power
matically increases the preset voltages at all the other Wave reads the current (amps) setting from the remote
wire feed speeds by 10 percent. In the GMAW FCAW control kit. It also controls the output of the machine
process, the display shows the Procedure Description, based on the position of the Output Terminals switch,
WFS and Preset Voltage. The preset voltage which which is also located on the remote control kit. When
was programmed at the factory, may be changed on this switch is in the ON position, the output terminals
the wire feeder voltage display. Note that, if you of the Power Wave are electrically hot. When the
change the default preset voltage up or down, a switch is in the OFF position, the output terminals of
V
respective “ ” or “V” sign will be displayed after the the Power Wave are electrically cold and the machine
preset value. When the gun trigger is pulled, note that cannot produce an output. In the stick process, the
the display changes to show WFS, Actual Arc Voltage LCD display shows Procedure Description, and Preset
and Actual Arc Current. See Table B.5 for display Current (SET=). The Current Trim is always equal to 1
summary. (T=1.00). When the trigger is pulled the Preset Current,
Actual Arc Voltage and Actual Arc Current are dis-

PULSE PROCEDURES played.

In these procedures, the actual voltage greatly See Tables B.3 through B.6 for a summary of the
depends on the waveform used. The peak currents, information discussed above.
background currents, rise times, fall times, and pulse
times all affect the actual voltage. The actual voltage WAVE CONTROL
for a given wire feed speed is not directly predictable The wave control settings of all procedures can be
unless the waveform is known. In this case, it is not changed on the Power Wave GMAW Pulse, GMAW
practical to preset an actual voltage for the procedure. FCAW, Stick Process Selection Overlay. The wave
Instead, an arc length adjustment is provided. The control is a setup parameter that may be adjusted
machine “knows” what the best arc length is at the when the welding procedures are set. This feature
given wire feed speed but allows the operator to provides an easy way to change the arc behavior with-
change it. out creating a new procedure. The wave control set-
The arc length can be adjusted between 0.5 and 1.5 ting of a procedure limits the speed at which the cur-
on the wire feeder’s Voltage display. An arc length trim rent waveform of that procedure can change. Typically,
of 1.0 means that no adjustments will be made to the each procedure is programmed to have average wave
preset arc lengths. An arc length trim greater than 1.0 control (at the center of the scale).
increases the preset arc lengths. An arc length trim
less than 1.0 decreases the preset arc lengths. The
arc length adjustment is factored in at all wire feed
speed settings. Refer to Table B.6 for summary of arc
length trim.
POWER WAVE 450

B-21 B-21
OPERATION
TABLE B.3 – RELATIONSHIP BETWEEN TABLE B.6 – RELATIONSHIP BETWEEN

VOLTAGE TRIM AND PRESET VOLTAGE SELECTED ARC LENGTH TRIM AND PRESET
ARC LENGTH AS INDICATED BY ARC LENGTH
Voltage Trim Relationship to Preset Voltage
0.6 60% of preset voltage
Arc Length Trim Preset Arc Length
0.6 60% of preset length
1.0 no change to preset voltage
1.0 no change to preset length
Explanation of Table B.3: 1.4 140% of preset length
If, for example, the minimum voltage trim is set to 0.8
and the maximum voltage trim is set to 1.4, this
means that the voltage for a given wire feed speed
can be adjusted to be anywhere between 80% and

140% of the preset voltage of that wire feed speed.
TABLE B.4 – ADJUSTABLE PARAMETERS
Adjustable GMAW GMAW

Parameters Pulse FCAW Stick
Wire Feeder Wire Feed Wire Feed —
WFS Display Speed Speed
Wire Feeder Arc Length Preset —
Voltage Display Trim Voltage
Power Wave 450 Display
(with GMAW Pulse, Wave Wave Wave
GMAW FCAW, Stick Control Control Control
Process Selection Overlay) (Frequency) (Inductance) (Arc Force)
TABLE B.5 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS

FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS
Power Wave 450 Wire Feeder

Trigger
Position1 GMAW GMAW STICK1 GMAW GMAW
Pulse FCAW Pulse FCAW
WFS DISPLAY: WFS DISPLAY:
Wire Feed Speed Wire Feed Speed
WFS and WFS and Preset VOLTAGE VOLTAGE
Open Arc Length Trim Preset Voltage Current DISPLAY: DISPLAY:
Arc Length Trim Preset Voltage
WFS, WFS, WFS DISPLAY: WFS DISPLAY:
Actual Arc Actual Arc Preset Current, Wire Feed Speed Wire Feed Speed2
Closed Voltage, Voltage, Actual Arc VOLTAGE VOLTAGE
Actual Arc Actual Arc Voltage, Actual DISPLAY: DISPLAY:
Current Current Arc Current Actual Arc Voltage Actual Arc Voltage
In Stick, trigger is on Remote Control Kit K941-1.

1
Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder.
2
POWER WAVE 450

B-22 B-22
OPERATION
In Pulse processes: The pulsing process greatly affects the heat input
to the workpiece. This can be a valuable tool for
The wave control adjustment allows the frequency set- either increasing or decreasing the heat input with a
ting to vary. Increasing the wave control allows the fre- given process. For instance, it is possible to greatly
quency setting to increase, and decreasing the wave increase the heat input when welding steel at high
control allows the frequency setting to decrease. deposition rates. On the other hand, it is possible to
Varying the wave control setting affects the droplet reduce the heat input using the pulsing process. For
transfer and allows fine-tuning for different welding example, heat input is reduced greatly with some of
positions. the low current stainless steel procedures using the
In GMAW and FCAW processes: processes programmed into the Power Wave. In all
cases, the Power Wave procedures have been
The wave control adjusts the inductance. (Inductance checked for their ability to deliver a sound weld.
is inversely proportional to pinch.) Increasing the wave However, the fusion of the weld metal into the work-
control setting decreases the inductance, which piece may be affected. It is the responsibility of the
results in the arc getting colder and pinched tighter. user to determine if the welds produced are suitable
Decreasing the wave control setting increases the and sound.
inductance, which results in the arc getting wider.
The Power Wave 450 is optimized for use with a

In Stick processes: 0.75” (1.9 cm) stickout. The adaptive behavior is pro-
grammed to support a stickout range from 0.5” to
The wave control adjusts the arc force. Increasing the 1.25” (1.3 to 3.2 cm). In the low and high end of the
wave control setting increases the arc force, making wire feed speed ranges of most processes, the adap-
the arc more harsh but less likely to stick. Decreasing tive behavior may be restricted. This is a physical
the wave control setting decreases the arc force, mak- restriction due to reaching the edge of the operating
ing the arc softer and smoother. range for the process. It is possible to achieve adap-
PULSE WELDING tive behavior for longer stickout lengths. However,
shielding gas is often lost when the stickout is too
Some people have trouble getting used to the behav- long.
ior of the pulsing arc. The parameters programmed
into the Power Wave have been thoroughly tested for A longer electrical stickout is often used with the
their ability to deliver a sound weld with good appear- pulsing process at higher deposition rates. A long
ance. There are, however, a few things to keep in mind stickout will increase the melt-off rate of the wire. In
when pulse welding. pulse welding, like other wire welding processes, the
arc length is determined by the voltage setting. This
Spatter levels are often very low with the pulse

voltage is programmed at the factory for each process

welding process. Pulsing is often used to eliminate and wire feed speed. It may be changed using the
cleaning operations necessary when using other weld- Voltage setting on the wire feeder.
ing processes.
When adaptive processes are used, the voltage will
Fume levels are sometimes lower with the pulsing vary with stickout. The machine must change the
process. Whether or not you will get lower fume lev- voltage to keep a stable arc. It is very important to
els depends on the pulsing programs used. Certain recognize this. “Actual” arc voltage when welding will
waveform characteristics are necessary to get low vary because the stickout will seldom be held at the
fume levels. Unfortunately, low fume procedures are nominal 1.9 cm value.
harder to weld with than procedures designed to opti-
mize the welding process.
The pulsing process is not slower than other
processes. The process is sometimes less forgiving
when the arc gets on or ahead of the puddle. More
attention must be paid to the weld to avoid losing the
puddle. Speed is a matter of deposition rate. All
things being equal regarding the joint being welded,

the speed will depend on the wire feed speed. The
travel speed is maximized by maintaining a very short
arc. Often the process is “trimmed” down until the arc
“crackles.” The spatter increases slightly, but many of
the advantages of pulsing are retained. When welding
steel, the Power Wave is designed to run well in this
region between pulse and short arc.
POWER WAVE 450
B-23 B-23
OPERATION
OVERLOAD PROTECTION
THERMAL PROTECTION OVER CURRENT PROTECTION
The Power Wave has thermostatic protection from The Power Wave 450 is limited to producing 750 amps
excessive duty cycles, overloads, loss of cooling, and peak current. If the average current exceeds 540
high ambient temperatures. When the power source is amps, then the peak current will be limited to 100
subjected to any of these conditions or any of the con- amps until the average current decreases to under 50
ditions mentioned above, a thermostat will open. The amps.
yellow high temperature light on the case front comes
on. See Figure B.1 for location. Machine output is
disabled, and welding is not possible until the machine
is allowed to cool and the High Temperature Light
goes out.
POWER WAVE 450

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES
POWER WAVE 450

Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
Wire Feeder Setup ...............................................................................................................C-2
Guns and Cables .................................................................................................................C-2
Water Cooler Usage ...................................................................................................................C-2
Recommended Coolants............................................................................................................C-3
Priming the Cooler......................................................................................................................C-3
Cooler Periodic Maintenance .....................................................................................................C-4
POWER WAVE 450

C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES GUNS AND CABLES

Several MAGNUM guns are recommended for use
• Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed
with the Power Wave as shown in Table C.1.
• MAGNUM 400 gun (K471-2) or 550 gun (K598)
Place the proper liner in the gun and connect the gun
• Internal water cooler to the feeder. Consult the specific instructions sup-
plied with the gun for detailed operating instructions.
• Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders)
FIGURE C.1 – WIRE FEEDER AND
• Remote control (stick welding) K941-1 WATER COOLER CONNECTIONS
• Amptrols (Hand K963-1 or -2, Foot K870)
• Limits Overlay K946-4
• Dual Wire Feeders, Dual Procedures Overlay K946-9
• Dual Feeder, Dual Procedure, Memory Selection Overlay K946-12
1
• Test and Calibration Overlay
3
WIRE FEEDER SETUP
5 4
The Power Wave must be used with wire feeders list-
ed above. Mount the feeder in a location suitable to
your needs.
For most applications, connect the electrode cable
between the feeder and the positive (+) connection of
the power source. When negative electrode polarity is
required, such as in some Innershield™ applications, 1 WIRE FEEDER CONNECTIONS (LOCATION)
connect the electrode cable between the feeder and 2 WATER COOLER LINE (IN)
the negative (-) connection of the power source. See 3 WATER COOLER LINE (OUT)
4 CIRCUIT BREAKER (WATER COOLER)
Figure C.1. 5 FILL SPOUT (WATER COOLER)
Connect the control cable between the feeder and Using a water-cooled gun is recommended to reduce
power source. The cable has different connectors on
the size of the gun and improve parts life. The Power
each end and will fit in only one way. If only one feed- Wave comes with a standard internal water cooler.
er is used, it must be connected to the Feeder 1 However, an external cooler may also be used.
Amphenol located on the back panel in the upper left-
hand corner (as you view the machine from the back). TABLE C.1 – RECOMMENDED GUNS FOR USE
If a second feeder is used, it must be plugged into the WITH POWER WAVE 450
Feeder 2 Amphenol receptacle located just to the right
of the Feeder 1 Amphenol receptacle.
Gun Application Cooling Product No.
Connect the work cable between the work and the MAGNUM 400 GMAW Gas K471-2
negative (-) connection of the power source. When
MAGNUM 550 GMAW Gas K598
negative electrode polarity is required, such as in
some Innershield™ applications, connect the work
cable between the work and the positive (+) connec- WATER COOLER USAGE
tion of the power source. See Figure C.1. The Power Wave is equipped with an optional internal
• Connect the feeder to a welding gas supply. water cooler. We recommend using the water cooler
when welding above 300 amps with argon blends on
• Load the wire into the feeder and gun.
a regular basis. The gun heating from pulsing above

• Configure wire feeders (Refer to Setup overlay in 300 amps average current is often excessive and
operation section. leads to reduced consumable life, reduced gun life,
and operator discomfort. Water cooling greatly
increases the durability of the gun and parts at high
current.
Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operators
1
Manual for available options.

POWER WAVE 450
C-3 C-3
ACCESSORIES
There are two water connections on the rear of the a. Install the Set-up overlay.
Power Wave. See Figure C.1. Connect the water lines

between these connectors and those on the wire feed- b. Keep accessories’ hose lengths horizontal, either
er. The water is fed through the feeder into the gun. coiled or straight, and no higher than 4 feet of the
When a water cooler is used, the water cooler must be specified coolant level.
enabled by using the Setup Overlay.
c. Switch on the Power Wave machine.
The water cooler contains a flow switch, which is
closed when there is adequate coolant circulating in d. Press the "WATER COOLER ENABLE" button so
the system. If this flow rate drops below the switch that the "WATER COOLER ENABLED" light is
manufacturer’s set point, the flow switch opens. A cou- illuminated.
ple of seconds after the flow switch opens the water
cooler shuts down. If the water cooler is enabled and e. Press the "PRIME WATER COOLER" button until
the flow switch opens, the machine beeps loudly indi- the "WATER COOLER PRESSURE" light is
cating that there is a problem with the water cooler steadily illuminated.
operation.
4. Check coolant level. Add more if required.
RECOMMENDED COOLANTS Figure C.2

Rear Panel of
Power Wave
1. The following coolants have been determined to be
Reservoir Screen
compatible with the wetted materials used in the
G3503-[ ] cooler assembly:
• Distilled or deionized water
• Potable tap water
Visible Coolant Level
• Sediment-free mixtures containing a maxi-
mum of 50% ethylene glycol or automotive-
grade antifreeze and the balance of distilled
or deionized water.
0.25 to 0.50
2. Ethylene glycol mixtures should be selected if the inches
cooler may be exposed to a temperature below the
freezing point of water.
Do Not Use: Any prepacked welding industry coolant
3. Consult gun, torch, and wire feeder manuals for mixture, such as those offered by Miller, OKI,
coolant recommendations and select one from the Bernhard, or Dynaflux. These coolants contain sub-
above list. stances which attack plastic components and may
shorten the life of the system. Once added, these
4. Pure solutions and mixtures of, or materials (i.e. substances are virtually impossible to purge from the
towels) wetted with ethylene glycol are toxic to system. DO NOT USE OIL-BASED COOLANTS OF
humans and animals. They must not be haphaz- ANY TYPE.
ardly discarded, especially by pouring liquids down
the drain. Contact the local EPA office for responsi- K961-1 Single Cylinder Undercarriage -
ble disposal methods or for recycling information. Designed for quick installation in the field. Consists of
a front caster assembly, a rear platform assembly, a
5. The cooler’s reservoir has a nominal liquid capaci- handle, and an upper cylinder support.
ty of 1.6 gallons.
PRIMING THE COOLER K962-1 Dual Cylinder Undercarriage -

Designed for quick installation in the field. Consists of
1. Select a recommended coolant and fill cooler to

specified level (see Fig. C.2). a front caster assembly, a dual bottle rear platform
assembly, a handle, and a dual bottle upper cylinder
2. Attach desired water-cooled accessory (gun and support.
wire feeder or TIG torch) to cooler’s QDs.
3. Prime the cooler:
POWER WAVE 450

C-4 C-4
ACCESSORIES
G3503-[ ] COOLER PERIODIC MAINTENANCE
8. Flush coolant from the system and replace with

1. Preparation: fresh, recommended coolant at least once a year.
• Always switch off the Power Wave machine More frequent flushing may be necessary, depend-
power. ing upon a user’s particular system or its usage.
• Always disconnect the Power Wave machine
from service input power. NOTE: Never run the pump dry. Always use a recom-
• Do not remove the pump relief valves' 3/4 in. mended coolant, otherwise pump damage may
acorn hex nut or attempt to adjust the relief result.
valve setting.
9. Reinstall the G3503-[ ] cooler into the Power Wave
2. Remove the G3503-[ ] cooler from the Power Wave machine.
machine.
G3503-[ ] COOLER SERVICE
3. Clean the pump’s inlet strainer:
• Drain the reservoir of coolant and dispose of it 1. Preparation:
in an environmentally responsible manner (see • Always switch off the Power Wave machine
Recommended Coolants). power.

• Place absorbent towels underneath pump • Always disconnect the Power Wave machine
head. from service input power.
• Hold pump head to apply countertorque when • Do not remove the pump relief valves' 3/4 in.
loosening strainer’s 7/8 acorn nut. Do not con- acorn hex nut or attempt to adjust the relief
fuse with 3/4 acorn nut. Remove nut and slide valve setting.
inlet strainer down and out from pump head.
• Gently rinse strainer under running water to 2. Remove the G3503-[ ] cooler from the Power Wave
thoroughly clean it. machine whenever:
• Use the mirror to inspect inside of pump for • replacing major cooler components (i.e. pump,
contamination. Carefully remove hardened motor, heat exchanger, etc.).
debris with dental pick if necessary, without • replacing hoses and electrical harnesses that
scratching inside of the pump. are kinked or damaged (cut, abraded, deterio-
• Reinstall strainer and acorn nut, tightening with rated or swollen, etc.).
75±15 in.-lbs. of torque. Wipe dry all areas wet- • investigating suspect coolant leakage.
ted by coolant. Dispose of towels in an envi-
ronmentally responsible manner (see 3. Pump replacement:
Recommended Coolants). a. Drain the reservoir of coolant and dispose of it

in an environmentally responsible manner (see
4. Gently rinse the reservoir’s strainer under running Recommended Coolants).
water to thoroughly clean it. b. Remove fan shroud.
c. Place absorbent towels underneath pump head
5. Remove fan shroud and inspect hoses and electrical and wherever coolant system is opened.
harnesses for kinking or damage (cut, abrasion, d. Carefully pull pump inlet hose and its elbow
swelling, etc.). Replace if necessary. from reservoir (bottom).
e. Loosen pump outlet hose clamp at QD then
6. Remove accumulated dust from cooler, especially carefully remove from fitting.
from the motor and heat exchanger, by blowing it off f. Disconnect v-band clamp from motor and
with shop air or vacuuming it out. remove pump:
• The heat exchanger fins are sharp but can be • Do not drop or lose drive coupling between
easily bent. Treat them with care to avoid per- pump and motor.
sonal injury and damaging them. • Do not discard old pump. Remove both fit-
• Remove the cooler from the machine for a tings, Keep v-clamp, Seal old pump in a
more thorough cleaning job. waterproof bag, Package into protective con-
tainer, and Return to nearest Lincoln Electric
7. Motor lubrication is recommended once a year: FSS center.
• Remove plug over lube port at top of motor
near fan end.
• Add 20 drops of electric motor or SAE 10 oil
then reinstall plug.
POWER WAVE 450

C-5 C-5
ACCESSORIES
g. Install new pump and v-band clamp:

• Do not apply any lubricant to pump’s
drive coupling.
• Pump body is properly oriented with its
strainer at the 6:00 position.
• Tighten v-clamp with 15 to 30 in-lbs. of
torque.
h. Attach coolant lines to QD and reser-
voir.
i. Wipe dry all areas wetted by coolant.
Dispose of towels in an environmentally
responsible manner (see Recommended
Coolants).
j. Reinstall cooler into machine.
4. Motor removal or replacement:

• Do not reuse the 4 internal-tooth star
washers. Replace with new parts.
5. Installing the fan:

• Slide onto motor shaft until the fan is
located between 0.25 to 0.50 inches
from the heat exchanger.
• Tighten set screw with 65 to 75 in-lbs
of torque against motor shaft’s flat.
• Fan rotation is counterclockwise, as
viewed from fan-end of motor’s shaft.
• Fan pulls air through the heat
exchanger, blows it over the motor,
then exhausts it through the reservoir.
POWER WAVE 450

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
C-6
NOTES
POWER WAVE 450

C-6
D-1 D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
Input Filter Capacitor Discharge.................................................................................................D-2
Preventive Maintenance .............................................................................................................D-5
General Component Locations...................................................................................................D-6
POWER WAVE 450

D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.
ROUTINE AND PERIODIC

MAINTENANCE
Perform the following preventive maintenance at least
once every six months.
WARNING
Prior to performing preventive maintenance it is impor-
tant to perform the following capacitor discharge pro-
cedure to avoid electric shock.
INPUT FILTER CAPACITOR DIS-

CHARGE PROCEDURE
1. Turn off input power and disconnect input power

lines.
2. Remove the hex head screws from the top and the
sides of the machine. Remove the handle bar and
the wrap-around machine cover.
3. Remove the two case sides. There are hex head
screws on each side.
CAUTION
TO PREVENT DAMAGE TO MACHINE, AVOID
UNNECESSARY MOVEMENT OF FRONT PANEL.
4. Obtain a high resistance and high wattage resistor

(25-1000 ohms and 25 watts minimum). This
resistor is not supplied with the machine. Secure
this resistor to a piece of insulating material such
as a glastic board. See Figure D.3. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
POWER WAVE 450

D-3 D-3
MAINTENANCE
FIGURE D.1 – RESISTOR LOCATIONS
5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN EACH
TERMINAL AND FROM EACH RESISTOR
TO CASE GROUND
5. Locate two sets of two resistors on the left side of

the machine and three sets of two resistors on the
right side of the machine. See Figure D.1. Do not
touch the resistors or any other internal machine

component. Using a DC voltmeter, check for any
DC voltage that may be present across the termi-
nals of each resistor and from each resistor to
case ground (20 measurements in all). If a voltage
is present, be careful not to touch these resistors.
WARNING

• Proceed with caution being care-
ful not to touch any internal
machine components during the
discharge procedure.
POWER WAVE 450

D-4 D-4
MAINTENANCE
6. Locate the #9 and #12 terminals, identified by the FIGURE D.3 – RESISTORS WITH LEADS
“Discharge” labels, on each of the four Switch CONNECTED
Boards. See Figure D.2.
7. Using insulated, needle nose-type jumper leads
and insulated gloves, connect one jumper lead to
one end of the resistor obtained in step 4.
Connect the other jumper lead to the other end of
the resistor.
8. Carefully connect the needle nose end of one of
the jumper leads to terminal #9. See Figure D.3.
Connect the needle nose end of the other jumper
lead to terminal #12. Terminals #9 and #12 are
indicated by the “Discharge” label. Leave resistor
connected for 10 seconds. DO NOT TOUCH TER-
MINALS, RESISTORS, OR ANY INTERNAL
MACHINE COMPONENT DURING THIS PROCE-

DURE!
FIGURE D.2 – DISCHARGE LABEL
D
I
S
C
D
I
S
C
D
H
A
R
G
H
A
R
G
I
E E
S
C 9. Check voltage across terminals (9 and 12) with a
H DC voltmeter. Terminal 9 has positive polarity and
A terminal 12 has negative polarity. Voltage should
R be zero. If any voltage remains, repeat this capac-
G itor discharge procedure.
D D
I I
S
C
S
C
E 10. Repeat discharge procedure (steps 7, 8 and 9) for
H H
A A
R
G
E
R
G
E
each of the other three Switch Boards.
POWER WAVE 450

D-5 D-5
MAINTENANCE
PREVENTIVE MAINTENANCE 8. Reconnect the shunt and wire #467 to the nega-
tive (-) output terminal. Make sure the connection
Perform the following preventive maintenance proce- is tight.
dures at least once every six months. It is good prac-
tice to keep a preventive maintenance record; a record 9. Replace and secure the machine covers and han-
tag attached to the machine works best. dle bar.
1. Remove the hex head screws from the sides and 10. Remove the overlay from the front panel of the
top of the machine. Remove the handle bar and machine. Clean the plastic case with a low pres-
the machine wrap-around cover. Remove the two sure airstream. Wipe the sensors (Fig D.4 Item 8)
case sides. There are hex head screws on each with a clean, soft cloth. Make sure the sensors are
side. not scratched in the process.
2. Perform the input filter capacitor discharge proce- 11. Check the back of the overlays. If the bar code
dure described at the beginning of the (black square(s)) on the back of the overlay is
Maintenance Section. scratched, apply a dull black spray finish to the
scratched-off areas only. If a large area of the bar
3. Disconnect the shunt from the negative (-) output code is scratched off, the machine either will not
terminal. Failure to do this could cause damage to recognize the overlay or will mistake the overlay
the shunt circuitry. for another one.
4. Clean the inside of the machine with a low pres- 12. Inspect gun and cables for good condition.
sure airstream. Be sure to clean the following
components thoroughly (Refer to Figure D.4):
• Display, Snubber, and Shunt printed circuit
boards
• Power Switch
• Main Transformer
• Auxiliary Transformers
• Input Rectifier
• Heat Sink Fins
• Input Filter Capacitors

• Output Terminals
• Terminal Strip
5. Examine the capacitors for leakage or oozing.
Replace if needed.
6. Examine the wrap-around and side covers for
dents and breakage. Repair them as needed. The
covers must be kept in good condition to assure
that high voltage parts are protected and that cor-
rect spacings are maintained.
7. Remove welding cables and check the electrical
ground continuity. Use an ohmmeter to measure
the resistance between each output terminal and
an unpainted surface of the machine case. The
meter reading should be 500,000 ohms or more. If

the meter reading is less than 500,000 ohms,

check for electrical components that are not prop-
erly insulated from the case. Correct component
insulation, if needed.
POWER WAVE 450

D-6 D-6
MAINTENANCE
FIGURE D.4 – GENERAL COMPONENT LOCATIONS
1 DISPLAY BOARD (BACK OF PANEL)

2 POWER SWITCH
3 MAIN TRANSFORMER
4 AUXILIARY TRANSFORMER
5 INPUT RECTIFIER
6 HEAT SINK FINS
7 OUTPUT TERMINALS
8 OVERLAY BAR CODE SENSORS
9 TERMINAL STRIP (LOCATION)
4
1
8
6
3
POWER WAVE 450

Section E-1 Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION-
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Voltage ...............................................................................................................................E-2
Precharge (Soft Start)..................................................................................................................E-3
Switch Boards.............................................................................................................................E-4
Main Transformer ........................................................................................................................E-5
Output Rectifier and Choke ........................................................................................................E-6
Control Board..............................................................................................................................E-7
Power Board ...............................................................................................................................E-8
Display Board..............................................................................................................................E-9
Thermal Protection....................................................................................................................E-10
Protective Circuits.....................................................................................................................E-10
Over Current Protection .....................................................................................................E-10
Over Voltage Protection......................................................................................................E-10
Field Effect Transistor (FET) Operation .....................................................................................E-11
Pulse Width Modulation............................................................................................................E-12
Minimum Output.................................................................................................................E-12
Maximum Output................................................................................................................E-12
FIGURE E.1 – POWER WAVE BLOCK LOGIC DIAGRAM

INPUT
RECTIFIER MAIN OUTPUT
INPUT AND TRAMSFORMER RECTIFIER
CONTACTOR RECONNECT CHOKE POSITIVE
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
COOLER DISPLAY DISPLAY
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
POWER WAVE 450

E-2 E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE CIRCUIT
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
GENERAL DESCRIPTION INPUT VOLTAGE

The Power Wave is an inverter type power source that The Power Wave can be connected for a variety of
can support most welding procedures. It is modeled three phase voltages. The initial input power is applied
after a P.C. (Personal Computer). There are no specif- to the Power Wave through a line switch located on
ic welding characteristics designed into the power the front of the machine. The voltage is connected to
portion of the machine. All welding characteristics are the Protection Board where it is current limited before
programmed into the software package. being passed on to the input rectifier and reconnect
switches. The reconnect panel allows the user to
switch to low or high voltage and connect the Auxiliary
Transformer to the appropriate input voltage. The
Auxiliary Transformer supplies power to the fan motors
and, through the Protection Board, to the printed cir-
cuit boards and wire feeder(s).
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER WAVE 450

E-3 E-3
THEORY OF OPERATION
FIGURE E.3 – PRECHARGE CIRCUIT
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
PRECHARGE (SOFT START)

The Protection Board contains a “soft Start” circuit,
which is powered by the Auxiliary Transformer. During

precharge or “soft start” only two phases of the input
power, with current limiting, are connected to the input
rectifier. This AC input voltage is rectified, and the DC
voltage is applied through the Reconnect Switches to
the input capacitors located on the Switch Boards.
The Protection Board monitors the voltage across the
capacitors. When the capacitors have charged to an
acceptable level, the Protection Board energizes the
Main Input Contactor, making all three phases of input
power available to the input capacitors. At this point
the Power Wave is in the “Run Mode” of operation. If
the capacitors become under- or overvoltaged, the
Protection Board will de-energize the Main Input
Contactor, and the machine output will be disabled.
POWER WAVE 450

E-4 E-4
THEORY OF OPERATION
FIGURE E.4 – SWITCH BOARD CIRCUIT
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
SWITCH BOARDS
There are four Switch Boards in the Power Wave, each
containing an input capacitor. The capacitors on

Switch Boards #1 and #2 are always in parallel, and
the capacitors on Switch Boards #3 and #4 are always
in parallel. When the filter capacitors are fully charged,
they act as power supplies for the Switch Boards. The
Switch Boards contain the Field Effect Transistors
(FETs) which, when switched on, supply the Main
Transformer primary windings with DC current flow.
See FET operation discussion and diagrams (Figures
E.10 and E11).
POWER WAVE 450

E-5 E-5
THEORY OF OPERATION
FIGURE E.5 – MAIN TRANSFORMER
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
MAIN TRANSFORMER
Each Switch Board assembly works as a switch pair.
Each board feeds current to a primary winding of the

Main Transformer. These primary currents are moni-
tored by the Current Transformer (CT). The CT sends
a signal through the Protection Board to the Control
Board. If the primary currents become abnormally
high, the Control Board will shut off the FETs, thus dis-
abling machine output. The right and left sides of the
transformer are isolated from each other. The right
side of the transformer is supplied from Switch Boards
#1 and #2, while the left side of the transformer is sup-
plied from Switch Boards #3 and #4. The DC current
flow through each primary winding is clamped back to
each respective input capacitor when the FETs are
turned off. The firing of the four Switch Board pairs
occurs during halves of a 50 microsecond interval,
creating two constant 20 kHz square waves on the pri-
mary side of the transformer. The current flow through
the Main Transformer primaries induces a 20 kHz AC

square wave output signal at the secondary of the
Main Transformer.
POWER WAVE 450

E-6 E-6
THEORY OF OPERATION
FIGURE E.6 – OUTPUT RECTIFIER AND CHOKE
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
OUTPUT RECTIFIER AND CHOKE

The Output Rectifier receives the AC output from the
Main Transformer secondary and rectifies it to a DC

level with a 40 kHz ripple.
Since the Output Choke is in series with the positive
leg of the Output Rectifier and also in series with the
welding load, a filtered DC output is applied to the
machine output terminals.
POWER WAVE 450

E-7 E-7
THEORY OF OPERATION
FIGURE E.7 – CONTROL BOARD
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
CONTROL BOARD
The Control Board is at the heart of controlling the out-
put of the machine. With the information it receives

from the Shunt (current feedback), the voltage sensing
leads, the wire feeder(s), and the other printed circuit
boards, the Control Board optimizes the welding
results by regulating the FETs’ switching times, which
in turn control the output of the machine. The Control
Board also monitors the thermal protection devices
and the regulation and fault signals produced on the
Protection Board.
POWER WAVE 450

E-8 E-8
THEORY OF OPERATION
FIGURE E.8 – POWER BOARD
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
POWER BOARD
The Power Board provides gate drives for the FETs on
the Switch Boards. It does so based on the “turn-on”

signals it receives from the Control Board. One func-
tion of the Power Board is to isolate the Control Board
from the Switch Boards. The Power Board also pro-
vides the other printed circuit boards with the DC volt-
age supply they require.
POWER WAVE 450

E-9 E-9
THEORY OF OPERATION
FIGURE E.9 – DISPLAY BOARD
INPUT
LEFT
SWITCH
THREE BOARD
PHASE
INPUT FET
POWER ASSEMBLY
AUX. CT
INPUT
LINE TRANS
SWITCH
RIGHT
SWITCH
PROTECTION BOARD
FAN
BOARD
FET
NEGATIVE
ASSEMBLY
SHUNT
POWER
BOARD
SNUBBER AND
SENSE LEADS
CONTROL
BOARD
WATER LCD
BOARD
KEYPAD
PC
INTERFACE
OVERLAY
WF1 WF2
DISPLAY BOARD
The Display Board allows the operator to select from
the procedures that are programmed into the

machine, and it lets the Control Board know which
procedure was selected. These procedures are pro-
grammed into the machine’s software package. The
Display Board is used to communicate with the oper-
ator. It determines what Overlay is installed in the
machine and which buttons are active on the keypad.
It also controls the LCD display, the lights on the front
of the machine, the Piezo Buzzer and the water cool-
er. Through the use of a current serial loop, the
Display Board and Control Board communicate (or
talk) to the wire feeder(s). The Display Board can also
communicate with a computer through the RS232
interface.
POWER WAVE 450

E-10 E-10
THEORY OF OPERATION
THERMAL PROTECTION PROTECTIVE CIRCUITS

Two normally closed (NC) thermostats protect the Protective circuits are designed into the Power Wave
machine from excessive operating temperatures. to sense trouble and shut down the machine before
These thermostats are wired in series and are con- damage occurs to the machine’s internal components.
nected to the Control Board. One of the thermostats
is located on the heat sink of a switch board, and the OVER CURRENT PROTECTION
other is located on the main choke. Excessive tem- If the average current exceeds 520 amps, then the
peratures may be caused by a lack of cooling air or peak current will be limited to 100 amps until the aver-
operating the machine beyond the duty cycle or out- age current decreases to under 50 amps.
put rating. If excessive operating temperatures should
occur, the thermostats will prevent output from the OVER VOLTAGE PROTECTION
machine. The displays will remain on during this time; A protective circuit is included on the Protection Board
and the yellow Thermal light, located of the front of the to monitor the voltage across the input capacitors. In
machine, will be illuminated. The thermostats are self- the event that a capacitor voltage is too high, the pro-
resetting once the machine cools sufficiently. If the tection circuit will prevent output. Also, in the event
thermostat shutdown was caused by excessive output

that a capacitor voltage is too low, the machine output

or duty cycle and the fans are operating normally, the is disabled and the “soft start” mode is repeated. The
Power Switch (SW1) may be left on and the reset protection circuit may prevent output if any of the fol-
should occur within a 15-minute period. If one or both lowing circumstances occur:
of the fans are not turning or the air intake louvers are
obstructed, then the power must be removed from the 1. Capacitor condition is required. (Required if
machine, and the fan problem air obstruction must be machine has been off for a long period of time and
corrected. is connected for high input voltage operation.)
2. Voltage across a capacitor exceeds 370 volts.
(High line surges or improper input voltage connec-
tions.)
3. Voltage across a capacitor is under 170 volts. (Due
to improper input voltage connections.)
4. Internal component damage.
POWER WAVE 450

E-11 E-11
THEORY OF OPERATION
FIELD EFFECT TRANSISTOR (FET) OPERATION

FIGURE E.10 – FIELD EFFECT TRANSISTOR OPERATION
GATE DRAIN
SOURCE TERMINAL TERMINAL
TERMINAL (0 VOLTS)
DRAIN (N)
SOURCE (N)
N CHANNEL
SUBSTRATE (P)
A. PASSIVE
GATE
TERMINAL
(+ 6 VOLTS)
SOURCE (N) DRAIN (N)

ELECTRONS
B. ACTIVE
An FET is a type of transistor. FETs are semi- Drawing B above shows the FET in an active
conductors well suited for high-frequency mode. When the gate signal, a positive DC
switching. voltage relative to the source, is applied to the
gate terminal of the FET, it can’t conduct cur-
Drawing A above shows an FET in a passive
rent. A voltage supply connected to the drain
mode. There is no gate signal (zero volts) from
terminal will allow the FET to conduct and
the source and, therefore, no current flow. The
henceforth supply current to downstream
drain terminal of the FET may be connected to
components. Current will flow through the
a voltage supply. But since there is no con-
conducting FET to downstream components
duction, the circuit will not supply current to
as long as the gate signal is present. This is
downstream components connected to the
similar to turning on a light switch.
source. The circuit is turned off like a light
switch in the OFF position.
POWER WAVE 450

E-12 E-12
THEORY OF OPERATION
PULSE WIDTH MODULATION

FIGURE E.11 – TYPICAL FET OUTPUTS
(+)
(–)
48 µsec
1 µsec
50 µsec
1 µsec
MINIMUM OUTPUT
(+)
(–)
20 µsec
10 µsec 20 µsec
50 µsec
MAXIMUM OUTPUT
The term PULSE WIDTH MODULATION is MAXIMUM OUTPUT

used to describe how much time is devoted to
By holding the gate signals on for 20 micro-

conduction in the positive and negative por-

tions of the cycle. Changing the pulse width is seconds each and allowing only 10 microsec-
known as MODULATION. Pulse Width onds of dwell time (off time) during the 50-
Modulation (PWM) is the varying of the pulse microsecond cycle, the output is maximized.
width over the allowed range of a cycle to The darkened area under the top curve can be
affect the output of the machine. compared to the area under the bottom curve.
The more dark area under the curve, the more
MINIMUM OUTPUT power is present.
By controlling the duration of the gate signal,
the FET is turned on and off for different dura-
tions during a cycle. The top drawing above
shows the minimum output signal possible
over a 50-microsecond time period.
The positive portion of the signal represents
one FET group1 conducting for 1 microsec-
ond. The negative portion is the other FET
group1. The dwell time (off time) is 48 micro-

seconds (both FET groups off). Since only 2
microseconds of the 50-microsecond time
period is devoted to conducting, the output
power is minimized.
A FET group consists of the sets of FET modules grouped onto one switch board.
1
POWER WAVE 450

Section F-1 Section F-1
TABLE OF CONTENTS
-TROUBLESHOOTING & REPAIR SECTION-
Troubleshooting & Repair Section.......................................................................................Section F

How to Use Troubleshooting Guide............................................................................................F-2
PC Board Troubleshooting Procedures and Replacement.........................................................F-3
Troubleshooting Guide ................................................................................................................F-5
Test Procedures ........................................................................................................................F-23
Capacitor Discharge Procedure .........................................................................................F-23
Auxiliary Transformer Test 1 ...............................................................................................F-27
Auxiliary Transformer Test 2 ...............................................................................................F-31
Auxiliary Transformer Primary Wiring Harness Test ...........................................................F-35
Auxiliary Transformer #1 Secondary and Wiring Harness Test ..........................................F-39
Input Power and Wiring Harness Test ................................................................................F-43
Input Rectifier Resistance Test ...........................................................................................F-47
Output Shunt/Welding Feedback Test................................................................................F-51
Piezo-Electric Alarm Buzzer Test........................................................................................F-55
Output Rectifier Diodes Test ..............................................................................................F-57

Field Effect Transistor/Switch Board Test...........................................................................F-59
Snubber and Bleeder Resistor Test....................................................................................F-75
Reconnect Switch Test 1....................................................................................................F-81
Reconnect Switch Test 2....................................................................................................F-85
Static Capacitor Balance Test ............................................................................................F-89
Dynamic Capacitor Balance Test .......................................................................................F-93
Internal and Auxiliary Supply Voltage Test .........................................................................F-97
Main Contactor Test .........................................................................................................F-103
Serial Loop Wiring Harness Test ......................................................................................F-107
Wire Feeder 1 Trigger Circuit Test ....................................................................................F-111
Wire Feeder 2 Trigger Circuit Test ....................................................................................F-115
Trigger Circuit and Wiring Harness Test ...........................................................................F-119
Internal Remote Control Test............................................................................................F-123
K941-1 Remote Control Kit Test ......................................................................................F-127
K941-1 Remote Control Kit Trigger Circuit Test ...............................................................F-131
LCD Display Test ..............................................................................................................F-135

Calibration Procedures............................................................................................................F-139
Sensor Calibration Test (For Display Board) ....................................................................F-141
Quick Voltage Calibration .................................................................................................F-143
Full Voltage Calibration.....................................................................................................F-145
Full Voltage Calibration Using A Welding Arc...................................................................F-147
Current Calibration ...........................................................................................................F-151
Replacement Procedures........................................................................................................F-155
T1 Auxiliary Transformer Removal and Replacement ......................................................F-155
Water Cooler Removal and Replacement ........................................................................F-157
Water Cooler Disassembly ...............................................................................................F-161
T2 Auxiliary Transformer Removal and Replacement ......................................................F-165
Fan Motor Removal and Replacement.............................................................................F-167
Input Rectifier Removal and Replacement.......................................................................F-171
Printed Circuit Board Removal and Replacement ...........................................................F-175
Display Board Removal and Replacement.......................................................................F-179
Main Input Contactor (CR1) Removal and Replacement .................................................F-183

Output Rectifier Bridge Removal and Replacement ........................................................F-187
FET Module Removal and Replacement ..........................................................................F-191
Main Transformer Removal and Replacement .................................................................F-197
Pre-Powerup Switch Board Test Procedure.....................................................................F-199
POWER WAVE 450

F-2 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 Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled “Recommended Course of
tions. Simply follow the three-step procedure Action,” lists the most likely components that
listed below. 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
Step 1. LOCATE PROBLEM (SYMPTOM). Look are a number of possible components, check the
under the column labeled “PROBLEM (SYMP- components in the order listed to eliminate one
TOMS). This column describes possible symp- possibility at a time until you locate the cause of
toms that the machine may exhibit. Find the list- your problem.
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems, All of the referenced test procedures referred to in
Function Problems, and Welding Problems. the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
Step 2. PERFORM EXTERNAL TESTS. The locate each specific Test Procedure. All of the
second column, labeled “POSSIBLE AREAS OF referred to test points, components, terminal
MISADJUSTMENT(S),” lists the obvious external strips, etc., can be found on the referenced elec-
possibilities that may contribute to the machine trical wiring diagrams and schematics. Refer to
symptom. Perform these tests/checks in the the Electrical Diagrams Section Table of Contents
order listed. In general, these tests can be con- to locate the appropriate diagram.
ducted without removing the case wrap-around
cover.
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 1-888-935-3877.
POWER WAVE 450

F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT

• Remove the PC Board from the static-shielding bag
WARNING 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
ELECTRIC SHOCK can kill. can’t be installed immediately, put it back in the sta-
Have an electrician install and ser- tic-shielding bag.
vice this equipment. Turn the • If the PC Board uses protective shorting jumpers,
machine OFF before working on don’t remove them until installation is complete.
equipment. Do not touch electrically hot parts.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shield-
ing bag. This will prevent further damage and allow
proper failure analysis.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be 4. Perform any necessary PC Board calibration pro-
traced to poor electrical connections. To avoid prob- cedures. See the flow chart on the next page.
lems when troubleshooting and replacing PC boards, 5. Test the machine to determine if the failure symp-
please use the following procedure: tom has been corrected by the replacement PC
1. Determine to the best of your technical ability that board.
the PC board is the most likely component causing NOTE: Allow the machine to heat up so that all elec-
the failure symptom. trical components can reach their operating
2. Check for loose connections at the PC board to temperature.
assure that the PC board is properly connected. 6. Remove the replacement PC board and substitute
3. If the problem persists, replace the suspect PC it with the original PC board to recreate the original
board using standard practices to avoid static elec- problem. Recalibrate if required.
trical damage and electrical shock. Read the warn- a. If the original problem does not reappear
ing inside the static resistant bag and perform the by substituting the original board, then the
following procedures. PC board was not the problem. Continue
PC Board can be damaged by to look for bad connections in the control
static electricity. wiring harness, junction blocks, and termi-

nal strips.
• Remove your body’s static
charge before opening the stat- b. If the original problem is recreated by the
ic-shielding bag. Wear an anti- substitution of the original board, then the
ATTENTION static wrist strap. For safety, PC board was the problem. Reinstall the
Static-Sensitive replacement PC board, recalibrate if
use a 1 Meg ohm resistive cord
Devices
connected to a grounded part of required, and test the machine.
Handle only at
Static-Safe the equipment frame. 7. Always indicate that this procedure was followed
Workstations • If you don’t have a wrist strap, when warranty reports are to be submitted.
touch an unpainted, grounded, NOTE: Following this procedure and write on the war-
part of the equipment frame. ranty report, “INSTALLED AND SWITCHED
Reusable
Container Keep touching the frame to pre- PC BOARDS TO VERIFY PROBLEM,” will help
Do Not Destroy vent static build-up. Be sure not avoid denial of legitimate PC board warranty
to touch any electrically live claims.
parts at the same time.
• Tools which come in contact with the PC Board

must be either conductive, anti-static or static-dis-
sipative.
POWER WAVE 450

F-4 F-4
PC BOARD REPLACEMENT
CALIBRATION REQUIREMENTS
SHUNT
DISPLAY SNUBBER CONTROL
AMPLIFIER
BOARD BOARD BOARD
BOARD
REPLACED REPLACED REPLACED
REPLACED
IF POSSIBLE CURRENT
QUICK CALIBRATION
VOLTAGE
CALIBRATION
FULL
VOLTAGE
CALIBRATION
POWER WAVE 450

F-5 F-5
TROUBLESHOOTING GUIDE Observe Safety Guidelines

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical dam- 1. Contact your local authorized
age is evident when the sheet Lincoln Electric Field Service
metal cover(s) are removed. Facility for technical assis-
tance.
Machine is dead – no output – no 1. Check the main input fuses. If 1. If fuse (F1) quickly fails, per-
fans – no displays. open, replace. form the Auxiliary
Transformer Primary Wiring
2. Make certain that the input

Harness Test.
power switch (S1) is in the
“ON” position. 2. If fuse (F1) does not fail, per-
form the Auxiliary
3. Check for proper input voltage
Transformer Test #1.
– must match the rating on the
machine nameplate.
4. Make certain the reconnect
panel is configured properly for
the applied voltage.
5. Check fuse (F1) in the recon-
nect panel. If faulty, replace
with 5-amp slow-blow fuse.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
POWER WAVE 450

F-6 F-6


OUTPUT PROBLEMS
Machine has no output – fans are 1. Turn power OFF immediately. 1. Perform the Auxiliary
running – display is on – a “click- Transformer Test #1
ing” sound is heard coming from
(per machine nameplate). 2. Perform the Main Contactor
the machine.
Test.
panel is configured properly for 3. Perform the Reconnect
the applied voltage. Switch Test #1.
4. Perform the Reconnect
Switch Test #2.

5. Perform the Input Rectifier
Test.
6. Perform the Switch Board
Test.
7. Perform the Snubber and
Bleeder Resistor Test.
8. The protection board may be
faulty. Replace.
9. The input filter capacitors may
be faulty. Replace.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-7 F-7


OUTPUT PROBLEMS
Fans run slow or intermittently – 1. Make certain the reconnect 1. Perform the Auxiliary
display is very dim – no weld out- panel and fuse (F1) jumper “A” Transformer Test #1.
put. is configured properly for the
input voltage being applied.
Machine has no output – no dis- 1. Make sure that not more than 1. The circuit breaker (5 amp)
play – fans run – circuit breaker (5 5 amps of auxiliary power are may be faulty. Test or replace.
amp) repeatedly trips. being drawn.

2. Perform the Auxiliary
2. Remove the wire feeder control Transformer #1 Secondary
cable from the Power Wave. If and Wiring Harness Test.
the symptom disappears, the
wire feeder or control cable is
faulty.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-8 F-8


OUTPUT PROBLEMS
Machine has no output – no fans 1. Check for proper input voltage 1. Perform the Input Power and
– no display. Main input fuses are connections. Wiring Harness Test.
open indicating excessive input
2. Make certain the reconnect 2. Perform the Input Rectifier
current draw.
panel is configured properly for Test.
the applied voltage.
3. Replace the input fuses with Switch Test #1.
proper size and ratings.

Test.
Machine has no output – no dis- 1. Check circuit breaker (5 amp) 1. Perform the Auxiliary
play – fans run. located on the front panel. Transformer Test #1.
Reset if necessary.
2. Perform the Internal and
Auxiliary Supply Voltage Test.
Machine has no output – fans run 1. Check for loose or faulty con- 1. Replace the Power P.C. Board.
- Display flashes On and Off nections at the Power P.C.
repeatedly. Board. See Wiring Diagram.

CAUTION
1-888-935-3877.
POWER WAVE 450

F-9 F-9


OUTPUT PROBLEMS
Circuit breaker (5 amp) trips when 1. Make sure that not more than 1. The 5 amp circuit breaker may
gun trigger is pulled – fans run. 5 amps of auxiliary power are be faulty. Test or replace.
being used.
2. Perform the Trigger Circuit
2. Remove the wire feeder’s con- and Wiring Harness Test.
trol cable(s) from the Power
Wave. If the symptoms disap-
pear, replace the wire feeder
and cables with known good

equipment. If the problem is
solved, the wire feeder or con-
trol cable is faulty.
The machine intermittently loses 1. If after a few seconds the con- 1. Perform the Static Capacitor
output. The wire feeder still feeds tactor “pulls” back in, then Balance Test.
wire. check for high input line
2. Perform the Welding
voltage.
Feedback Test.
3. The control board may be
faulty. Replace.
4. The shunt board assembly may
be faulty. Replace.
Test.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-10 F-10


OUTPUT PROBLEMS
Machine has no welding output – 1. Make sure that the machine 1. Perform the Wire Feeder
fans run – display is on. was powered up with a proper- Trigger Circuit Test (#1 or #2)
ly installed overlay. Without an for the appropriate wire feeder
overlay installed in the Power receptacle (amphenol).
Wave, or an invalid overlay
2. If a K941-1 Remote Control Kit
installed, the machine will not
is attached to the Power Wave,
have welding output.
then perform the K941-1
2. Check to see if the Limits or Remote Control Kit Trigger
Setup overlay is installed on Circuit Test.

the front panel. These two
overlays cannot be used for
Switch Test #1.
welding.
4. Perform the Output Rectifier
Diodes Test.
per machine nameplate.
Test.
panel is configured properly.
5. Check to see that when the
trigger is pulled on the wire
feeder the wire feeder’s voltage 7. Perform the Static Capacitor
display changes to indicate arc Balance Test.
voltage. If this does not hap-
8. Perform the Dynamic
pen, the feeder or control
Capacitor Balance Test.
cable may be faulty.
6. Check wire feeder control

cable for loose or faulty con-
nections.
7. If the machine is connected for
380VAC or higher and has not
been used for a long period of
time, the capacitors may
require “conditioning.” Let the
Power Wave run at an idle
state for 30 minutes.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-11 F-11


OUTPUT PROBLEMS
Machine regularly overheats-yel- 1. Welding application may 1. One of the thermostats located
low light (LED) on the front panel exceed recommended duty on the output rectifier or FET
glows, indicating a thermal over- cycle. heat sink may be faulty. Test
load. The display is on. or replace.
2. Dirt and dust may have
clogged the cooling channels
inside the machine. Refer to
the Maintenance Section of
this manual.
3. Air intake and exhaust louvers

may be blocked due to inade-
quate clearance around
machine.
4. Make sure both fans are func-
tioning correctly.
Machine does not appear to over- NONE 1. Check thermostats on output

heat, but yellow light turns on and rectifier and switch board #1.
off intermittently. Output is dis- These thermostats are normal-
abled whenever yellow light is on. ly closed.
2. Check leads from thermal
switches to molex plug J23 on
the control board for loose or
faulty connections.

faulty. Replace, and perform
voltage calibration and current
calibration procedures.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-12 F-12


FUNCTION PROBLEMS
The voltage and or wire feed 1. Certain limits may have been NONE
speed will not adjust to user satis- imposed on the welding para-
faction. meters. Refer to the Limits
Overlay section of this manual.
The voltage and or wire feed 1. When the Limits Overlay or the 1. Try the other wire feeder
speed can be adjusted on the Setup Overlay is installed in receptacle. If the problem is
wire feeder, but the changes are the Power Wave, the machine solved, the initial receptacle or
not shown on the Power Wave and wire feeder displays do associated wiring is faulty.
display. not match. These overlays
2. If the problem persists with
cannot be used for welding.
both wire feeder receptacles,
2. If two wire feeders are con- check or replace the wire feed-
nected to the Power Wave, er and control cable.
only one of the feeder’s set-
3. If the wire feeder and control
tings can be displayed on the
cable are OK, then perform the
Power Wave at one tme. Pull
Serial Loop Wiring Harness
the trigger of the wire feeder
Test.
whose settings you want dis-
played on the Power Wave. 4. The display board may be
faulty. Replace and perform
voltage calibration.

calibration.
The Dual Procedure overlay is 1. Check for proper installation of 1. Perform the Serial Loop
installed, and the user cannot the Dual Procedure overlay. Wiring Harness Test.
change from procedure “A” to
2. Check the Dual Procedure Gun
procedure “B” or vice versa.
Trigger or separate dual proce-
dure switch.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-13 F-13


FUNCTION PROBLEMS
The display cannot be seen clear- 1. Adjust the viewing angle of the 1. Perform the LCD Display Test.
ly or cannot be seen at all. display. Follow the instructions
provided in the Operation
Section of this manual. (Look
under the “LCD DISPLAY
ADJUSTMENTS” in the “CON-
TROLS AND SETTINGS” sub-
section of the Operation
Section.)
Machine does not respond to 1. Each time an overlay is 1. Using the test and calibration
keys being pressed, or the changed, make certain that the overlay L9660-255, perform
machine has improper displays. machine is powered-up with the keyboard/LED test. See
the new overlay in place. overlay.
2. Make certain that the correct 2. Perform the Serial Loop
overlay ID number is displayed Wiring Harness Test.
on power-up. Refer to the
3. Replace the control board and
Operation Section of this
perform voltage calibration and
manual for the overlay descrip-
current calibration.
tion.
4. Replace the display board and
3. In some cases, some of the
perform voltage calibration.
keys on the overlay may be
locked out. Refer to the 5. Replace the power board.
Operation Section of this

manual for the overlay descrip-

tions.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-14 F-14


FUNCTION PROBLEMS
Machine display reads “Error 1. Make certain the overlay is 1. Perform the Sensor
Invalid Overlay,” or it displays an installed properly. Calibration Test.
invalid ID number on power-up.
2. Inspect the infrared sensors on
the front panel. If they are
dirty, blow them out with low
pressure air and clean with a
soft cloth.
3. Inspect for damage to the Bar

Code(s) (black squares) on the
back of the overlay. Also
check for dirt build-up on back
of overlay. Wipe off with a soft
rag.
Machine displays “ERROR: S.L. 1. Contact your local Lincoln 1. Perform the Serial Loop
NOT INITIALIZED” on power-up. Authorized Field Service Wiring Harness Test.
Facility for technical assis-
tance.
calibration.
3. The display board may be
4. The power board may be
faulty. Replace.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-15 F-15


FUNCTION PROBLEMS
The Beeper (Piezoelectric Buzzer) 1. Background noise may be too 1. Perform the Piezoelectric
cannot be heard – machine oper- loud for user to hear beeper. Buzzer Test.
ating normally.
The welding parameters that were 1. Make certain that a remote 1. Check the continuity of wire
saved in memory are different control unit is NOT connected. #445 (8J44 to 8J16).
when recalled. When a remote control unit is
2. The power board may be
used, the weld parameters are
faulty. Replace.
set by the remote control
potentiometers. 3. The display board may be
faulty. Replace.
The water cooler does not turn 1. Make sure that the water cool- 1. Perform the Auxiliary
on. er has been installed and also Transformer #2 Test.
enabled. Refer to the Setup
2. Check the continuity of leads
Overlay description in the
#453, 454, 455 & 456. From
Operation Section of the
plug J3 to J11. See wiring dia-
manual.
gram.
2. If the water cooler is enabled
but there is insufficient flow
faulty. Replace.
rate in the water cooler hose,

the Power Wave will beep 4. The water cooler may be faulty.
loudly, and the water cooler
will shut down. Prime the
water cooler. Refer to the
Setup Overlay description in
the Operation Section of this
manual.
3. The coolers circuit breaker
may have tripped. Reset if
necessary
CAUTION
1-888-935-3877.
POWER WAVE 450

F-16 F-16


FUNCTION PROBLEMS
The machine beeps without the If the water cooler is enabled and 1. Perform the Auxiliary
keys being pressed. the flow switch inside the water Transformer #2 Test.
cooler opens (due to inadequate
2. The water cooler may be
coolant flow rate), the machine
defective. Replace.
indicates this by beeping. This
happens regardless of the overlay 3. Check the continuity of lead
placed on the machine. In this #453, 454, 455 & 456 from
case, do the following. plug J3 to J11. See wiring dia-
gram.
1. Turn the machine off and on a
couple of times and see if the 4. The display board may be
beeping continues. If the flow faulty. Replace.
rate dropped momentarily, then
turning the machine off and on
eliminates the beeping. A
momentary drop in flow rate
could be due to a temporary
restriction in the water cooler
hose.
2. Check the water cooler and
accessory hoses for kinks,
internal obstructions or block-
age, or ruptures. If such prob-
lems were found then correct
them. Turn the machine Off

and On to check if the beeping
has been eliminated.
3. Check the water cooler fluid
level. Low coolant level could
cause the flow rate to drop.
4. Prime the water cooler. Refer
to the Setup Overlay section
of this manual for instructions.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-17 F-17


FUNCTION PROBLEMS
Foreign characters are shown on Contact your local Lincoln 1. Make sure molex plug J19 is
the Power Wave display. Authorized Field Service Facility. plugged into the Display board
securely and the pins are
secure in the plug body.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-18 F-18


FUNCTION PROBLEMS
The control knob on the Remote 1. Make sure that a stick welding 1. Perform the (K941-1) Remote
Control Kit (K941-1) does not procedure is selected on the Control Kit Test or install a
change the preset current on the Power Wave. new K941-1.
Power Wave display.
2. Make certain that the (K941-1) 2. Perform the Internal Remote
remote control is securely Control Test.
plugged into the Power Wave 6
pin amphenol receptacle.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-19 F-19


WELDING PROBLEMS
Machine loses output while weld- 1. Check the yellow High 1. Perform the Welding
ing. Fans and display are func- Temperature light on the front- Feedback Test.
tioning properly. panel. If the light is “ON,” then
refer to the Output Problems
Test.
section in this table relating to
this condition. 3. Perform the Snubber and
2. Check for proper input volt-
ages (per machine nameplate). 4. Perform the Static Capacitor

Balance Test.
3. Check for balanced three-
phase input supply voltages. 5. Perform the Dynamic
Capacitor Test.
4. Check electrode and work
cables for loose or poor con- 6. Perform the appropriate Wire
nections. Feeder Trigger Circuit Test.
If a K941-1 Remote Control Kit
is used, perform the K941-1
Remote Control Kit Trigger
Circuit Test.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-20 F-20


WELDING PROBLEMS
For no apparent reason the weld 1. Check for proper wire feed 1. If zero arc voltage is displayed
characteristics have changed. speed setting. In the while welding, the voltage
MIG/MAG and FCAW Modes, sense leads may be broken.
check for proper voltage set- Check the following molex
tings. In the MIG/MAG Pulse plugs and associated wiring for
Modes, check the arc length loose or faulty connections:
trim setting. These controls
J60, J62 on the snubber board
are on the wire feeder. In the
J20 on the control board

Stick Mode, check for proper
preset current setting. 2. Perform the Welding
Feedback Test.
2. Check for proper shielding gas
and gas flow. 3. The control board may be
3. Check for loose or faulty weld-
ing cables.
calibration.
The arc is “too hot,” and cannot 1. Perform the full voltage cali- 1. Check plugs J60, J62 and J20
be adjusted. bration. for loose or faulty connections.
See Wiring Diagram.
2. The snubber board may be
full voltage calibration.

calibration.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-21 F-21


WELDING PROBLEMS
Machine often “noodle welds” with 1. The machine may be trying to If problem occurs all the time -
a particular procedure. deliver too much power. When change the control board.
the average output current
exceeds a maximum limit, the
peak current is drastically cut
back. Lower the welding para-
meter settings and/or increase
the stickout length to eliminate
this problem.
Power Wave 450 – When the
average output current exceeds
540 amps, the peak output cur-
rent is folded back to 100 amps.
Erratic output or greater than 6 None Replace shunt and lead assembly.
amps reading on display with no
output.
CAUTION
1-888-935-3877.
POWER WAVE 450

F-22
TOP VIEW
J40 J41 J42 J43 J44

16 12 1 12
16 4
1 1 1
POWER BD
1 1 1 1 1 1 1 1
PROTECTION BD
1 1 1
4
16 14 6 6 14 6 4 4 4
J30 J31 J32 J33 J34 J35 J36 J37 J38 J39
GROUND PLANE
1 1 1 1 1
POWER WAVE 450

CONTROL BD
1 1 1 1
8 8 12
6 14 10 6 4 4
J20 J21 J22 J23 J24 J25 J26 J27 J28
PC BOARD CONNECTOR LOCATIONS
FIGURE F.1 – PC BOARD CONNECTOR LOCATIONS
DISPLAY
F-22
F-23 F-23
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 elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
PURPOSE FOR THE PROCEDURE

This procedure will drain off any charge stored in the four large capacitors that are part of the
FET or IGBT switch board assembly. This procedure MUST be performed, as a safety pre-
caution, before conducting any test or repair procedure that requires you to touch internal
components of the machine.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver
Insulated gloves
Jumper wire with insulated leads and needle-nose ends

High wattage resistor - 25 to 1000 ohms, 25 watts minimum
Piece of glastic board or similar insulating materials on which to secure the resistor
This procedure takes approximately 25 minutes to perform.

POWER WAVE 450

F-24 F-24
CAPACITOR DISCHARGE PROCEDURE (continued)
TEST PROCEDURE
1. Remove main input supply power to the 7. Locate the two sets of two resistors on the
machine. left side of the machine and three sets of
two resistors on the right side of the
2. With the 3/8" nut driver, remove the screws
machine. See Figure F.2. Do not touch the
that hold the handle to the machine.
resistors or any other internal machine
3. Remove the rubber gasket (cover seal) component. Using a DC voltmeter, check
from the lift bail. for any DC voltage that may be present
across the terminals of each resistor and
4. With the 5/16" nut driver, remove the sheet
from each resistor to case ground (20 mea-
metal screws from the case top.
surements in all). If a voltage is present, be
5. With the 5/16" nut driver, remove the careful not to touch these resistors.
screws holding the right and left case
8. Locate terminals #9 and #12 on the switch

sides. Remove the case sides by lifting up
boards. They can be identified by the
and out.
“Discharge” labels, which are located on
6. Obtain a high resistance and high wattage each of the four switch boards. See Figure
resistor (25 - 1000 ohms, 25 watts mini- F.3.
mum). This resistor is not supplied with the
machine. Secure this resistor to a piece of
insulating material such as a glastic board.
See Figure F.4. NEVER USE A SHORTING
STRAP FOR THIS PROCEDURE.
FIGURE F.2 – RESISTOR LOCATIONS

CHECK VOLTAGES BETWEEN
EACH TERMINAL AND FROM
EACH RESISTOR TO CASE
GROUND
POWER WAVE 450

F-25 F-25

FIGURE F.3 – DISCHARGE LABEL
D
I
S
C
D
I
S
C
D
H
A
R
G
H
A
R
G
I
E E
S
C
H
A
R
D
I
D
I
G
S
C
H
A
S
C
H
A
E
R R
G G
E E
WARNING

Proceed with caution. Be careful not to touch any internal machine components
during the discharge procedure.
9. Using the insulated, needle nose type 10. Carefully connect the needle nose end of
jumper leads and insulated gloves, con- one of the jumper leads to terminal #9.
nect one jumper lead to one end of the See Figure F.5. Connect the needle nose
resistor obtained in step 6. Connect the end of the other jumper lead to terminal
other jumper lead to the other end of the #12. Terminals #9 and #12 are indicated
resistor. by the "Discharge" label. Leave the resis-
tor connected for 10 seconds. DO NOT
TOUCH TERMINALS, RESISTORS, OR
ANY INTERNAL MACHINE COMPO-

NENTS DURING THIS PROCEDURE!
POWER WAVE 450

F-26 F-26

FIGURE F.4 - RESISTOR WITH LEADS CONNECTED.
11. Check the voltage across terminals #9 and 12. Repeat discharge procedure steps 9, 10,
#12 with the DC voltmeter. Terminal #9 and 11 for each of the other three switch
has positive polarity and terminal #12 has boards of the FET or IGBT switch board
negative polarity. Voltage should be zero. assembly.
If any voltage remains, repeat this capaci-
tor discharge procedure.
POWER WAVE 450

F-27 F-27
AUXILIARY TRANSFORMER TEST #1
WARNING
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer #1 and also if the correct voltages are being induced on the secondary wind-
ings of the transformer.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.6.

POWER WAVE 450

F-28 F-28
AUXILIARY TRANSFORMER TEST #1 (continued)

FIGURE F.5 - TRANSFORMER T1 AND T2 LOCATION
2
4
1. AUXILIARY TRANSFORMER T1, PLUG

1 J5 LOCATED IN BASE
2. PROTECTION BOARD
3. PLUG J30
4. AUXILIARY TRANSFORMER T1
TEST PROCEDURE
1. Remove main input supply power to the 7. After you have completed the capacitor
machine. discharge procedure for all four switch
boards, remove the PC board cover. Use

2. With the 3/8" nut driver, remove the 4

the 5/16" nut driver.
screws that hold the handle to the machine.
8. Remove plug J5 from the T2 transformer
3. Remove the rubber gasket (cover seal) from
located in the machine base assembly.
the lift bail.
This is a 6-pin molex plug with 5 wires;
4. With the 5/16" nut driver, remove the sheet see Figure F. 5 for location. T2 is con-
metal screws from the case top. nected in parallel with T1. Leaving the two
transformers connected in parallel for the
5. With the 5/16" nut driver, remove the
test might result in incorrect readings;
screws holding the right and left case sides.
therefore plug J5 should be disconnected.
Remove the case sides by lifting up and
out. 9. Remove plug J30 from the protection
board. See Figure F.1 for location of the
6. Perform the Capacitor Discharge Proce-
board and plug J30.
dure described earlier in this section of the
manual. 10. Remove the 5 leads ( 3 heavy and 2 small)
T1, T2, T3 from main input contactor CR1.
WARNING
This is a safety precaution. It prevents

Before continuing with the high voltage from being put on the
test procedure, perform the machine during the test. Wrap tape
capacitor discharge proce- around the lead ends to insulate them and
dure to avoid electric shock. prevent them from touching.
POWER WAVE 450

F-29 F-29

11. Remove plugs J32 and J33 from the pro- If these voltages are wrong or missing, check
tection board. the associated wiring to the transformer prima-
ry. Check the leads at power switch S1. See
12. Turn the main input supply power to the
the Input and Auxiliary Circuit Wiring Diagram,
machine back ON.
Figure F.6.
WARNING If the correct voltages are applied to the pri-
mary and the secondary voltages are incorrect,
ELECTRIC SHOCK the transformer may be faulty. Replace the
can kill. transformer. Refer to the T1 Auxiliary
Transformer Removal and Replacement
Proceed with caution. Be procedure in this section of the manual.
careful not to touch any
internal machine compo- 14. After the test is completed and the prob-
nents during the remainder of the test proce- lem successfully repaired, reconnect
dure. plugs J30, J32 and J33 to the protection

board.
15. Reconnect plug J5 to the T2 transformer.
13. Check for the correct AC voltage at plugs
J32 and J33 as follows. (DO NOT CHECK 16. Reconnect the 5 leads to the main con-
THE VOLTAGE ON THE PROTECTION tactor CR1.
BOARD!) 17. Install the PC board cover.
Test A: J33 - pin 1 (lead 32A) to J33 - pin 18. Install the machine case sides and top.
3 (lead 333) = 42 VAC
19. Install the handle and the lift bail rubber
Test B: J33-1 (32A) to J33-4 (334) = 24 gasket.
VAC
Test C: J32-1 (321) to J32-3 (323) = 24
VAC
Test D: J33-1 (leads 32A) to J33-6
(lead 336) = 115VAC.
If the voltage checks are good, then Auxiliary

Transformer #1 is good.
If Test C is good but Tests A and B are not cor-
rect, check the 5 amp circuit breaker (located
on the front panel of the machine). See the
Input and Auxiliary Circuit Wiring Diagram,
Figure F.6.
If all the secondary voltages are wrong or miss-
ing, check the associated wiring to the trans-
former primary. These voltages are most eas-
ily checked at the terminal strip. The correct
voltages are as follows:
H1 to H2 = 200 - 208 VAC
H1 to H3 = 220 - 230 VAC
H1 to H4 = 380 - 415 VAC

H1 to H5 = 440 - 460 VAC
POWER WAVE 450

F-30
TOP
(220VAC) FAN
BOT. H1 H1 321 J32

(220VAC) FAN 1 1 1
(H1) 24VAC 323 CR1 CR2
4 3 J32
H2 H2 P71
4 R(115V) 6 336 J33
200-208 (H2) 200-208V 6
U(42V) 333 J33
5 3
4 FUSE
(L1A) 3 220-230 (H3) H3 H3
F1 N(24V) 334 J33
2 3 4
(L3A) 2 1 220-230V
(321B) W 33 32A J33
2 1
POWER 380-415 (H4) H4 3 H4 P70 5A
SWITCH JUMPER "A" 380-415V CIRCUIT
(HIB) 321A BREAKER
SWI AUX. PROTECTION
TRANSF. J32
BOARD
440-460 (H5) H5 6 H5 1
MAIN R CR1 R CR2
CONTACTOR INPUT 440-460V
RECTIFIER P73
J4 H1A H1 R(115V)
U (L1) (T1) 2 1 6 16 6 11 1 6 4
POWER WAVE 450

AC1 POS J30 J30 J30 J32
V (L2) (T2) (T3) (T1)
AC2 (HIB) (321A)
W (L3) (T3) J4 H2A U(42V)
AC3 NEG 5 H2
4 5
G 200-208V
CR1 H3A
H3 N(24V)
2 3
220-230V
(324) (326) AUXILIARY H4A

H4 W
TRANF 2 3 2
24VAC P2 380-415V 1
H5A H5 24VAC
P5 6 4
440-460V
FIGURE F.6 – INPUT AND AUXILIARY CIRCUIT WIRING DIAGRAM
F-30
F-31 F-31
AUXILIARY TRANSFORMER TEST #2
WARNING
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer #2 and also if the correct voltages are being induced on the secondary wind-
ings of the transformer. Note: Transformer #2 is not present on all models.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Input and Auxiliary Circuit Wiring Diagram – Figure F.8

POWER WAVE 450

F-32 F-32

FIGURE F.7 - TRANSFORMER T1 AND T2 LOCATION
3
1
1. AUXILIARY TRANSFORMER T1 WITH

PLUG J73
2. PLUG J30
3. PROTECTION BOARD
TEST PROCEDURE

8. Remove plug J73 from the T1 transformer.
T2 is connected in parallel with T1.
the lift bail.
Leaving the two transformers connected
4. With the 5/16" nut driver, remove the sheet in parallel for the test might result in incor-
metal screws from the case top. rect readings; therefore plug J73 should
be disconnected.
screws holding the right and left case sides. 9. Remove plug J30 from the protection
Remove the case sides by lifting up and board. See Figure F.1 for location of the
out. board and plug J30.
6. Perform the Capacitor Discharge Proce- 10. Remove the 5 leads ( 3 heavy and 2 small)
dure described earlier in this section of the T1, T2, T3 from main input contactor CR1.
manual. This is a safety precaution. It prevents
high voltage from being put on the
WARNING machine during the test. Wrap tape
around the lead ends to insulate them and

Before continuing with the prevent them from touching.
test procedure, perform the
capacitor discharge proce-
dure to avoid electric shock.
POWER WAVE 450

F-33 F-33
11. To conduct this test, you will be measuring If this voltage is wrong or missing, check the
the voltage between pin 2 and pin 5 of associated wiring to the transformer primary.
plug J4. The plug is located in the
If the correct voltage IS applied to the primary
machine undercarriage and is somewhat
but the voltage at H1A to H3A is not correct,
difficult to reach. It is probably easiest to
the transformer may be faulty. Replace the
disconnect the plug and insert the probes
transformer. Refer to the T2 Auxiliary Trans-
of your voltmeter alongside pins 2 and 5
former Removal and Replacement
before turning on input power, which is the
Procedure in this section of the manual.
next step.
14. After the test is completed and the prob-
12. Turn the main input supply power to the
lem successfully repaired, reconnect plug
machine back ON.
J30 to the protection board.
WARNING 15. Reconnect plug J73 to the T1 transformer.

16. Reconnect the 5 leads to the main con-

ELECTRIC SHOCK tactor CR1.
can kill. 17. Install the PC board cover.
Proceed with caution. Be 18. Install the machine case sides and top.
internal machine components during the 19. Install the handle and the lift bail rubber
remainder of the test procedure. gasket.
13. Check for the correct AC voltage between

plug J4 - pin 2 and J4 - pin 5. It should be
220 - 230 VAC.
If the voltage is correct, then Auxiliary
Transformer #2 is good.
If the voltage is wrong or missing, check the

associated wiring to the transformer primary.
See the Input and Auxiliary Circuit Wiring
Diagram, Figure F.8. These voltages are most
easily checked at the terminal strip. The cor-
rect voltages are as follows:
H1A to H3A = 220 - 230 VAC
POWER WAVE 450

F-34
TOP
(220VAC) FAN
BOT. H1 H1 321 J32

(220VAC) FAN 1 1 1
(H1) 24VAC 323 CR1 CR2
4 3 J32
H2 H2 P71
4 R(115V) 6 336 J33
200-208 (H2) 200-208V 6
U(42V) 333 J33
5 3
4 FUSE
(L1A) 3 220-230 (H3) H3 H3
F1 N(24V) 334 J33
2 3 4
(L3A) 2 1 220-230V
(321B) W 33 32A J33
2 1
POWER 380-415 (H4) H4 3 H4 P70 5A
(HIB) 321A BREAKER
SWI AUX. PROTECTION
TRANSF. J32
BOARD
440-460 (H5) H5 6 H5 1
MAIN R CR1 R CR2
RECTIFIER P73
J4 H1A H1 R(115V)
U (L1) (T1) 2 1 6 16 6 11 1 6 4
AC1 POS J30 J30 J30 J32
POWER WAVE 450

V (L2) (T2) (T3) (T1)
AC2 (HIB) (321A)
W (L3) (T3) J4 H2A U(42V)
AC3 NEG 5 H2
4 5
G 200-208V
CR1 H3A
H3 N(24V)
2 3
220-230V

H4 W
TRANF 2 3 2
24VAC P2 380-415V 1
H5A H5 24VAC
P5 6 4
440-460V
F-34
F-35 F-35
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST
WARNING
machine operator and will invalidate your factory warranty. For your safety and to avoid electri-
cal shock, please observe all safety notes and precautions detailed throughout this manual.
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the circuit feeding the
primary windings of the auxiliary transformers, which would cause the fuse (F1) on the recon-
nect panel to blow.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Machine Wiring Diagram in the Electrical Diagrams section of this manual
Protection PC Board Schematic in the Electrical Diagrams section of this manual

POWER WAVE 450

F-36 F-36
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued)

FIGURE F.9 - RECONNECT PANEL/TERMINAL STRIP LOCATION
2
1. RECONNECT PANEL (ON LEFT SIDE)

2. TERMINAL STRIP
3. FAN MOTORS
4. AUXILIARY TRANSFORMERS
TEST PROCEDURE

8. Remove the 5 leads ( 3 heavy and 2 small)
the lift bail.
4. With the 5/16" nut driver, remove the sheet high voltage from being put on the
metal screws from the case top. machine during the test. Wrap tape
prevent them from touching.
Remove the case sides by lifting up and 9. Remove plug J30 from the protection
out. board. See Figure F.1 for location of the
board and plug J30.
6. Perform the Capacitor Discharge
Procedure described in this section of the NOTE: If removing plug J30 solves the prob-
manual. lem, check for a short circuit or a fault in the 24
VAC circuit (plug P71) and the main contactor

WARNING coil. See the Input and Auxiliary Circuit Wiring
Before continuing with the Diagram, Figure F.10.
POWER WAVE 450

F-37 F-37
AUXILIARY TRANSFORMER PRIMARY WIRING HARNESS TEST (continued)
10. Check the wires that run from the recon- 14. After the test is completed and the prob-
nect panel to the terminal strip. Look for lem successfully repaired, reconnect plug
shorts between wires caused by broken or J30 to the protection board.
burned insulation. See the Input and
15. Reconnect plugs P70 and P71 to the T1
Auxiliary Circuit Wiring Diagram, Figure
transformer.
F.10.
16. Reconnect the 5 leads to the main con-
11. Check for shorts in the wires that run from
tactor CR1.
the terminal strip to the auxiliary trans-
formers and to the fan motors. 17. Install the PC board cover.
12. The fan motors or the auxiliary transformer 18. Install the machine case sides and top.
may be faulty. Disconnect these compo-
nents one at a time and see if fuse F1
gasket.
blows when input power is applied. The

internal resistance of the fan motors
should be about 16 ohms.
13. Remove plug P70 from the transformer. If
this solves the problem, check for a short
in the secondary circuit. See the machine
Wiring Diagram and the Protection PC
Board Schematic in the Electrical
Diagrams section of this manual.
POWER WAVE 450

F-38
TOP
(220VAC) FAN
BOT. H1 H1 321 J32

(220VAC) FAN 1 1 1
(H1) 24VAC 323 CR1 CR2
4 3 J32
H2 H2 P71
4 R(115V) 6 336 J33
200-208 (H2) 200-208V 6
U(42V) 333 J33
5 3
4 FUSE
(L1A) 3 220-230 (H3) H3 H3
F1 N(24V) 334 J33
2 3 4
(L3A) 2 1 220-230V
(321B) W 33 32A J33
2 1
POWER 380-415 (H4) H4 3 H4 P70 5A
(HIB) 321A BREAKER
SWI AUX. PROTECTION
TRANSF. J32
BOARD
440-460 (H5) H5 6 H5 1
MAIN R CR1 R CR2
RECTIFIER P73
J4 H1A H1 R(115V)
POWER WAVE 450

U (L1) (T1) 2 1 6 16 6 11 1 6 4
AC1 POS J30 J30 J30 J32
V (L2) (T2) (T3) (T1)
AC2 (HIB) (321A)
W (L3) (T3) J4 H2A U(42V)
AC3 NEG 5 H2
4 5
G 200-208V
CR1 H3A
H3 N(24V)
2 3
220-230V
H4 W
TRANF 2 3 2
24VAC P2 380-415V 1
H5A H5 24VAC
P5 6 4
440-460V
F-38
F-39 F-39
AUXILIARY TRANSFORMER #1 SECONDARY

AND WIRING HARNESS TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the load circuits
fed by the secondary windings of the auxiliary transformer, which would cause the trans-
former to overheat or the fuse (F1 - primary side) on the reconnect panel to blow.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.12

POWER WAVE 450

F-40 F-40
AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued)

FIGURE F.11 - PLUG AND RECEPTACLE INSPECTION POINTS
5
1. WIRE FEEDER RECEPTACLES

2 2. SQUARE WAVE TIG PROTECTION BOARD
3. DISPLAY BOARD
4. PROTECTION BOARD
5. CONTROL BOARD
6. POWER BOARD
3
TEST PROCEDURE 7. After you have completed the capacitor dis-

charge procedure for all four switch boards,
1. Remove main input supply power to the remove the PC board cover. Use the 5/16"
machine. nut driver.
2. With the 3/8" nut driver, remove the 4 8. Disconnect all plugs and wirefeeder recep-
screws that hold the handle to the machine. tacles associated with the auxiliary trans-
3. Remove the rubber gasket (cover seal) from former secondary. This is done to isolate
the lift bail. the machine electrically. Inspect all the dis-
connected plugs and receptacles, looking
4. With the 5/16" nut driver, remove the sheet for shorted pins and wires. See the
metal screws from the case top. Auxiliary Transformer #1 Secondary Circuit
5. With the 5/16" nut driver, remove the Wiring Diagram, Figure F.12, for the specif-
screws holding the right and left case sides. ic plugs and receptacles to check, which
Remove the case sides by lifting up and include:
out. • WF2 Receptacle
6. Perform the Capacitor Discharge Proce- • WF1 Receptacle
manual. • Square Wave TIG Protection Board
• Display Board
WARNING • Power Board
Before continuing with the • Protection Board

test procedure, perform the 9. Check for shorts on the associated PC
capacitor discharge proce- boards. See the Auxiliary Transformer #1
dure to avoid electric shock. Secondary Circuit Wiring Diagram, Figure
F.12.
POWER WAVE 450

F-41 F-41
AUXILIARY TRANSFORMER #1 SECONDARY AND WIRING HARNESS TEST (continued)
10. Check for shorts at plugs J33, J34, J35,

J37, and J38 on the protection board.
Inspect the board for evidence of arcing.
lem successfully repaired, reconnect all
plugs disconnected for the test.
12. Install the PC board cover.
13. Install the machine case sides and top.
gasket.
POWER WAVE 450

F-42
DISPLAY POWER
BOARD BOARD
(P82) (P83) SQUARE WAVE TIG

WF2 RECEPTACLE WF1 RECEPTACLE PROTECTION BOARD
TRIG 1
TRIG 2
COMMON
COMMON
COMMON
COMMON
42V
24V
115V
TRIG 2
COMMON
COMMON
42V
24V
115V
TRIG 1
24V
TRIG 1
COMMON
J92
J92
J12
J13
J12
J13
J43
J43 42V
A
I
K
C
J
D
A
I
K
C
J
D
4
2
2
4
6
3
3
1
32D
32E
42C
102D
31C
106A
32B
32C
42B
102B
31B
105A
374
372
371
373
296
293
351
356
FIGURE F.12
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J38
J38
J37
J37
J37
J37
J35
J35
1
6
4
2
1
3
3
2
5
6
3
4
1
7
8
12
13
10
11
14
POWER WAVE 450

5A
C.B.
W 33 32A J33
2 1
COMMON
U 333 J33
5 3
42V
N 334 J33
3 4
24V
R 336
*336 J33
6 6
115V
AUXILIARY
TRANSFORMER 1
PROTECTION BOARD
AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM
F-42
F-43 F-43
INPUT POWER AND WIRING HARNESS TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems on the input power
circuit that would cause the input fuses to repeatedly blow.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-44 F-44
INPUT POWER AND WIRING HARNESS TEST

FIGURE F.13 - INPUT POWER INSPECTION POINTS
2
1. POWER SWITCH (S1)

2. MAIN CONTACTOR INPUT LEADS (TOP)
3. PROTECTION BOARD
TEST PROCEDURE 7. After you have completed the capacitor dis-

1. Remove main input supply power to the remove the PC board cover. Use the 5/16"
machine. nut driver.
2. With the 3/8" nut driver, remove the 4 8. Manually check the power switch (S1) for
screws that hold the handle to the machine. proper operation by turning it back and
3. Remove the rubber gasket (cover seal) from forth. At the back of the front panel where
the lift bail. the switch is mounted, make a visual
inspection. Be sure the input and output
4. With the 5/16" nut driver, remove the sheet leads are not shorted together. Make sure
metal screws from the case top. the switch contacts are not fused together
5. With the 5/16" nut driver, remove the or shorted to another phase. (Because of
screws holding the right and left case sides. the high input voltage involved, you should
Remove the case sides by lifting up and be able to see physical evidence if any of
out. these problems exist.) Remove the tape
covering the switch and check the switch
6. Perform the Capacitor Discharge Pro- with an ohmmeter. High resistance should
cedure described earlier in this section of be present.
the manual.
WARNING
Before continuing with the

POWER WAVE 450

F-45 F-45
INPUT POWER AND WIRING HARNESS TEST (continued)
9. Check for shorts or fusing at the input

(top) leads to the main contactor.
10. Remove plug J30 from the protection
board. Check the resistance on the J30
header (the plug mounted on the board)
between pin 1 and pin 6. Resistance
should be very high. If resistance is low or
zero ohms, the protection board is faulty.
11. Check plug J30 and associated wires for
shorts or damaged connections. See the
Input and Auxiliary Circuit Wiring Diagram,
Figure F.14.
12. If any of the tests reveal signs of heavy

current flow, check the switch boards and
the input rectifier. Refer to the Switch
Board Test and the Input Rectifier
Resistance Test in this section of the
manual.
lem successfully repaired, reconnect all
plugs disconnected for the test.
14. Install the PC board cover.
gasket.
POWER WAVE 450

F-46
TOP
(220VAC) FAN
BOT. H1 H1 321 J32

(220VAC) FAN 1 1 1
(H1) 24VAC 323 CR1 CR2
4 3 J32
H2 H2 P71
4 R(115V) 6 336 J33
200-208 (H2) 200-208V 6
U(42V) 333 J33
5 3
4 FUSE
(L1A) 3 220-230 (H3) H3 H3
F1 N(24V) 334 J33
2 3 4
(L3A) 2 1 220-230V
(321B) W 33 32A J33
2 1
POWER 380-415 (H4) H4 3 H4 P70 5A
(HIB) 321A BREAKER
SWI AUX. PROTECTION
TRANSF. J32
BOARD
440-460 (H5) H5 6 H5 1
MAIN R CR1 R CR2
RECTIFIER P73
J4 H1A H1 R(115V)
U (L1) (T1) 2 1 6 16 6 11 1 6 4
AC1 POS J30 J30 J30 J32
POWER WAVE 450

V (L2) (T2) (T3) (T1)
AC2 (HIB) (321A)
W (L3) (T3) J4 H2A U(42V)
AC3 NEG 5 H2
4 5
G 200-208V
CR1 H3A
H3 N(24V)
2 3
220-230V

H4 W
TRANF 2 3 2
24VAC P2 380-415V 1
H5A H5 24VAC
P5 6 4
440-460V
F-46
F-47 F-47
INPUT RECTIFIER RESISTANCE TEST
WARNING
TEST DESCRIPTION
This test will determine if any of the internal diodes in the three-phase rectifier are shorted
or open.
MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-48 F-48
INPUT RECTIFIER RESISTANCE TEST (continued)

FIGURE F.15 - RECONNECT SWITCH LOCATION
2
1. RECONNECT SWITCH
2. INPUT RECTIFIER
3. MAIN CONTACTOR
TEST PROCEDURE WARNING

1. Remove main input supply power to the Before continuing with the
machine. test procedure, perform the
2. With the 3/8" nut driver, remove the 4 dure to avoid electric shock.
the lift bail. 7. After you have completed the capacitor dis-
4. With the 5/16" nut driver, remove the sheet use the 5/16" nut driver to remove the two
metal screws from the case top. 5/16" sheet metal screws holding the
5. With the 5/16" nut driver, remove the reconnect switch assembly. Twist the
screws holding the right and left case sides. reconnect switch out to access the lead
Remove the case sides by lifting up and connections on the back.
out. 8. Use the 3/8" wrench to disconnect the two
6. Perform the Capacitor Discharge negative leads from the reconnect switch.
Procedure described earlier in this section By disconnecting the leads at the recon-
of the manual. nect switch, you will not have to disturb the
silicon applied to the input rectifier.
Electrically isolate the leads from all other
leads.
POWER WAVE 450

F-49 F-49
INPUT RECTIFIER RESISTANCE TEST (continued)
9. Check all leads connected to the input 11. After the test is completed and the prob-
rectifier. Check for looseness or shorted lem successfully repaired, reconnect the
wires. negative leads to the reconnect switch.
Fasten the reconnect switch assembly
10. Using an analog type meter, perform the
back into position on the machine.
resistance test Steps A through L accord-
ing to the Table F.1. NOTE: If input rectifier was shorted, other
components may be faulty.
NOTE: If terminals AC1, AC2, and AC3 of
Perform Field Effect Transistor/
the input rectifier are not easily
Switch Board Test and check for
accessible, use terminals T1, T2,
“leaky” or “shorted” capacitors.
and T3, respectively, of main con-
tactor CR1 for the resistance mea- 12. Install the machine case sides and top.
surements. Similarly, if terminals
POS and NEG of the input rectifier
gasket.
are not easily accessible, use ter-

minals POS and NEG of the recon-
nect switch for the resistance mea-
surements.
TABLE F.1 – INPUT RECTIFIER RESISTANCE VALUES

Step Place Place
(See + Lead - Lead
Note) Test for on . . . on . . . If . . . Then . . .
A 1K Ohms POS AC1 >1K Ohms Go to step B.

<100 Ohms Tested failed.
B 1K Ohms POS AC2 >1K Ohms Go to step C.
C 1K Ohms POS AC3 >1K Ohms Go to step D.

D 1K Ohms AC1 NEG >1K Ohms Go to step E.
E 1K Ohms AC2 NEG >1K Ohms Go to step F.
F 1K Ohms AC3 NEG >1K Ohms Go to step G.
G <100 Ohms AC1 POS <100 Ohms Go to step H.
>1K Ohms Test failed.
H <100 Ohms AC2 POS <100 Ohms Go to step I.
I <100 Ohms AC3 POS <100 Ohms Go to step J.
J <100 Ohms NEG AC1 <100 Ohms Go to step K.

K <100 Ohms NEG AC2 <100 Ohms Go to step L.
L <100 Ohms NEG AC3 <100 Ohms Input Rectifier OK
POWER WAVE 450

F-50
NOTES
POWER WAVE 450

F-50
F-51 F-51
OUTPUT SHUNT/WELDING FEEDBACK TEST
WARNING
TEST DESCRIPTION
The following procedure will determine whether the shunt amplifier board is receiving the
correct supply voltage from the control board and providing the correct feedback voltage.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Load Bank

POWER WAVE 450

F-52 F-52
QUICK SHUNT TEST
TEST PROCEDURE
1. Remove main input supply power to the
Power Wave 450.
2. Disconnect the Output leads from the
machine.
3. If a wire feeder is connected to the Power
Wave 450, release the drive roll tension so
the unit will not feed wire when the trigger is
activated.
4. Turn on the Power Wave 450 and activate
the gun trigger and hold for several sec-
onds. Trigger the machine on and off sev-
eral times in this manner and observe the

display. The “I=” reading should be less
than five amps when the machine is trig-
gered and NOT welding.
5. If after several trigger cycles the “I=” value
is at or above 5 amps the shunt assembly is
suspect and should be replaced.
6. If the “I=” value is below 5 amps when the
trigger is activated and not welding, the sta-
bility of the shunt assembly is at an accept-
able level.
7. To further test the shunt assembly, continue
with the output shunt/welding feedback
test.
POWER WAVE 450

F-53 F-53
OUTPUT SHUNT/WELDING FEEDBACK TEST (continued)

FIGURE F.16 - SHUNT AMPLIFIER BOARD LOCATION
1. SHUNT AMPLIFIER BOARD
TEST PROCEDURE
WARNING
machine. Before continuing with the
2. With the 3/8" nut driver, remove the 4 test procedure, perform the
screws that hold the handle to the machine. capacitor discharge proce-
the lift bail.
4. With the 5/16" nut driver, remove the sheet 7. After you have completed the capacitor dis-
metal screws from the case top. charge procedure for all four switch boards,
locate plug J50 at the shunt amplifier
5. With the 5/16" nut driver, remove the board. Locate the plug and insert your
screws holding the right and left case sides. voltmeter positive (+) probe into pin 3 and
Remove the case sides by lifting up and negative probe (-) into pin 1. Right-angle
out. probes are recommended.
6. Perform the Capacitor Discharge 8. Turn supply power to the machine ON.
Procedure described earlier in this section

of the manual.
POWER WAVE 450

F-54 F-54
OUTPUT SHUNT/WELDING FEEDBACK TEST (continued)
12. If the supply voltage readings are correct,

WARNING load the machine to 400 amps.
ELECTRIC SHOCK CAUTION

can kill.
Do not run the machine under load for more
Proceed with caution. Be than 15 sec. with case removed.
careful not to touch any inter-
nal machine components during the remainder
of the test procedure. 13. Use a current probe to check for 5 ma of
current through lead #218 (plug J50 - pin
4). This also reads approximately 1 VDC if
9. Check for +15 VDC between plug J50 - you use a voltmeter.
pin 3+ and J50 - pin 1-.
14. If the current reading is NOT correct, the
10. Carefully move the probes, placing the shunt amplifier board may be faulty.
negative probe (-) at plug J50 - pin 6 and Replace the shunt amplifier assembly and
the positive (+) probe at J50 - pin 1. perform current calibration.
Check for -15 VDC.
15. If the current reading IS correct, the con-
11. If the voltage readings are NOT correct, trol board may be faulty. Replace the con-
check the associated wiring to the control trol board. Refer to the Printed Circuit
board. If the wiring is okay, the control Board Removal and Replacement proce-
board may be faulty. Replace the control dure in this section of the manual.
board. Refer to the Printed Circuit Board
Removal and Replacement Procedure 16. After the test is completed and the prob-
in this section of the manual. lem successfully repaired, install the
machine case sides and top.
gasket.
F-55 F-55
PIEZO-ELECTRIC ALARM BUZZER TEST
WARNING
DESCRIPTION
The following procedure will determine whether the piezo-electric alarm buzzer is function-
ing properly.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-56 F-56
PIEZO-ELECTRIC ALARM BUZZER TEST

FIGURE F.17 - ALARM BUZZER LOCATION
1. LEADS 300, 301 TO PLUG J15 ON

DISPLAY BOARD
1 2. PIEZO-ELECTRIC ALARM BUZZER
TEST PROCEDURE 7. After you have completed the capacitor

discharge procedure for all four switch
1. Remove main input supply power to the boards, locate and remove plug J15 from
machine. the display board. See Figure F.17 for
location.

screws that hold the handle to the machine. 8. Using lead #300 as positive (+) and lead
3. Remove the rubber gasket (cover seal) from #301 as negative (-), apply 12 to 15 VDC
the lift bail. to the piezo-electric buzzer.
4. With the 5/16" nut driver, remove the sheet 9. If the buzzer does not work, replace it.
metal screws from the case top. 10. If the buzzer does work, the display board
5. With the 5/16" nut driver, remove the may be faulty. Replace the display board.
screws holding the right and left case sides. Refer to the Display Board Replacement
Remove the case sides by lifting up and procedure in this section of the manual.
out. 11. After the test is completed and the prob-
6. Perform the Capacitor Discharge lem successfully repaired, reconnect plug
Procedure described earlier in this section J15 to the display board.
of the manual. 12. Install the machine case sides and top.
WARNING
gasket.

POWER WAVE 450

F-57 F-57
OUTPUT RECTIFIER DIODES TEST
WARNING
TEST DESCRIPTION
The following procedure will determine whether one of the output rectifier diodes is
shorted. If one of the diodes is shorted, the output rectifier assembly must be replaced.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-58 F-58
OUTPUT RECTIFIER DIODES TEST

FIGURE F.18 - SNUBBER BOARD, OUTPUT TERMINAL LOCATION
1
1. PC BOARD FRONT/BOTTOM COVER

2. SNUBBER PC BOARD 3 4
3. NEGATIVE OUTPUT TERMINAL
4. POSITIVE OUTPUT TERMINAL
TEST PROCEDURE 7. After you have completed the capacitor

1. Remove main input supply power to the boards, disconnect plug J62 from the
machine. snubber board. See Figure F.18 for loca-
tion.
screws that hold the handle to the machine. 8. Remove any output load that may be con-
nected to the machine.

the lift bail. 9. With the volt/ohmmeter, measure the
resistance between the positive and neg-
4. With the 5/16" nut driver, remove the sheet ative output terminals. IMPORTANT: The
metal screws from the case top. positive (+) probe must be attached to
the positive (+) output terminal and the
5. With the 5/16" nut driver, remove the negative probe (-) must be attached to
screws holding the right and left case sides. the negative (-) output terminal.
out. 10. If the reading is 40 ohms, the output recti-
fier diodes are good. If the reading is less
6. Perform the Capacitor Discharge than 40 ohms, replace the output rectifier.
Procedure described earlier in this section Refer to the Output Rectifier
of the manual. Replacement Procedure in this section
of the manual.
WARNING 11. After the test is completed and the prob-

lem successfully repaired, reconnect plug
J62 to the snubber board.

test procedure, perform the 12. Install the machine case sides and top.
capacitor discharge proce- 13. Install the handle and the lift bail rubber
dure to avoid electric shock. gasket.
POWER WAVE 450

F-59 F-59
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST

OR
IGBT/SWITCH BOARD TEST
WARNING
DESCRIPTION
The following procedure will determine if the four switch boards and their related circuitry
are functioning properly. This is a resistance test, not a voltage test. The machine does
not have to be powered up to perform the test, which is both safer for the technician and
less likely to result in accidental damage to the switch boards.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver


POWER WAVE 450

F-60 F-60
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST

FIGURE F.19 – F.E.T. SWITCH BOARD LOCATION
1
1. FET OR IGBT SWITCH BOARD ASSEMBLY
TEST PROCEDURE
WARNING

2. With the 3/8" nut driver, remove the screws test procedure, perform the
that hold the handle to the machine. following capacitor dis-
charge procedure to avoid
3. Remove the rubber gasket (cover seal) from electric shock.
the lift bail.
5. With the 5/16" nut driver, remove the 6. Obtain a high resistance and high wattage
screws holding the right and left case sides. resistor (25 - 1000 ohms and 25 watts min-
Remove the case sides by lifting up and imum). This resistor is not supplied with the
out. machine. Secure this resistor to a piece of
insulating material such as a glastic board.
See Figure F.22. NEVER USE A SHORTING
STRAP FOR THIS PROCEDURE.
POWER WAVE 450

F-61 F-61
FIELD EFFECT TRANSISTOR/SWITCH BOARD TEST (continued)

FIGURE F.20 - RESISTOR LOCATIONS
CHECK VOLTAGES BETWEEN
EACH TERMINAL AND FROM
EACH RESISTOR TO CASE

GROUND
7. Locate the two sets of two resistors on the 8. Locate terminals #9 and #12 on the switch
left side of the machine and three sets of boards. They can be identified by the
two resistors on the right side of the “Discharge” labels, which are located on
machine. See Figure F.20. Do not touch each of the four switch boards. See Figure
the resistors or any other internal machine F.21.
component. Using a DC voltmeter, check
for any DC voltage that may be present
across the terminals of each resistor and
from each resistor to case ground (20 mea-
surements in all). If a voltage is present, be
careful not to touch these resistors.
WARNING
ELECTRIC SHOCK
can kill.
Proceed with caution. Be

internal machine components during the dis-
charge procedure.
POWER WAVE 450

F-62 F-62
FIGURE F.21 - DISCHARGE LABEL FIGURE F.22

RESISTOR WITH LEADS CONNECTED
D
I
S
C
D
I
S
C
D
H
A
R
G
H
A
R
G
I
E E
S
C
H
A
R
D
I
D
I
G
S
C
H
A
S
C
H
A
E
R R
G G
E E
9. Using insulated, needle nose type jumper 12. Repeat discharge procedure steps 9, 10,
leads and insulated gloves, connect one and 11 for each of the other three switch
jumper lead to one end of the resistor boards.
obtained in step 6. Connect the other

13. After you have completed the capacitor
jumper lead to the other end of the resistor.
10. Carefully connect the needle nose end of boards, Visually inspect the switch
one of the jumper leads to terminal #9. boards. If any of them appear burned or
See Figure F.22. Connect the needle nose overheated, replace all four switch boards
end of the other jumper lead to terminal and input filter capacitors C1, C2, C3, and
#12. Terminals #9 and #12 are indicated C4. Refer to the FET Module Assembly
by the "Discharge" label. Leave the resis- Removal and Replacement Procedure
tor connected for 10 seconds. DO NOT in this section of the manual.
TOUCH TERMINALS, RESISTORS, OR
14. If none of the switch boards shows physi-
ANY INTERNAL MACHINE COMPO-
cal damage, test each switch board
NENTS DURING THIS PROCEDURE!
according to the procedures given below.
11. Check the voltage across terminals #9 and If any test shows that one of the switch
#12 with the DC voltmeter. Terminal #9 boards is damaged, replace all four switch
has positive polarity and terminal #12 has boards and input filter capacitors C1, C2,
negative polarity. Voltage should be zero. C3, and C4. Refer to the FET Module
If any voltage remains, repeat this capaci- Assembly Removal and Replacement
tor discharge procedure. Procedure in this section of the manual.
POWER WAVE 450

F-63 F-63

FIGURE F.23 - SWITCH BOARD ASSEMBLY CONNECTION DECAL
3W 2W
TOP
3R 2R
406 401
3T 2T
12C 9A
CAP 3
CAP 1
9C 12A
4T 1T
405 402
4R 1R
4W 1W
3W 2W
3R 2R
408 403
3B 2B
12D 9B
CAP 4
CAP 2
9D 12B
4B 1B
407 404
4R 1R
4W 1W
M16740
POWER WAVE 450 4/98

F-64 F-64
Switch Board Test 1: (For Switch Board B. With the volt/ohmmeter, measure the resis-
Marked CAP 1 on the Switch Board Assem- tance between terminals according to
bly Connection Decal - See Figure F.23.) Table F. 4. If any test fails, replace all four
switch boards. Refer to the FET Module
A. Disconnect all wiring harness leads from
Assembly Removal and Replacement pro-
switch board 1. Fold the leads up so that
cedure in this section of the manual.
they do not interfere with the exposed PC
board terminals. If none of the tests fails, reconnect the
wiring harness leads to switch board 3 and
B. With the volt/ohmmeter, measure the resis-
perform switch board test 4.
tance between terminals according to
Table F. 2. See Figure F.23 for the locations
of the terminals. If any test fails, replace all
Switch Board Test 4: (For Switch Board
four switch boards. Refer to the FET
Marked CAP 4 on the Switch Board Assem-
Module Assembly Removal and Re-
bly Connection Decal - See Figure F.23.)

placement procedure in this section of the

manual. A. Disconnect all wiring harness leads from
switch board 4. Fold the leads up so that
If none of the tests fails, reconnect the
they do not interfere with the exposed PC
board terminals.
B. With the volt/ohmmeter, measure the resis-
Switch Board Test 2: (For Switch Board Table F. 5. If any test fails, replace all four
Marked CAP 2 on the Switch Board Assem- switch boards. Refer to the FET Module
bly Connection Decal - See Figure F.23.) Assembly Removal and Replacement pro-
switch board 2. Fold the leads up so that If none of the tests fails, reconnect the
they do not interfere with the exposed PC wiring harness leads to switch board 4.
board terminals.
IGBT Switch Board Test (G3165-1) See Table
B. With the volt/ohmmeter, measure the resis- F.6.

Table F. 3. If any test fails, replace all four
the switch boards. Fold the leads up so
that they do not interfere with the exposed
PC board terminals.
B. With the Volt/Ohmmeter, measure the
If none of the tests fails, reconnect the
resistance between terminals according to
Table F.6. If any test fails, replace all four
Switch Board Test 3: (For Switch Board
Marked CAP 3 on the Switch Board Assem- If none of the tests fail, reconnect the wiring
bly Connection Decal - See Figure F.23.) harness leads to the switch boards.
A. Disconnect all wiring harness leads from 15. After the test is completed and the prob-
switch board 3. Fold the leads up so that lem successfully repaired, install the
they do not interfere with the exposed PC machine case sides and top.
board terminals.
gasket.
POWER WAVE 450

F-65 F-65

TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE
Apply Apply
Positive Negative
Test Test
Probe to Probe to Test Repair Next
Terminal Terminal Result Conclusion Action Procedure
2T 12A Greater OK None Continue
than 1K
ohm
Less than Replace 4 Snubber
100 ohms Shorted Switch Resistor
Boards Test
12A 2T Less than OK None Continue

100 ohms
Greater Open Replace 4 Snubber
than 1K Switch Resistor
ohm Boards Test
9A 1T Greater OK None Continue
than 1K
ohm
Less than Shorted Replace 4 Snubber
100 ohms Switch Resistor
Boards Test
1T 9A Less than OK None Continue
100 ohms

ohm Boards Test
2T 9A Less than OK None Continue
100 ohms
ohm Boards Test
9A 2T Greater OK None Continue
than 1K
ohm
boards Test
NOTE: K ohm = ohm reading multiplied by 1000.

NOTE: Always make sure that all four Switch Boards are changed at the same time. Never mix
an old style (different part number) Switch Board with a new style (new part
number).
POWER WAVE 450

F-66 F-66

TABLE F.2 – SWITCH BOARD 1 RESISTANCE TEST TABLE (Continued)
Apply Apply
Positive Negative
Test Test
12A 1T Less than OK None Continue
100 ohms
ohm Boards Test
1T 12A Greater OK None Continue

than 1K
ohm
Boards Test
12A 401 Greater OK None Continue
than 1K
ohm
Boards Test
401 12A Less than OK None Continue
100 ohms

ohm Boards Test
9A 402 Less than OK None Continue
100 ohms
ohm Boards Test
402 9A Greater OK None Continue
than 1K
ohm
boards Test

NOTE: Always make sure that all four Switch Boards are changed at the same time. Never
mix an old style (different part number) Switch Board with a new style (new part
number).
POWER WAVE 450
F-67 F-67

Apply Apply
Positive Negative
Test Test
2B 12B Greater OK None Continue
than 1K
ohm
Boards Test
12B 2B Less than OK None Continue

100 ohms
ohm Boards Test
than 1K
ohm
Boards Test
100 ohms

ohm Boards Test
100 ohms
ohm Boards Test
than 1K
ohm
boards Test

number).
POWER WAVE 450

F-68 F-68

Apply Apply
Positive Negative
Test Test
100 ohms
ohm Boards Test

than 1K
ohm
Boards Test
12B 403 Greater OK None Continue
than 1K
ohm
Boards Test
403 12B Less than OK None Continue
100 ohms

ohm Boards Test
9B 404 Less than OK None Continue
100 ohms
ohm Boards Test
404 9B Greater OK None Continue
than 1K
ohm
boards Test

number).
POWER WAVE 450
F-69 F-69

Apply Apply
Positive Negative
Test Test
4T 12C Greater OK None Continue
than 1K
ohm
Boards Test
12C 4T Less than OK None Continue

100 ohms
ohm Boards Test
9C 3T Greater OK None Continue
than 1K
ohm
Boards Test
3T 9C Less than OK None Continue
100 ohms

ohm Boards Test
4T 9C Less than OK None Continue
100 ohms
ohm Boards Test
9C 4T Greater OK None Continue
than 1K
ohm
boards Test

number).
POWER WAVE 450

F-70 F-70

Apply Apply
Positive Negative
Test Test
12C 3T Less than OK None Continue
100 ohms
ohm Boards Test
3T 12C Greater OK None Continue

than 1K
ohm
Boards Test
12C 405 Greater OK None Continue
than 1K
ohm
Boards Test
405 12C Less than OK None Continue
100 ohms

ohm Boards Test
9C 406 Less than OK None Continue
100 ohms
ohm Boards Test
406 9C Greater OK None Continue
than 1K
ohm
boards Test

number).
POWER WAVE 450
F-71 F-71

Apply Apply
Positive Negative
Test Test
4B 12D Greater OK None Continue
than 1K
ohm
Boards Test
12D 4B Less than OK None Continue

100 ohms
ohm Boards Test
9D 3B Greater OK None Continue
than 1K
ohm
Boards Test
3B 9D Less than OK None Continue
100 ohms

ohm Boards Test
4B 9D Less than OK None Continue
100 ohms
ohm Boards Test
9D 4B Greater OK None Continue
than 1K
ohm
boards Test

number).
POWER WAVE 450

F-72 F-72

Apply Apply
Positive Negative
Test Test
12D 3B Less than OK None Continue
100 ohms
ohm Boards Test
3B 12D Greater OK None Continue

than 1K
ohm
Boards Test
12D 407 Greater OK None Continue
than 1K
ohm
Boards Test
407 12D Less than OK None Continue
100 ohms

ohm Boards Test
9D 408 Less than OK None Continue
100 ohms
ohm Boards Test
408 9D Greater OK None Continue
than 1K
ohm
boards Test

number).
POWER WAVE 450
F-73 F-73
IGBT/SWITCH BOARD TEST (G3165-1)

TABLE F.6 – NOTE: This test will NOT determine if an individual IGBT device is open.
Apply Apply
Positive Negative
Test Test
2/4 12 Greater than OK None Continue
1k ohms
Less Shorted Replace Snubber
ohms Boards Test
9 1/3 Greater OK None Continue

than 1K
ohms
Less than Shorted Replace Snubber
1k ohms Switch Resistor
Boards Test
2/4 9 Less OK None Continue
than 100
ohms
Greater than Open Replace Snubber
Boards Test
9 2/4 Greater than OK None Continue
1k ohms
Less Shorted Replace Snubber

ohms Boards Test

number).
POWER WAVE 450

F-74 F-74
IGBT/SWITCH BOARD TEST (Continued)

TABLE F.6 (Continued)
Apply Apply
Positive Negative
Test Test
12 1/3 Less than OK None Continue
100 ohms
Greater Open Replace Snubber
ohms Boards Test
1/3 12 Greater OK None Continue
than 1K
ohms

Boards Test
12 401/403 Greater OK None Continue
405/407 than 1K
ohms
Boards Test
401/403 12 Less than OK None Continue
405/407 100 ohms
ohms Boards Test
9 402/404 Less than OK None Continue

406/408 100 ohms
ohms Boards Test
402/404 9 Greater OK None Continue
406/408 than 1K
ohms
boards Test

number).
POWER WAVE 450

F-75 F-75
SNUBBER AND BLEEDER RESISTOR TEST
WARNING
TEST DESCRIPTION
This test will determine if the eight snubber resistors and two bleeder resistors are of the
proper value and their associated leads intact.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Snubber and Bleeder Resistor Wiring Diagram – Figure F.25

POWER WAVE 450

F-76 F-76
SNUBBER AND BLEEDER RESISTOR TEST

FIGURE F.24 - SWITCH BOARD ASSEMBLY CONNECTION DECAL
3W 2W
TOP
3R 2R
406 401
3T 2T
12C 9A
CAP 3
CAP 1
9C 12A
4T 1T
405 402
4R 1R
4W 1W
3W 2W
3R 2R
408 403
3B 2B
12D 9B
CAP 4
CAP 2
9D 12B
4B 1B
407 404
4R 1R
4W 1W
M16740
POWER WAVE 450 4/98

F-77 F-77
SNUBBER AND BLEEDER RESISTOR TEST (continued)
TEST PROCEDURE C. With the volt/ohmmeter, check for 25

ohms resistance between lead #402 and
1. Remove main input supply power to the #9E.
machine.
If the measurement reads between 20 and
2. With the 3/8" nut driver, remove the 4 30 ohms, resistor R2 and leads #402 and
screws that hold the handle to the machine. #9E are okay. Go to step D.
3. Remove the rubber gasket (cover seal) from If the measurement does not read between
the lift bail. 20 and 30 ohms, check for continuity in
4. With the 5/16" nut driver, remove the sheet leads #402 and #9E. Then test for 25
metal screws from the case top. ohms resistance across R2 directly. If the
measurement does not read between 20
5. With the 5/16" nut driver, remove the and 30 ohms, replace resistor R2.

Remove the case sides by lifting up and D. With the volt/ohmmeter, check for 7.5 K-
out. ohms resistance between lead #12L (12E)
and #9L (9E).
dure described earlier in this section of the If the measurement reads between 6.75
manual. and 8.25 K-ohms, resistor R9 and leads
#12L(12E) and #9L (9E) are okay. Go to
step E.
WARNING
If the measurement does not read between
Before continuing with the 6.75 and 30 K-ohms, check for continuity
test procedure, perform the in leads #12L (12E) and #9L(9E). Then test
capacitor discharge proce- for 7.5 K-ohms resistance across R9
dure to avoid electric shock. directly. If the measurement does not read
between 6.75 and 8.25 K-ohms, replace
resistor R9.
7. Perform the following tests on the four
E. Reconnect quick connect terminals #401,

switch boards: #402, #9, and #12 on switch board 1.
Switch Board 1: (Switch Board 1 is Marked Switch Board 2: (Switch Board 2 is Marked
CAP 1 on the Switch Board Assembly CAP 2 on the Switch Board Assembly
Connection Decal - See Figure F.24.) Connection Decal - See Figure F.24.)
A. Remove quick connect terminals #401, A. Remove quick connect terminals #403,
#402, #9, and #12 from switch board 1. #404, #9, and #12.
B. With the volt/ohmmeter, check for 25 B. With the volt/ohmmeter, check for 25
ohms resistance between lead #401 and ohms resistance between lead #403 and
#12E. #12F.
If the measurement reads between 20 and If the measurement reads between 20 and
30 ohms, resistor R1 and leads #401 and 30 ohms, resistor R3 and leads #403 and
#12E are okay. Go to step C. #12F are okay. Go to step C.
If the measurement does not read between If the measurement does not read between
20 and 30 ohms, check for continuity in 20 and 30 ohms, check for continuity in
leads #401 and #12E. Then test for 25 leads #403 and #12F. Then test for 25
ohms resistance across R1 directly. If the ohms resistance across R3 directly. If the
measurement does not read between 20 measurement does not read between 20
and 30 ohms, replace resistor R1. and 30 ohms, replace resistor R3.
POWER WAVE 450

F-78 F-78
SNUBBER AND BLEEDER RESISTOR TEST (continued)
C. With the volt/ohmmeter, check for 25 If the measurement reads between 6.75
ohms resistance between lead #404 and and 8.25 K-ohms, resistor R10 and leads
#9F. #12G (12M) and #9G (9M) are okay. Go to
step E.
30 ohms, resistor R4 and leads #404 and If the measurement does not read between
#9F are okay. Go to step D. 6.75 and 30 K-ohms, check for continuity
in leads #12G (12M) and #9G (9M). Then
test for 7.5 K-ohms resistance across R10
20 and 30 ohms, check for continuity in
directly. If the measurement does not read
leads #404 and #9F. Then test for 25 ohms
between 6.75 and 8.25 K-ohms, replace
resistance across R4 directly. If the mea-
resistor R10.
surement does not read between 20 and
30 ohms, replace resistor R4. E. Reconnect quick connect terminals #405,
#406, #9, and #12 on switch board 3.
D. Reconnect quick connect terminals #403,

Switch Board 4: (Switch Board 4 is Marked
CAP 4 on the Switch Board Assembly
Switch Board 3: (Switch Board 3 is Marked
Connection Label - See Figure F.24.)
CAP 1 on the Switch Board Assembly
Connection Decal - See Figure F.24.) A. Remove quick connect terminals #407,
#408, #9, and #12 from switch board 4.
A. Remove quick connect terminals #405,
#406, #9, and #12 from switch board 3. B. With the volt/ohmmeter, check for 25
B. With the volt/ohmmeter, check for 25
#12H.
#12G. If the measurement reads between 20 and
30 ohms, resistor R7 and leads #407 and
#12H are okay. Go to step C.
#12G are okay. Go to step C. If the measurement does not read between

leads #407 and #12H. Then test for 25
ohms resistance across R3 directly. If the
leads #405 and #12G. Then test for 25
and 30 ohms, replace resistor R7.
and 30 ohms, replace resistor R5. C. With the volt/ohmmeter, check for 25
C. With the volt/ohmmeter, check for 25
#9H.
#9G. If the measurement reads between 20 and
#9H are okay. Go to step D.
#9G are okay. Go to step D. If the measurement does not read between
leads #408 and #9H. Then test for 25
leads #406 and #9G. Then test for 25
and 30 ohms, replace resistor R8.

and 30 ohms, replace resistor R5. D. Reconnect quick connect terminals #407,
D. With the volt/ohmmeter, check for 7.5 K-
ohms resistance between lead #12G (12M) 8. Install the machine case sides and top.
and #9G (9M).
gasket.
POWER WAVE 450
F-79 F-79
FIGURE F.25 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
(401)
SWITCH
BOARD
#1 401 (12E)
R1 ( 25W
25Ω
) (12L)
12A
(12A)
TO RECONNECT SWITCH
C1 (402) R9 ( 7.5KΩ
25W )
402 (9E)
R2 ( 25W
25Ω
) (9L)
9A
(9A)
TO RECONNECT SWITCH
(403)
SWITCH
BOARD
#2 403 (12F)
R3 ( 25W
25Ω
)
12B
(12B)
TO RECONNECT SWITCH
C2 (404)
404 (9F)
R4 ( 25W
25Ω
)
9B
(9B)
TO RECONNECT SWITCH
(405)
SWITCH
BOARD
#3 405 (12G)
R5 ( 25W
25Ω
) (12M)
12C
(12C)
TO RECONNECT SWITCH
C3 (406) R10 ( 7.5KΩ

25W )
406 (9G)
R6 ( 25W
25Ω
) (9M)
9C
(9C)
TO RECONNECT SWITCH
(407)
SWITCH
BOARD
#4 407 (12H)
R7 ( 25W
25Ω
)
12D
(12D)
TO RECONNECT SWITCH
C4 (408)
408 (9H)
R8 ( 25W
25Ω
)
9D
(9D)
TO RECONNECT SWITCH
POWER WAVE 450

F-80
NOTES
POWER WAVE 450

F-80
F-81 F-81
RECONNECT SWITCH TEST 1
WARNING
TEST DESCRIPTION
This test will determine if there are any short circuits between the leads connected to the
reconnect switch.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Phillips head screw driver
Input and Reconnect Wiring Diagram – Figure F.27

POWER WAVE 450

F-82 F-82

FIGURE F.26 - RECONNECT SWITCH
1. RECONNECT PANEL
2. RECONNECT SWITCH
3. LEAD CONNECTIONS
3
2
TEST PROCEDURE
WARNING

the lift bail.
4. With the 5/16" nut driver, remove the sheet 7. Test the reconnect switch for short circuits
metal screws from the case top. according to the voltage for which the machine
is wired:
screws holding the right and left case sides. For 230 VAC:
Remove the case sides by lifting up and A. Check that the following leads are con-
out. nected together at the reconnect switch:
6. Perform the Capacitor Discharge #9A, #9B, #9C, #9D, #9K, #9J, and POS.
Procedure described earlier in this section B. Check that the following leads are con-
of the manual. nected together at the reconnect switch:

#12A, #12B, #12C, #12D, #12K, #12J, and
NEG.
C. With the volt/ohmmeter, check that there is
no continuity between the two groups of
leads in A and B above.
POWER WAVE 450

F-83 F-83
RECONNECT SWITCH TEST 1 (continued)
For 380 or 460 VAC: D. Remove leads #9A, #9B, #9C, #9D, #12A,
#12B, #12C, and #12D from the four
A. Check that the following leads are connect-
switch boards. If this eliminates the short,
ed together at the reconnect switch: #9A,
check these leads to make sure they are
#9B, #9K, and POS.
not exposed, damaged, or shorted. If the
B. Check that the following leads are con- leads are okay, perform the Switch Board
nected together at the reconnect switch: Test and the Snubber and Bleeder
#9C, #9D, #9J, #12A, #12B, and #12J. Resistor Test to find the cause of the
short. Reconnect leads #9A, #9B, #9C,
C. Check that the following leads are con-
#9D, #12A, #12B, #12C, and #12D to the
nected together at the reconnect switch:
four switch boards before conduction
#12C, #12D, #12K and NEG.
these tests.
D. With the volt/ohmmeter, check that there is
10. Replace the PC board cover and install the

no continuity between the three groups of
leads in A, B, and C above.
8. If any of the leads tested above are short-
gasket.
ed, go to step 9. If none of the leads are
shorted, the test is complete. Install the
machine case sides, top, handle and the
lift bail rubber gasket.
9. Perform the following steps:
A. With the 5/16" nut driver, remove the
screws that hold the PC board cover.
Remove the cover.
B. Disconnect plug J31 from the protection
board. If this eliminates the short, the pro-
tection board may be faulty. Replace the
protection board. If the short persists, go

to step 9C.
C. With the Phillips head screw driver, remove
the POS and NEG leads from the recon-
nect switch. If this eliminates the short,
either the input rectifier or the harness
(leads POS and NEG) between the input
rectifier and the reconnect switch is faulty.
Check the harness and if it is not faulty,
perform the Input Rectifier Test.
Reconnect leads POS and NEG to the
input rectifier. If the short persists, go to
step 9D.
POWER WAVE 450

F-84
TOP
FAN
H1
BOT. P71
FAN 1 321
P73
24VAC
1 323
H1 4
3 (321B) (R)
(L1A) 4 F1 P70115V
LOAD 336
LINE 4 6
1 (H1) H2 (U)
(L3A) 2 42VAC 333
2 5
H3 (N)
U L1 T1 24VAC 334
3 3
V L2 T2 H4
W L3 T3 (W) 33 32A
6 2
H5 AUX 1 5A
(R) CIRCUIT
CR1
HIA P5 115
G 2 J4 1 6 BREAKER
TO WATER COOLER (U)42
J4 H2A 115
(326) (324) 5 4 5
(N)24
H3A 115
2 (W) 3
H4A 115
3 2
H5A
6 1
AUX 2 24VAC
380V 4
230V 460V P2 T1
AC1 + POS ON OFF 321A
AC2
- NEG T3 HIB
AC3 OFF ON
POWER WAVE 450

12J 9K 9J 12K 429 24V 115V
J32
ON OFF 12 14 10 1 16 6 1 11 1 4 3 6 3 1
CR1
J31 J31 J31 J31 J30 J30 J30 J30 J33 J33 J33 J33
CR2
R9 R10 PROTECTION BD
9A 12A 9B 12B 9C 12C 9D 12D
24VAC
OPTOTRAIAC R CR1 CR2 R
C1 C2 C3 C4 J32 J32 2 3
4 6
J39 J39
SWITCH SWITCH SWITCH SWITCH
BOARD #1 BOARD #2 BOARD #3 BOARD #4 (329) FREQUENCY
MEASUREMENT
(326)
234 232
FIGURE F.27 – INPUT AND RECONNECT WIRING DIAGRAM
J23 J23
4 2
CONTROL
BOARD
F-84
F-85 F-85
WARNING
TEST DESCRIPTION
This test will determine if any leads connected to the reconnect switch are damaged.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-86 F-86

FIGURE F.28 - RECONNECT SWITCH
1
1. RECONNECT PANEL
2. RECONNECT SWITCH
3. LEAD CONNECTIONS
3
2
TEST PROCEDURE
WARNING

screws that hold the handle to the capacitor discharge proce-
machine. dure to avoid electric shock.
3. Remove the rubber gasket (cover seal)

from the lift bail.
4. With the 5/16" nut driver, remove the sheet 7. Visually check that the following leads are
metal screws from the case top. not damaged or exposed. With the
5. With the 5/16" nut driver, remove the volt/ohmmeter, also test the leads for con-
screws holding the right and left case tinuity:
sides. Remove the case sides by lifting up
and out.


of the manual.
POWER WAVE 450

F-87 F-87
• Lead #9A between the reconnect switch and 8. With the volt/ohmmeter, test THAT THERE
switch board #1. IS CONTINUITY between the leads in the
following groups according to the voltage
• Lead #9B between the reconnect switch and
for which the machine is wired:
switch board #2.
• Lead #9C between the reconnect switch and
switch board #3. For 200-230 VAC:
• Lead #9D between the reconnect switch and A. Test for continuity between leads #9A,
switch board #4. #9B, #9C, #9D, #9K, #9J, and POS con-
nected together at the reconnect switch.
• Lead #9J between the reconnect switch and
plug J31 - pin 10 of the protection board. B. Test for continuity between leads #12A,
#12B, #12C, #12D, #12K, #12J, and NEG
• Lead #9K between the reconnect switch and

connected together at the reconnect

plug J31 - pin 14 of the protection board.
switch.
• Lead #12A between the reconnect switch

For 380 - 460 VAC:
and switch board #1.
A. Test for continuity between leads #9A,
• Lead #12B between the reconnect switch
#9B, #9K, and POS connected together at
the reconnect switch.
• Lead #12C between the reconnect switch
B. Test for continuity between leads #9C,
#9D, #9J, #12A, #12B, and #12J connect-
• Lead #12D between the reconnect switch ed together at the reconnect switch.
C. Test for continuity between leads #12C,
• Lead #12J between the reconnect switch #12D, #12K and NEG connected together
and plug J31 - pin 12 of the protection board. at the reconnect switch.
• Lead #12K between the reconnect switch 9. If there is continuity within the groups of
and plug J31 - pin 1 of the protection board. leads tested, the test is complete. Install
the machine case sides, top, handle and
the lift bail rubber gasket.
• Lead POS between the reconnect switch and
the input rectifier.
• Lead NEG between the reconnect switch
and the input rectifier.
POWER WAVE 450

TOP
F-88
FAN
H1
BOT. P71
FAN 1 321
P73
24VAC
1 323
H1 4
3 (321B) (R)
(L1A) 4 F1 P70115V
LOAD 336
LINE 4 6
1 (H1) H2 (U)
(L3A) 2 42VAC 333
2 5
H3 (N)
U L1 T1 24VAC 334
3 3
V L2 T2 H4
W L3 T3 (W) 33 32A
6 2
H5 AUX 1 5A
(R) CIRCUIT
CR1
HIA P5 115
G 2 J4 1 6 BREAKER
J4 H2A 115
(326) (324) 5 4 5
(N)24
H3A 115
2 (W) 3
H4A 115
3 2
H5A
6 1
AUX 2 24VAC
380V 4
230V 460V P2 T1
AC2
- NEG T3 HIB
AC3 OFF ON
12J 9K 9J 12K 429 24V 115V
J32
ON OFF
POWER WAVE 450

12 14 10 1 16 6 1 11 1 4 3 6 3 1
CR1
J31 J31 J31 J31 J30 J30 J30 J30 J33 J33 J33 J33
CR2
9A 12A 9B 12B 9C 12C 9D 12D
24VAC
C1 C2 C3 C4 J32 J32 2 3
4 6
J39 J39

MEASUREMENT
(326)
234 232
J23 J23
4 2
CONTROL
BOARD
F-88
F-89 F-89
STATIC CAPACITOR BALANCE TEST
WARNING
TEST DESCRIPTION
This test will determine if, with no machine output, the input capacitors are balanced.
Before conducting this test, perform the following tests:
Switch Board Test - to ensure that none of the switch boards are faulty.
Snubber and Bleeder Resistance Test - to ensure that the bleeder resistors are properly
connected to the switch boards.
Reconnect Switch Test 1 and Reconnect Switch Test 2 - to ensure that input power is
properly connected to the switch boards.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Snubber and Bleeder Resistor Wiring Diagram – Figure F.31

POWER WAVE 450

F-90 F-90
STATIC CAPACITOR BALANCE TEST (continued)

FIGURE F.30 - BLEEDER RESISTORS R9 AND R10 LOCATION
1
1. RESISTORS R9 AND R10 (BLEEDER RESISTORS)
TEST PROCEDURE
WARNING

screws that hold the handle to the capacitor discharge proce-
3. Remove the rubber gasket (cover seal)

from the lift bail. 7. After you have completed the capacitor
4. With the 5/16" nut driver, remove the sheet discharge procedure for all four switch
metal screws from the case top. boards, use the 5/16" nut driver to remove
the two screws holding the PC board
5. With the 5/16" nut driver, remove the cover. Remove the cover.
screws holding the right and left case
sides. Remove the case sides by lifting up 8. If possible, set the machine up for 380 VAC
and out. or above by setting the reconnect switch
and Jumper A to 380 VAC. If only 220 VAC
6. Perform the Capacitor Discharge is available, perform the test that way.
Procedure described earlier in this section Turn the machine on but have no output.
of the manual.
POWER WAVE 450

F-91 F-91
STATIC CAPACITOR BALANCE TEST (continued)
For 380 VAC Input Voltage or Higher:

WARNING
If the difference is less than 75 VDC, static
capacitive balance is okay.
ELECTRIC SHOCK
can kill. If the difference is more than 75 VDC, sta-
tic capacitive balance is not okay. Perform
With input supply power ON, the Input Rectifier Test. Also visually
there are high voltages check input filter capacitors C1, C2, C3,
inside the machine. Do not reach into the and C4 for any signs of damage; replace
machine or touch any internal part of the the FET or IGBT assembly.
machine, including resistors R9 and R10. Use
insulated gloves to measure the resistance For 220 VAC Input Voltage:
across these resistors. The two resistance measurements should
be the same. If one or both is less than

175 VDC, perform the Main Contactor
9. Turn input supply power to the machine Test and the Input Rectifier Test. Also
ON. Machine output must be OFF. visually check input filter capacitors C1,
10. Measure and record the DC voltage C2, C3, and C4 for any signs of damage;
across bleeder resistors R9 and R10. replace the FET or IGBT assembly.
Compare the voltage recorded to the 12. After the test is completed and the prob-
desired values in Table F.7, depending on lem successfully repaired, install the
the input supply voltage setup. machine case sides and top.
11. Determine the difference between the two 13. Install the handle and the lift bail rubber
bleeder resistor voltages. gasket.
TABLE F.7
BLEEDER RESISTOR R9 AND R10 VOLTAGE VALUES
VAC INPUT VDC ACROSS BLEEDER RESISTORS R9 AND R10

460 VAC 325 VDC
440 VAC 311 VDC
415 VAC 293 VDC
380 VAC 269 VDC
230 VAC 325 VDC
208 VAC 294 VDC
POWER WAVE 450

F-92 F-92
Figure F.31 – SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
SNUBBER AND BLEEDER RESISTOR WIRING DIAGRAM
(401)
SWITCH
BOARD
#1 401 (12E)
R1 ( 25W
25Ω
) (12L)
12A
(12A)
TO RECONNECT SWITCH
C1 (402) R9 ( 7.5KΩ
25W )
402 (9E)
R2 ( 25W
25Ω
) (9L)
9A
(9A)
TO RECONNECT SWITCH
(403)
SWITCH
BOARD
#2 403 (12F)
R3 ( 25W
25Ω
)
12B
(12B)
TO RECONNECT SWITCH
C2 (404)
404 (9F)
R4 ( 25W
25Ω
)
9B
(9B)
TO RECONNECT SWITCH
(405)
SWITCH
BOARD
#3 405 (12G)
R5 ( 25W
25Ω
) (12M)
12C
(12C)
TO RECONNECT SWITCH
C3 (406) R10 ( 7.5KΩ

25W )
406 (9G)
R6 ( 25W
25Ω
) (9M)
9C
(9C)
TO RECONNECT SWITCH
(407)
SWITCH
BOARD
#4 407 (12H)
R7 ( 25W
25Ω
)
12D
(12D)
TO RECONNECT SWITCH
C4 (408)
408 (9H)
R8 ( 25W
25Ω
)
9D
(9D)
TO RECONNECT SWITCH
POWER WAVE 450

F-93 F-93
DYNAMIC CAPACITOR BALANCE TEST
WARNING
TEST DESCRIPTION
This test will determine if, with no machine output, the control board is receiving the correct
frequency signal from the protection board.
NOTE: Conduct this test after the Static Capacitor Balance Test has been performed suc-
cessfully. The reconnect switch and Jumper A must be set for 380 VAC input voltage or
higher. The selected input voltage must be the actual voltage applied.
MATERIALS NEEDED
Oscilloscope
5/16" Nut driver
3/8" Nut driver


POWER WAVE 450

F-94 F-94
DYNAMIC CAPACITOR BALANCE TEST (continued)

FIGURE F.32- CONTROL BOARD PLUG LOCATIONS
TOP VIEW
1 1 1 1 1 1 1 2
PROTECTION BD
1 1 1
3 4
16 14 6 6 14 6 4 4 4
J30 J31 J32 J33 J34 J35 J36 J37 J38 J39
GROUND PLANE
2 1 1 1 1 1
CONTROL BD
1 1 1 1
8 8 12 4
6 14 10 6 4 4
J20 J21 J22 J23 J24 J25 J26 J27 J28
DISPLAY
TEST PROCEDURE
WARNING

the lift bail.
use the 5/16" nut driver to remove the two
5. With the 5/16" nut driver, remove the screws that hold the PC board cover.
screws holding the right and left case sides. Remove the cover.
out. 8. Connect the machine negative (-) output
terminal to earth ground. Connect the
6. Perform the Capacitor Discharge Proce- oscilloscope case ground to earth ground.
manual. 9. Connect the oscilloscope to plug J23 - pin
4 (positive side) and plug J23 - pin 2 (nega-

tive side) on the control board. See Figure

F.32 for location If these connections are
reversed, you will not be able to see the fre-
quency train on the oscilloscope. Set the
oscilloscope to be DC coupled with 2
volts/division and 0.2 milliseconds/division.
POWER WAVE 450

F-95 F-95
DYNAMIC CAPACITOR BALANCE TEST (continued)
14. Test leads #232 and #234 for continuity.

WARNING These leads are between the protection
board and the control board. Lead #232 is
ELECTRIC SHOCK between J39 - pin 3 and J23 - pin 2. Lead
can kill. #234 is between J39 - pin 2 and J23 - pin
4. These leads must be intact for the fre-
With input power ON, there quency signal to be measured, because
are high voltages inside the the transistor side of the optocoupler
machine, including the pro- needs the power from the control board.
tection board. Do not reach into the machine
or touch any internal part of the machine while 15. If all the leads tested in step 14 are okay,
power is ON. make sure that the molex plugs are all
plugged in correctly and pushed far
enough into their headers. Check the fre-

10. Turn input power ON. Machine output quency again on the oscilloscope.
must be OFF. 16. If the frequency is still incorrect, the pro-
11. Measure the frequency between J23 - pin tection board may be faulty. Replace the
4 and J23 - pin 2 on the control board. protection board and perform the
You should see between 3.2 and 5.3 divi- Dynamic Capacitor Balance Test again.
sions per cycle (950 to 1550 Hz.). If you 17. If the frequency is still incorrect, the con-
do see this, the test is completed. If you trol board may be faulty. Replace the con-
do not see this, go to the next step. trol board.
12. Turn the power switch SW1 to the OFF 18. Install the machine case sides and top.
position, disconnect input power to the
machine, and perform the Capacitor 19. Install the handle and the lift bail rubber
Discharge Procedure. gasket.
WARNING
Before continuing with the test procedure, per-

form the capacitor discharge procedure to
avoid electric shock.
13. After you have completed the capacitor

boards, with the volt/ohmmeter, test leads
9J, 9K, 12J, and 12K for continuity
between the between the reconnect
switch and the protection board.
POWER WAVE 450

F-96
TOP
FAN
H1
BOT. P71
FAN 1 321
P73
24VAC
1 323
H1 4
3 (321B) (R)
(L1A) 4 F1 P70115V
LOAD 336
LINE 4 6
1 (H1) H2 (U)
(L3A) 2 42VAC 333
2 5
H3 (N)
U L1 T1 24VAC 334
3 3
V L2 T2 H4
W L3 T3 (W) 33 32A
6 2
H5 AUX 1 5A
(R) CIRCUIT
CR1
HIA P5 115
G 2 J4 1 6 BREAKER
J4 H2A 115
(326) (324) 5 4 5
(N)24
H3A 115
2 (W) 3
H4A 115
3 2
H5A
6 1
AUX 2 24VAC
380V 4
230V 460V P2 T1
AC2
- NEG T3 HIB
AC3 OFF ON
12J 9K 9J 12K 429 24V 115V
J32
ON OFF
POWER WAVE 450

12 14 10 1 16 6 1 11 1 4 3 6 3 1
CR1
J31 J31 J31 J31 J30 J30 J30 J30 J33 J33 J33 J33
CR2
9A 12A 9B 12B 9C 12C 9D 12D
24VAC
C1 C2 C3 C4 J32 J32 2 3
4 6
J39 J39

MEASUREMENT
(326)
234 232
J23 J23
4 2
CONTROL
BOARD
F-96
F-97 F-97
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST
WARNING
TEST DESCRIPTION
This test will determine if the proper voltages are present at the protection board, the
power board, the control board, and the display board.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Internal Auxiliary Supply Wiring Diagram – Figure F.34

POWER WAVE 450

F-98 F-98
INTERNAL AND AUXILIARY SUPPLY VOLTAGE TEST (continued)
TEST PROCEDURE
WARNING
machine.
ELECTRIC SHOCK
2. With the 3/8" nut driver, remove the 4 can kill.
With input power ON, there
3. Remove the rubber gasket (cover seal) from are high voltages inside the
the lift bail. machine, including plug J30
4. With the 5/16" nut driver, remove the sheet and the protection board. Do not reach into
metal screws from the case top. the machine or touch any internal part of the
machine while power is ON.
Remove the case sides by lifting up and 11. Turn input power ON. Machine output
out. must be OFF.
6. Perform the Capacitor Discharge 12. Verify the following voltage measure-
Procedure described earlier in this section ments:
of the manual.
A. Protection Board:
WARNING 115 VAC Between J33 - pin 6 and J33 -

pin 1 (Power Wave 450 only)
Before continuing with the test procedure, per- 42 VAC Between J33 - pin 3 and J33 -
form the capacitor discharge procedure to pin 1
24 VAC Between J33 - pin 4 and J33 -
pin 1
If any of these voltages are not present on the
7. After you have completed the capacitor dis- protection board, and the Auxiliary Transformer
charge procedure for all four switch boards, 1 Test has been completed successfully, do
remove the PC board cover. Use the 5/16" the following: Turn the power switch SW1 OFF
nut driver. and disconnect input power to the machine.
Check the pins of plug J33 to be sure they are
8. Remove the 5 leads ( 3 heavy and 2 small) not loose or broken. Since Auxiliary
T1, T2, T3 from main input contactor CR1. Transformer 1 Test determined that voltages
This is a safety precaution. It prevents high are present at plug J33, the fault must be that
voltage from being put on the machine dur- these signals are not getting to header J33.
ing the test. Wrap tape around the lead
ends to insulate them and prevent them B. Protection Board:
from touching. 115 VAC Between J34 - pin 1 and J34 -
9. Remove plug J30 from the protection pin 5 (Power Wave 450 only)
board. See Figure F.1 for location of the 42 VAC Between J34 - pin 3 and J34 -
board and plug J30. pin 5
10. Make sure that none of the pins are loose 24 VAC Between J34 - pin 4 and J34 -
or open on the following molex plugs: J33, pin 5
J34, J35, J37, J38 (on the protection

board), J12, J13, J16 (on the display If any of these voltages are not present on the
board), J22 (on the control board), J42, protection board (and the voltages in part A,
J43, and J44 (on the power board). See above, were present, replace the protection
the Internal Auxiliary Supply Wiring board.
Diagram, Figure F.34.
POWER WAVE 450

F-99 F-99
C. Protection Board: +5 VDC Between J44 - pin 11 and J44

- pin 12
pin 12 (Power Wave 450 only) -5 VDC Between J44 - pin 9 and J44 -
pin 12
42 VAC Between J34 - pin 10 and J34
- pin 12 -8 VDC Between J44 - pin 6 and J44 -
pin 12
24 VAC Between J34 - pin 11 and J34
- pin 12 If any of these voltages are NOT present,
replace the power board. If these voltages ARE
If any of these voltages are not present on the
present, check the wiring first. Then replace
protection board (and the voltages in part A,
the display board.
above, were present, replace the protection
board.
F. Control Board:
D. Power Board: +15 VDC Between J22 - pin 10 and J22
- pin 12
pin 3 -15 VDC Between J22 - pin 6 and J22-
pin 12
If this voltage is not present (and the voltages
in part A, above, were present), disconnect +5 VDC Between J22 - pin 11 and J22
plug J35 from the protection board and check - pin 12
for 42 VAC at header J35 between pin 1 and
If any of these voltages are not present (and
pin 6. If this voltage is NOT present, replace
the voltages in part D, above, were present),
the protection board. If this voltage IS present,
disconnect plug J42 from the power board and
check the wiring between the boards. Then
check the following voltages at header J42 on
replace the power board.
the power board:
+15 VDC Between J42 - pin 10 and J42
E. Display Board: - pin 12
+5 VDC Between J16 - pin 2 and J16 - -15 VDC Between J42 - pin 6 and J42 -
pin 3 pin 12
+15 VDC Between J16 - pin 10 and J16 +5 VDC Between J42 - pin 11 and J42
- pin 7 - pin 12
+5 VDC Between J16 - pin 1 and J16 - If any of these voltages are NOT present,
pin 7 replace the power board. If these voltages ARE
present, check the wiring. Then replace the
-5 VDC Between J16 - pin 9 and J16 -
control board.
pin 7
pin 7
If any of these voltages are not present (and
the voltages in part D, above, were present),
disconnect plug J44 from the power board and
check the following voltages at header J44 on

the power board:
+5 VDC Between J44 - pin 3 and J44 -
pin 2
- pin 12
POWER WAVE 450

F-100 F-100
13. With the Volt/ohmmeter, check the follow- C. Between the protection board and the
ing leads for continuity: square wave TIG protection board:
A. Between the Protection Board and Wire Lead #296 Between J38 - pin 3 and J92
Feeder 2 Receptacle: - pin 6
Lead #32D Between J34 - pin 5 and P82 14. After the test is completed and the prob-
- pin A lem successfully repaired, disconnect
input power to the machine.
Lead #32E Between J34 - pin 6 and P82
- pin I 15. Connect the five leads to main input con-
tactor CR1 and insert plug J30 into the
Lead #42C Between J34 - pin 3 and P82
protection board.
- pin K
Lead #102D Between J34 - pin 4 and P82

- pin C 17. Install the handle and the lift bail rubber
gasket.
Lead #31C Between J34 - pin 1 and P82
- pin J
Lead #106A Between J34 - pin 7 and P82
- pin D
B. Between the Protection Board and Wire
Feeder 1 Receptacle:
Lead #32B Between J34 - pin 12 and
P83 - pin A
Lead #32C Between J34 - pin 13 and
P83 - pin I
P83 - pin K

P83 - pin C
Lead #31B Between J34 - pin 8 and P83
- pin J
Lead #105A Between J34 - pin 14 and
P83 - pin D
POWER WAVE 450

P82 P83 SQUARE WAVE TIG

WF2 RECEPTACLE WF1 RECEPTACLE PROTECTION BD
F-101
24V
TRIG 1
COMMON
COMMON
42V
24V
115V
COMMON
COMMON
42V
24V
115V
P82 TRIG 2
P83 TRIG 1
J92
J92
A
I
K
C
J
D
A
I
K
C
J
D
6
3
32D
32E
42C
102D
31C
106A
32B
32C
42B
102B
31B
105A
296
293
PROTECTION POWER
BOARD BOARD
5A
J34
J34
J38
3
2
INPUTS:
5
6
3
4
1
7
8
12
13
10
11
14
C.B.
W 33 32A 351 COMMON
2 1 1 3
U 333 356 42V
5 3 6 1
(42V)
J35 J43
N 334
3 4
(24V)
R 336
6 6
(115V) J33
J37
J37
J37
J37
4
2
3
1
AUXILIARY
372
373
374
TRANFORMER 1
DISPLAY
2
4
2
4
J13
J13 371
J12
J12
BOARD
OUTPUTS:
TRIG 2 TRIG 1 442
RS232 3 2 COMMON
POWER 443
POWER WAVE 450

2 3 +5VDC
444
6 6 -8VDC
446
9 9 -5VDC
DISPLAY
BOARD 447
10 10 +15VDC
POWER 448
1 11 +5VDC
449
7 12 COMMON
J16 J44
INTERNAL AUXILIARY SUPPLY

WIRING DIAGRAM
CONTROL
BOARD
226
6 6 -15VDC
223
FIGURE F.34 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM
CONTROL 10 10 +15VDC
BOARD 224
POWER 11 11 +5VDC
225
12 12 COMMON
J22 J42
F-101
F-102
NOTES
POWER WAVE 450

F-102
F-103 F-103
MAIN CONTACTOR TEST
WARNING
TEST DESCRIPTION
This test will determine if main input contactor CR1 and its associated wiring and compo-
nents are faulty or damaged.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Slot head screw driver

POWER WAVE 450

F-104 F-104
MAIN CONTACTOR TEST (continued)

FIGURE F.35 - MAIN CONTACTOR
A
L1
L3
L1 L2 L3
CR1
T1 T2 T3
TEST PROCEDURE
WARNING
the lift bail.
metal screws from the case top. 7. After you have completed the capacitor dis-
5. With the 5/16" nut driver, remove the charge procedure for all four switch boards,
screws holding the right and left case sides. visually inspect the input terminals L1, L2,
Remove the case sides by lifting up and and L3 of the main contactor. Make sure
out. they are not shorted together. If they are
shorted, go to step 8. If they are not short-
6. Perform the Capacitor Discharge ed, go to step 9.

of the manual. 8. With the slot head screw driver, remove
leads L1A and L3A from the main contactor.
POWER WAVE 450

F-105 F-105
MAIN CONTACTOR TEST (continued)

A. With the power switch SW1 OFF, check to If any of these measurements shows continu-
see if leads L1A and L3A are shorted ity, replace the main contactor. If no continuity
together. If they are shorted, visually is shown, go to step 12.
inspect the leads. If the leads are okay,
12. Visually check the following leads for
then power switch SW1 is faulty and must
damage, then check for continuity as
be replaced.
described:
B. Remove leads L1, L2, and L3 from the
Lead #324 Between the main contactor
main contactor. Check if the terminals of
and plug J32 - pin 4 of the
the main contactor are still shorted. If they
protection board
are, the main contactor is faulty and must
be replaced. If the terminals are not short- Lead #326 Between the main contactor
ed, the input lines themselves are shorted. and plug J32 - pin 6 of the
Reconnect leads L1, L2, L3, L1A, and L3A protection board
to the main contactor.
Lead #321 Between plug J71 - pin 1 of
9. Visually inspect terminals T1, T2, and T3 auxiliary Transformer 1 and

of the main contactor. Make sure they are plug J32 - pin 1 of the protec-
not shorted together in any way. If they tion board
are not shorted, go to step 11. If they are
Lead #323 Between plug J71 - pin 4 of
shorted, go to step 10.
auxiliary Transformer 1 and
10. Remove leads T1, T2, and T3 from the plug J32 - pin 3 of the protec-
main contactor. tion board
A. Check if the terminals of the main contac- Lead T1 Between the main contactor
tor are still shorted. If they are, the main and the protection board plug
contactor is faulty and must be replaced. J30 - pin 11
B. Reconnect leads T1, T2, and T3 to the Lead T3 Between the main contactor
main contactor. Remove plug J30 from the and the protection board plug
protection board. Make sure that leads T1 J30 - pin 16
and T3 of plug J30 between the main con-
Put the power switch SW1 in the ON position
tactor and the protection board are not
for the next two continuity tests:

damaged, exposed, or shorted together.
Check again for shorts across the contacts Lead H1B Between terminal L3 of the
of the main contactor. If the terminals are main contactor and plug J30
not shorted now, the protection board is - pin 6 of the protection board
faulty. Replace the protection board.
Lead #321A Between terminal L1 of the
C. Visually inspect leads T1, T2, and T3 main contactor and plug J30
between the main contactor and the input - pin 1 of the protection board
rectifier and between the main contactor
Put the power switch SW1 in the OFF position.
and the protection board. If these leads
are not damaged or exposed, then the Replace any broken or damaged leads discov-
input rectifier may be faulty and should be ered by these tests.
checked. Perform the Input Rectifier
13. Connect any plugs disconnected for the
Test described in this section of the man-
tests. Replace the PC board cover with
ual.
two sheet metal screws.
11. With the volt/ohmmeter, check for conti-
nuity between the following terminals of

the main contactor: 15. Install the handle and the lift bail rubber
gasket.
L1 and T1
L2 and T2
L3 and T3
POWER WAVE 450

TOP
FAN
F-106
H1
BOT. P71
FAN 1 321
P73
24VAC
1 323
H1 4
3 (321B) (R)
(L1A) 4 F1 P70115V
LOAD 336
LINE 4 6
1 (H1) H2 (U)
(L3A) 2 42VAC 333
2 5
H3 (N)
U L1 T1 24VAC 334
3 3
V L2 T2 H4
W L3 T3 (W) 33 32A
6 2
H5 AUX 1 5A
(R) CIRCUIT
CR1
HIA P5 115
G 2 J4 1 6 BREAKER
J4 H2A 115
(326) (324) 5 4 5
(N)24
H3A 115
2 (W) 3
H4A 115
3 2
H5A
6 1
AUX 2 24VAC
380V 4
230V 460V P2 T1
AC2
- NEG T3 HIB
AC3 OFF ON
12J 9K 9J 12K 429 24V 115V
J32
ON OFF
POWER WAVE 450

12 14 10 1 16 6 1 11 1 4 3 6 3 1
CR1
J31 J31 J31 J31 J30 J30 J30 J30 J33 J33 J33 J33
CR2
9A 12A 9B 12B 9C 12C 9D 12D
24VAC
C1 C2 C3 C4 J32 J32 2 3
4 6
J39 J39

MEASUREMENT
(326)
234 232
J23 J23
4 2
CONTROL
BOARD
F-106
F-107 F-107
SERIAL LOOP WIRING HARNESS TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the serial loop
wiring between the power board, the control board, the display board, wire feeder 1
amphenol (P83) and wire feeder 2 amphenol (P82).
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Serial Loop Wiring Diagram Figure – F.38

POWER WAVE 450

F-108 F-108
SERIAL LOOP WIRING HARNESS TEST (continued)

FIGURE F.37 - WIRE FEEDER AMPHENOL LOCATIONS
1
1. WIRE FEEDER CONNECTIONS (ON BACK PANEL)
TEST PROCEDURE
WARNING
the lift bail.
metal screws from the case top. 7. After you have completed the capacitor dis-
5. With the 5/16" nut driver, remove the charge procedure for all four switch boards,
screws holding the right and left case sides. remove the PC board cover. Use the 5/16"
Remove the case sides by lifting up and nut driver.
out. 8. Perform the following test for faults on the
6. Perform the Capacitor Discharge serial loop circuitry between wire feeder 1
amphenol (P83) and the control board.


of the manual. A. Disconnect the wire feeder from the wire
feeder 1 amphenol (P83).
POWER WAVE 450

F-109 F-109
SERIAL LOOP WIRING HARNESS TEST (continued)

B. Check for loose or broken leads between A. Check for loose or broken leads between
the following pins: the following pins:
P83 - pin L and J27 - pin 1 on the control J22 - pin 5 on the control board and J44 -
board (lead #111A) pin 5 on the power board (lead #5R)
P83 - pin M and J27 - pin 4 on the control J22 - pin 4 on the control board and J44 -
board (lead #112A) pin 4 on the power board (lead #5W)
C. Make sure that plug J27 is plugged into B. Make sure that plug J22 is plugged into
the control board securely and that none of the control board securely and that none of
its pins are loose. its pins are loose. Also make sure that
plug J44 is securely plugged into the
D. Reconnect the wire feeder to the wire
power board and that none of its pins are
loose.
9. Perform the following test for faults on the
With the DC voltmeter, check for at least 30

serial loop circuitry between wire feeder 2

VDC between plug J44 - pin 5 and pin 4 on the
amphenol (P82) and the control board.
power board. This is the voltage source for the
A. Disconnect the wire feeder from the wire 40 mA current for the serial loop. If the voltage
feeder 2 amphenol (P82). is low or not present, the power board may be
faulty. Replace the power board.
B. Check for loose or broken leads between
the following pins: 12. After the test is completed and the prob-
lem successfully repaired, replace the PC
P82 - pin L and J28 - pin 1 on the control
board cover with two sheet metal screws.
board (lead #117A)
P82 - pin M and J28 - pin 4 on the control
board (lead #118A) 14. Install the handle and the lift bail rubber
gasket.
C. Make sure that plug J28 is plugged into
the control board securely and that none of
its pins are loose.
D. Reconnect the wire feeder to the wire


serial loop circuitry between the display
board and the control board.
A. Check for loose or broken leads between
the following pins:
J26 - pin 3 on the control board and J14 -
pin 6 on the display board (lead #263)
J26 - pin 4 on the control board and J14 -
pin 3 on the display board (lead #264)
B. Make sure that plug J26 is plugged into
the control board securely and that none of
its pins are loose. Also make sure that
plug J14 is securely plugged into the dis-

play board and that none of its pins are

loose.
serial loop circuitry 40 mA current supply.
POWER WAVE 450
1/96
F-110 F-110
FIGURE F.38 – SERIAL LOOP WIRING DIAGRAM
J22 (5R) J44

5 5
40mA current supply
Serial Loop TxD
Master
DISPLAY BOARD POWER BOARD
Transmit & RxD
Receive Lines
DK+
J26 (263) J14
3 6
TRN
Display Board
Port Switch REC
Open: DK Board S.L. DK-
J26 (264) J14
Comunication 4 3
enabled
Closed: DK Board S.L.
Comunication 14-pin WF1
disabled WF1 8-pin
WF+ J27 (111A)
1 P83 82(+)
L H
WF1 TRN
Port Switch
Open: WF1 S.L. REC
Comunication WF- J27 (112A)
P83 81(-)
enabled 4 M G
Closed: WF1 S.L.
Comunication
disabled 14-pin WF2
WF2 8-pin
OPT+ J28 (117A) P82 82(+)
1 L H
TRN
WF2
Port Switch
Open: WF2 S.L. REC
Comunication OPT- J28 (118A)
P82 81(-)
enabled 4 M G
Closed: WF2 S.L.
Comunication
disabled
POWER BOARD
J22
(5W) J44
4 4
40mA
CONTROL BOARD
current path
POWER WAVE 450

F-111 F-111
WIRE FEEDER 1 TRIGGER CIRCUIT TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit integral to the
Power Wave and the wire feeder 1 amphenol (P83).
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Short piece of jumper wire
Trigger Circuit Wiring Diagram – Figure F.40

POWER WAVE 450

F-112 F-112
WIRE FEEDER 1 TRIGGER CIRCUIT TEST (continued)

FIGURE F.39 - DISPLAY BOARD PLUG LOCATIONS
J17 J16 J15 J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING

the lift bail.
metal screws from the case top. 7. After you have completed the capacitor
5. With the 5/16" nut driver, remove the discharge procedure for all four switch
screws holding the right and left case sides. boards, remove the PC board cover. Use
Remove the case sides by lifting up and the 5/16" nut driver.
out. 8. Remove plug J12 from the display board.
6. Perform the Capacitor Discharge 9. Place a jumper wire between pins C and D
Procedure described earlier in this section of wire feeder receptacle #1.
of the manual.
machine during the test. Wrap tape
POWER WAVE 450
F-113 F-113

board. See Figure F.1 for location of the WARNING
board and plug J30.
WARNING With the input power ON, there are high volt-
ages inside the machine, including the protec-
ELECTRIC SHOCK tion board. Do not reach into the machine or
can kill. touch any internal parts.
With the input power ON,

there are high voltages 17. Turn input power ON. The LCD display
inside the machine. Do not will read: ERROR: S.L. NOT INITIALIZED.
reach into the machine or touch any internal Disregard this; the test can still be per-
parts.
formed.
18. Remove the jumper between pins C and D
12. Turn input power ON. of wire feeder #1 receptacle.
13. With the volt/ohmmeter, check for 24 VAC 19. With the volt/ohmmeter, measure the volt-
between plug J12 - pin 2 and pin 4. age drop across the 150 ohm resistor
between J26 - pins 1 and 2. With the
A. If 24 VAC IS present, go to step 14. jumper removed, the reading should be
NOTE: A voltage of 5 to 10 VDC is normal zero volts (NO voltage drop).
between these pins without the C to D 20. Replace the jumper between pins C and D
jumper installed in the wirefeeder recepta- of wire feeder #1 receptacle. Measure the
cle. voltage drop with the jumper installed.
B. If 24 VAC is NOT present, check for 24 The reading should be about 2 VDC
VAC between plug J33 - pin 4 and pin 1. across the resistor.
See the Trigger Circuit Wiring Diagram, A. If 2 VDC is NOT present, check the conti-
Figure F.40. nuity and integrity of leads #262 and 261
C. If 24 VAC IS present between plug J33 pin and their associated pins and connectors.
4 and pin 1, check the continuity and The display board may be faulty -- replace
integrity of leads #371, 374, 102B, and the display board.
105A and their associated pin connectors. B. If 2 VDC IS present across the resistor, the
See the Trigger Circuit Wiring Diagram. If control board may be faulty -- replace the
the continuity checks are good, the pro- control board.
tection board may be faulty. Replace the
protection board. 21. Turn input power to the machine OFF and
connect the five leads to the main contac-
D. If 24 VAC is NOT present between plug tor. Connect all molex plugs to the PC
J33 pin 4 and pin 1, check Auxiliary boards and replace the cover with two
Transformer #1, the 5 amp circuit breaker, sheet metal screws. Install the machine
and the associated wiring. See the Trigger case sides, top, handle, and lift bail rubber
Circuit Wiring Diagram, Figure F.40. gasket.
14. Turn input power to the machine OFF and
perform the Capacitor Discharge
Procedure.
15. Remove plug J26 from the control board.
Attach a 150 ohm resistor between plug
J26 - pin 1 and J26 - pin 2 (the J26 plug,
not the header on the control board).
16. Replace plug J12 into the display board.
POWER WAVE 450

F-114
Amphenols
AUXILIARY
24VAC
TRANSFORMER 1
P70
P70
5A
3 2 C.B.
8-pin 14-pin (334) (33) (32A)
Amphenols Amphenols J33 J33 +5V
J14 J26
"Amphenol 2" 4 1 5 (265) 5
P82 J37 (373) J13 J14 (266) J26
(2) (102D) J34 3 4 AC 4 6
C C 4
TO
FEEDER 2 (106A) J34 J37 (372) J13
(4) D D 7 2 2 DC +5V
"Amphenol 1" J14 (261) J26

P83 J37 (371) J12 1 1
(2) J34 1 2 AC J14 (262) J26
C C (102B) 11 2 2
FEEDER 1 TO
(105A) J34 J37 (374) J12
(4) D D 14 4 4 DC
P1
F F
(2) (102C) J93 J92 J38 PROTECTION BD DISPLAY BD CONTROL BD
E E 5 6 3
(4) D (105B) J38
D 7 3 2
(293) (296)
(75)
C (175A) (292) J10
C 4 2 7
(76) (176A) (291) J10 - TO MICRO
R B B 3 1 6
POWER WAVE 450

(177A) (294) J10 +10V PROCESOR
(77) A A 2 9 10
SQUARE WAVE TIG
PROTECTION BD
Remote Control Kit
6-pin
K941-1
Amphenols
AUXILIARY POWER WAVE

EQUIPMENT
FIGURE F.40 – TRIGGER CIRCUIT WIRING DIAGRAM
EXTERNAL INTERNAL
F-114
F-115 F-115
WIRE FEEDER 2 TRIGGER CIRCUIT TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit integral to the
Power Wave and the wire feeder 2 amphenol (P82).
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Trigger Circuit Wiring Diagram – Figure F.42.

POWER WAVE 450

F-116 F-116

J17 J16 J15 J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING

the lift bail.
metal screws from the case top. 7. After you have completed the capacitor
5. With the 5/16" nut driver, remove the discharge procedure for all four switch
screws holding the right and left case sides. boards, remove the PC board cover. Use
Remove the case sides by lifting up and the 5/16" nut driver.
out. 8. Remove plug J13 from the display board.
6. Perform the Capacitor Discharge 9. Place a jumper wire between pins C and D
Procedure described earlier in this section of wire feeder receptacle #2.
of the manual.

machine during the test. Wrap tape
POWER WAVE 450

F-117 F-117

board. See Figure F.1 for location of the WARNING
board and plug J30.
WARNING With the input power ON, there are high volt-
ages inside the machine, including the protec-
ELECTRIC SHOCK tion board. Do not reach into the machine or
can kill. touch any internal parts.

there are high voltages inside 17. Turn input power ON. The LCD display
the machine. Do not reach will read: ERROR: S.L. NOT INITIALIZED.
into the machine or touch any internal parts. Disregard this; the test can still be per-
formed.
12. Turn input power ON. 18. Remove the jumper between pins C and D
of wire feeder #2 receptacle.
13. With the volt/ohmmeter, check for 24 VAC
between plug J13 - pin 2 and pin 4. 19. With the volt/ohmmeter, measure the volt-
age drop across the 150 ohm resistor
A. If 24 VAC IS present, go to step 14. between J26 - pins 1 and 2. With the
NOTE: A voltage of 5 to 10 VDC is normal jumper removed, the reading should be
between these pins without the C to D zero volts (NO voltage drop).
jumper installed in the wirefeeder recepta- 20. Replace the jumper between pins C and D
cle. of wire feeder #2 receptacle. Measure the
B. If 24 VAC is NOT present, check for 24 voltage drop with the jumper installed.
VAC between plug J33 - pin 4 and pin 1. The reading should be about 2 VDC
See the Trigger Circuit Wiring Diagram, across the resistor.
Figure F.42. A. If 2 VDC is NOT present, check the conti-
C. If 24 VAC IS present between plug J33 pin nuity and integrity of leads #265 and 266
4 and pin 1, check the continuity and and their associated pins and connectors.
integrity of leads #373, 372, 102D, and The display board may be faulty -- replace
106A and their associated pin connectors. the display board.
See the Trigger Circuit Wiring Diagram. If B. If 2 VDC IS present across the resistor, the
the continuity checks are good, the pro- control board may be faulty -- replace the
tection board may be faulty. Replace the control board.
protection board.
D. If 24 VAC is NOT present between plug connect the five leads to the main contac-
J33 pin 4 and pin 1, check Auxiliary tor. Connect all molex plugs to the PC
Transformer #1, the 5 amp circuit breaker, boards and replace the cover with two
and the associated wiring. See the Trigger sheet metal screws. Install the machine
Circuit Wiring Diagram, Figure F.42. case sides, top, handle, and lift bail rubber
14. Turn input power to the machine OFF and gasket.
perform the Capacitor Discharge
Procedure.
15. Remove plug J26 from the Protection-

Control board. Attach a 150 ohm resistor
between plug J26 - pin 5 and J26 - pin 6
(the J26 plug, not the header on the con-
trol board).
16. Replace plug J13 into the display board,
POWER WAVE 450

F-118
Amphenols
AUXILIARY
24VAC
TRANSFORMER 1
P70
P70
5A
3 2 C.B.
8-pin 14-pin (334) (33) (32A)
J14 J26
"Amphenol 2" 4 1 5 (265) 5
P82 J37 (373) J13 J14 (266) J26
(2) (102D) J34 3 4 AC 4 6
C C 4
TO
FEEDER 2 (106A) J34 J37 (372) J13
(4) D D 7 2 2 DC +5V
"Amphenol 1" J14 (261) J26

P83 J37 (371) J12 1 1
(2) J34 1 2 AC J14 (262) J26
C C (102B) 11 2 2
FEEDER 1 TO
(105A) J34 J37 (374) J12
(4) D D 14 4 4 DC
P1
F F
E E 5 6 3
(4) D (105B) J38
D 7 3 2
(293) (296)
(75)
C (175A) (292) J10
C 4 2 7
(76) (176A) (291) J10 - TO MICRO
R B B 3 1 6
(177A) (294) J10 PROCESOR
POWER WAVE 450

(77) A 2 9 10 +10V
A
SQUARE WAVE TIG
PROTECTION BD
Remote Control Kit
6-pin
K941-1
Amphenols

EQUIPMENT
EXTERNAL INTERNAL
F-118
F-119 F-119
TRIGGER CIRCUIT AND WIRING HARNESS TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any short circuits or other problems in the trigger circuit
wiring or if there are any faulty PC boards, which would cause the 5 amp circuit breaker to
trip repeatedly.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Auxiliary Transformer #1 Secondary Circuit Wiring Diagram – Figure F.44.

POWER WAVE 450

F-120 F-120
TRIGGER CIRCUIT AND WIRING HARNESS TEST (continued)

FIGURE F.43 - PROTECTION BOARD PLUG/HEADER LOCATIONS
1 1 4 7 1 1 12 1 1
PROTECTION BD
1 1 1
4
16 14 6 6 11 14 6 4 4 4
J30 J31 J32 J33 J34 J35 J36 J37 J38 J39
3
TEST PROCEDURE C. With the volt/ohmmeter, check for continu-

ity again between J37 - pin 1 and J37 - pin
1. Remove main input supply power to the 4 of header J37. There should be continu-
machine. ity now. Remove the jumper.
2. With the 3/8" nut driver, remove the 4 D. With the volt/ohmmeter, check for continu-
screws that hold the handle to the machine. ity between J37 - pin 2 and J37 - pin 3 of
3. Remove the rubber gasket (cover seal) from header J37. There should be no continuity.
the lift bail. E. Connect a jumper between J34 - pin 4 and

4. With the 5/16" nut driver, remove the sheet J34 - pin 7 of header J34 on the protection
metal screws from the case top. board. This simulates the closing of the
trigger on wire feeder 2.
screws holding the right and left case sides. F. With the volt/ohmmeter, check for continu-
Remove the case sides by lifting up and ity again between J37 - pin 2 and J37 - pin
out. 3 of header J37. There should be continu-
ity now. Remove the jumper and connect
6. Perform the Capacitor Discharge plugs J34, J37, and J38 back into the pro-
Procedure described earlier in this section tection board.
of the manual.
If the continuity tests above detect a fault,
WARNING replace the protection board.
Before continuing with the board and inspect its pins and leads.

Make sure that the TRIG 1, TRIG 2, and

capacitor discharge proce- COMMON pins of plug J37 are not short-
dure to avoid electric shock. ed together (pins 1, 2, 3, 4, respectively).
Make sure that leads #371, #372, #373,
and #374 are not exposed. See the
7. After you have completed the capacitor dis- Auxiliary Transformer #1 Secondary
charge procedure for all four switch boards, Circuit Wiring Diagram, Figure F.44.
remove the PC board cover. Use the 5/16"
nut driver. 10. Connect plug J37 to the Protection board.
If you found no problem with plug J37 pins
8. Remove plugs J34, J37, and J38 from the and leads, replace the display board.
protection board. See Figure F.1 for loca-
tion. Continue with the following checks: 11. After the tests are completed and the
problem successfully repaired, reconnect
NOTE: Do not remove plug J33 from the pro- all plugs to their respective boards.
tection board. Replace the PC board cover with the two
A. With the volt/ohmmeter, check for continu- sheet metal screws.
ity between J37 - pin 1 and J37 - pin 4 of


header J37. There should be no continuity.
B. Connect a jumper between J34 - pin 11 gasket.
and J34 - pin 14 of header J34 of the pro-
tection board. This simulates the closing of
the trigger on wire feeder 1 or the remote.
POWER WAVE 450

F-121
DISPLAY POWER
BOARD BOARD
(P82) (P83) SQUARE WAVE TIG

WF2 RECEPTACLE WF1 RECEPTACLE PROTECTION BOARD
TRIG 1
TRIG 2
COMMON
COMMON
COMMON
COMMON
42V
24V
115V
TRIG 2
COMMON
COMMON
42V
24V
115V
TRIG 1
24V
TRIG 1
COMMON
J92
J92
J12
J13
J12
J13
J43
J43 42V
A
I
K
C
J
D
A
I
K
C
J
D
4
2
2
4
6
3
3
1
32D
32E
42C
102D
31C
106A
32B
32C
42B
102B
31B
105A
374
372
371
373
296
293
351
356
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J38
J38
J37
J37
J37
J37
J35
J35
1
6
4
2
1
3
3
2
5
6
3
4
1
7
8
12
13
10
11
14
5A
C.B.
FIGURE F.44
W 33 32A J33
2 1
POWER WAVE 450

COMMON
U 333 J33
5 3
42V
N 334 J33
3 4
24V
R 336
*336 J33
6 6
115V
AUXILIARY
TRANSFORMER 1
PROTECTION BOARD
AUXILIARY TRANSFORMER #1 SECONDARY CIRCUIT WIRING DIAGRAM
F-121
F-122
NOTES
POWER WAVE 450

F-122
F-123 F-123
INTERNAL REMOTE CONTROL TEST
WARNING
TEST DESCRIPTION
This test will determine if there is a fault in the circuitry that reads the control knob com-
mands of the K941-1 Remote Control Kit.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-124 F-124
INTERNAL REMOTE CONTROL TEST (continued)

J17 J16 J15 J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
the lift bail.
5. With the 5/16" nut driver, remove the nut driver.
Remove the case sides by lifting up and 8. Remove the 5 leads (3 heavy and 2 small)
out. T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents high
6. Perform the Capacitor Discharge voltage from being put on the machine dur-
Procedure described earlier in this section ing the test. Wrap tape around the lead
of the manual. ends to insulate them and prevent them
from touching.
board and plug J30.
POWER WAVE 450

F-125 F-125
INTERNAL REMOTE CONTROL TEST (continued)
WARNING A. No continuity between J10 - pin 10 and P1

- pin A (of the remote amphenol):
ELECTRIC SHOCK
can kill. • Check lead #177A between the remote
amphenol and the square wave TIG pro-
With input power ON, there tection board for continuity.
are high voltages inside the
machine, including the pro- • Check lead #294 between the square
tection board. Do not reach wave TIG protection board and the dis-
into the machine or touch any internal part. play board for continuity.
• Check plugs J10, J92, and J93 to make
sure the pins are seated properly and not
10. Turn input power ON. opened up or loose.
11. Turn the knob on the Remote Control Kit • Replace the square wave TIG protection
all the way counterclockwise. board.
12. With the volt/ohmmeter, check the voltage B. No continuity between J10 - pin 6 and P1
between plug J10 - pin 6 (positive) and - pin B (of the remote amphenol)
J10 - pin 7 (negative) on the display board.
It should be about zero volts. • Check lead #176A between the remote
amphenol and the square wave TIG pro-
13. With the Power Wave set in the SMAW tection board for continuity.
(CC) mode of operation, turn the knob on
the Remote Control Kit clockwise. The • Check lead #291 between the square
voltage between plug J10 - pin 6 and J10 wave TIG protection board and the dis-
- pin 7 should increase smoothly to about play board for continuity.
10.25 volts. If this happens but the dis- • Check plugs J10, J92, and J93 to make
play shows no change in the preset cur- sure the pins are seated properly and not
rent value (SET = ), replace the display opened up or loose.
board. If the voltage between pins 6 and 7
does not increase smoothly, test the asso- • Replace the square wave TIG protection
ciated wiring as follows: board.
A. Turn power switch SW1 to the OFF posi- C. No continuity between J10 - pin 7 and P1
tion and disconnect input power to the - pin C (of the remote amphenol)
machine.
• Check lead #175A between the remote
B. Perform the Capacitor Discharge Proce- amphenol and the square wave TIG pro-
dure described earlier in this section of the tection board for continuity.
manual.
• Check lead #292 between the square
wave TIG protection board and the dis-
WARNING play board for continuity.
• Check plugs J10, J92, and J93 to make
Before continuing with the test procedure, per- sure the pins are seated properly and not
form the capacitor discharge procedure to opened up or loose.
• Replace the square wave TIG protection
board.
C. Remove plug J10 from the display board.
Check for continuity between the following 15. Connect all the plugs disconnected for the
pins: tests above.
J10 - pin 10 and P1 - pin A (of the remote 16. Connect plug J30 into the protection
amphenol) board and replace the PC board cover
with two sheet metal screws.

J10 - pin 6 and P1 - pin B (of the remote
amphenol) 17. Connect the five leads to the main con-
tactor.
J10 - pin 7 and P1 - pin C (of the remote
amphenol) 18. Install the machine case sides and top.
14. If you find no continuity between any of 19. Install the handle and the lift bail rubber
these pins, do the following: gasket.
POWER WAVE 450

F-126
Amphenols
AUXILIARY
24VAC
TRANSFORMER 1
P70
P70
5A
3 2 C.B.
8-pin 14-pin (334) (33) (32A)
J14 J26
"Amphenol 2" 4 1 5 (265) 5
P82 J37 (373) J13 J14 (266) J26
(2) (102D) J34 3 4 AC 4 6
C C 4
TO
FEEDER 2 (106A) J34 J37 (372) J13
(4) D D 7 2 2 DC +5V
"Amphenol 1" J14 (261) J26

P83 J37 (371) J12 1 1
(2) J34 1 2 AC J14 (262) J26
C C (102B) 11 2 2
FEEDER 1 TO
(105A) J34 J37 (374) J12
(4) D D 14 4 4 DC
P1
F F
E E 5 6 3
(4) D (105B) J38
D 7 3 2
(293) (296)
(75)
C (175A) (292) J10
C 4 2 7
(76) (176A) (291) J10 - TO MICRO
R B B 3 1 6
POWER WAVE 450

(177A) (294) J10 +10V PROCESOR
(77) A A 2 9 10
SQUARE WAVE TIG
PROTECTION BD
Remote Control Kit
6-pin
K941-1
Amphenols

EQUIPMENT
EXTERNAL INTERNAL
F-126
F-127 F-127
K941-1 REMOTE CONTROL KIT TEST
WARNING
bleshooting assistance before you proceed. Call 1-888-935-3877
TEST DESCRIPTION
This test will determine if the K941-1 Remote Control Kit is faulty.
MATERIALS NEEDED

POWER WAVE 450

F-128 F-128
K941-1 REMOTE CONTROL KIT TEST (continued)

FIGURE F.47 - 6-PIN AMPHENOL LOCATION
1. MACHINE FRONT PANEL

2. REMOTE CONTROL AMPHENOL RECEPTACLE (6-PIN)
TEST PROCEDURE D. Set the Output Terminals switch to the OFF

position. With the volt/ohmmeter, check

1. Remove the Remote Control Kit from the the continuity between pins D and E of the
power source. amphenol. There should be NO continuity.
2. Perform the following tests. If any test fails, E. With the volt/ohmmeter, check the resis-
the Remote Control Kit is faulty and should tance between pins A and C of the amphe-
be replaced. nol. There should be 10 Kohm (+/- 10%)
A. With the volt/ohmmeter, check the conti- resistance between these pins at all times.
nuity between pin F of the 6-pin amphenol F. Turn the knob of the Remote Control Kit all
and the case of the Remote Control Kit. the way counterclockwise. With the
The reading should be zero ohms. volt/ohmmeter, check the resistance
B. With the volt/ohmmeter, check the conti- between pins A and B of the amphenol.
nuity between pin F and the other five pins There should be 10 Kohm (+/- 10%) resis-
of the 6-pin amphenol. The reading should tance between these pins now. Turn the
be open (no continuity). knob clockwise. The resistance between
pins A and B should smoothly decrease to
C. Set the Output Terminals switch to the ON zero ohms (+/- 10%).
position. With the volt/ohmmeter, check

the continuity between pins D and E of the
amphenol. There SHOULD BE continuity
(zero ohms).
POWER WAVE 450

F-129
Amphenols
AUXILIARY
24VAC
TRANSFORMER 1
P70
P70
5A
3 2 C.B.
8-pin 14-pin (334) (33) (32A)
J14 J26
"Amphenol 2" 4 1 5 (265) 5
P82 J37 (373) J13 J14 (266) J26
(2) (102D) J34 3 4 AC 4 6
C C 4
TO
FEEDER 2 (106A) J34 J37 (372) J13
(4) D D 7 2 2 DC +5V
"Amphenol 1" J14 (261) J26

P83 J37 (371) J12 1 1
(2) J34 1 2 AC J14 (262) J26
C C (102B) 11 2 2
FEEDER 1 TO
(105A) J34 J37 (374) J12
(4) D D 14 4 4 DC
P1
F F
E E 5 6 3
(4) D (105B) J38
D 7 3 2
(293) (296)
(75)
C (175A) (292) J10
C 4 2 7
POWER WAVE 450

(76) (176A) (291) J10 - TO MICRO
R B B 3 1 6
(177A) (294) J10 +10V PROCESOR
(77) A A 2 9 10
SQUARE WAVE TIG
PROTECTION BD
Remote Control Kit
6-pin
K941-1
Amphenols

EQUIPMENT
EXTERNAL INTERNAL
F-129
F-130
NOTES
POWER WAVE 450

F-130
F-131 F-131
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any faults in the 24 VAC trigger circuit between the
Power Wave and the K941-1 Remote Control Kit.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-132 F-132
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)

J17 J16 J15 J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING
NOTE: Before troubleshooting the remote con-
trol trigger circuit, troubleshoot the Before continuing with the
remote control kit itself. Refer to the


K941-1 Remote Control Kit Test in capacitor discharge proce-
this section of the manual. If that test is dure to avoid electric shock.
successful, perform the trigger circuit
test below.
2. With the 3/8" nut driver, remove the 4 the 5/16" nut driver.
8. Remove plug J12 from the display board.
the lift bail. 9. Place a jumper wire between pins D and E
of the six-pin amphenol.
metal screws from the case top. 10. Remove the 5 leads ( 3 heavy and 2 small)
5. With the 5/16" nut driver, remove the This is a safety precaution. It prevents


Remove the case sides by lifting up and machine during the test. Wrap tape
out. around the lead ends to insulate them and
6. Perform the Capacitor Discharge prevent them from touching.
of the manual.
POWER WAVE 450

F-133 F-133
K941-1 REMOTE CONTROL KIT TRIGGER CIRCUIT TEST (continued)

11. Remove plug J30 from the protection 15. Remove plug J26 from the protection
board. See Figure F.1 for location of the board. Attach a 150 ohm resistor between
board and plug J30. plug J26 - pin 1 and J26 - pin 2 (the J26
plug, not the header on the control board).
WARNING 16. Replace plug J12 into the display board,
ELECTRIC SHOCK can kill. WARNING

With the input power ON, there are high volt-
ages inside the machine. Do not reach into the ELECTRIC SHOCK can kill.
machine or touch any internal parts.
there are high voltages inside
the machine, including the
12. Turn input power ON.
protection board. Do not
13. With the volt/ohmmeter, check for 24 VAC reach into the machine or
between plug J12 - pin 2 and pin 4. touch any internal parts.
A. If 24 VAC IS present, go to step 14.
NOTE: A voltage of 5 to 10 VDC is normal 17. Turn input power ON. The LCD display
between these pins without the D will read: ERROR: S.L. NOT INITIALIZED.
to E jumper installed in the six-pin Disregard this; the test can still be per-
amphenol receptacle. formed.
B. If 24 VAC is NOT present, check for 24 18. Remove the jumper between pins D and E
VAC between plug J33 - pin 4 and pin 1. of the six-pin amphenol receptacle.
See the Trigger Circuit Wiring Diagram,
19. With the volt/ohmmeter, measure the volt-
Figure F.50.
age drop across the 150 ohm resistor
C. If 24 VAC IS present between plug J33 pin between J26 - pins 1 and 2. With the
4 and pin 1, check the continuity and jumper removed, the reading should be
integrity of leads #371, 374, 102C, 105B, zero volts (NO voltage drop).
296, and 293 and their associated pin con-

20. Replace the jumper between pins D and E
nectors. See the Trigger Circuit Wiring
of the six-pin amphenol receptacle.
Diagram. If the continuity checks are
Measure the voltage drop with the jumper
good, check the square wave TIG protec-
installed. The reading should be about 2
tion board by checking the continuity
VDC across the resistor.
through the following pins. See the Trigger
Circuit Wiring Diagram, Figure F.50. A. If 2 VDC is NOT present, check the conti-
nuity and integrity of leads #262 and 261
Plug J92 - pin 6 to plug J93 - pin 5.
and their associated pins and connectors.
Normal resistance is 4 ohms.
The display board may be faulty -- replace
Plug J92 - pin 3 to plug J93 - pin 7. the display board.
Normal resistance is 4 ohms.
B. If 2 VDC IS present across the resistor, the
If the square wave TIG protection board is control board may be faulty -- replace the
good, then the protection board may be faulty. control board.
Replace the protection board.
D. If 24 VAC is NOT present between plug connect the five leads to the main contac-
J33 pin 4 and pin 1, check Auxiliary tor. Connect all molex plugs to the PC
Transformer #1, the 5 amp circuit breaker, boards and replace the cover with two
and the associated wiring. See the Trigger sheet metal screws. Install the machine
Circuit Wiring Diagram, Figure F.50. case sides, top, handle, and lift bail rubber
gasket.
perform the capacitor discharge proce-
dure.
POWER WAVE 450
F-134
Amphenols
AUXILIARY
24VAC
TRANSFORMER 1
P70
P70
5A
3 2 C.B.
8-pin 14-pin (334) (33) (32A)
J14 J26
"Amphenol 2" 4 1 5 (265) 5
P82 J37 (373) J13 J14 (266) J26
(2) (102D) J34 3 4 AC 4 6
C C 4
TO
FEEDER 2 (106A) J34 J37 (372) J13
(4) D D 7 2 2 DC +5V
"Amphenol 1" J14 (261) J26

P83 J37 (371) J12 1 1
(2) J34 1 2 AC J14 (262) J26
C C (102B) 11 2 2
FEEDER 1 TO
(105A) J34 J37 (374) J12
(4) D D 14 4 4 DC
P1
F F
E E 5 6 3
(4) D (105B) J38
D 7 3 2
(293) (296)
(75)
C (175A) (292) J10
C 4 2 7
POWER WAVE 450

(76) (176A) (291) J10 - TO MICRO
R B B 3 1 6
(177A) (294) J10 +10V PROCESOR
(77) A A 2 9 10
SQUARE WAVE TIG
PROTECTION BD
Remote Control Kit
6-pin
K941-1
Amphenols

EQUIPMENT
EXTERNAL INTERNAL
F-134
F-135 F-135
LCD DISPLAY TEST
WARNING
TEST DESCRIPTION
This test will determine if there are any faults in the LCD display on the front panel or in the
associated hardware and wiring harness.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Internal Auxiliary Supply Wiring Diagram – Figure F.52

POWER WAVE 450

F-136 F-136
LCD DISPLAY TEST (continued)

J17 J16 J15 J14 J13 J12 J11 J10
TEST PROCEDURE
WARNING

the lift bail.
5. With the 5/16" nut driver, remove the nut driver.
Remove the case sides by lifting up and 8. Remove the 5 leads ( 3 heavy and 2 small)
out. T1, T2, T3 from main input contactor CR1.
This is a safety precaution. It prevents high
6. Perform the Capacitor Discharge voltage from being put on the machine dur-
ing the test. Wrap tape around the lead

of the manual. ends to insulate them and prevent them

from touching.
board and plug J30.
POWER WAVE 450

F-137 F-137
LCD DISPLAY TEST (continued)
13. Perform the following tests to locate the

WARNING problem: Auxiliary Transformer 1 Test
and Internal and Auxiliary Voltage
ELECTRIC SHOCK Supply Test. If these tests show no com-
can kill. ponent failures, go to step 14.
With input power ON, there 14. Make sure plug J19 is plugged into the
are high voltages inside the display board securely and that none of its
machine. Do not reach into the machine or pins are loose or broken. If the pins are all
touch any internal part. okay, replace the LCD display.
15. If the problem persists after replacing the
LCD display, replace the display board.
10. Turn input power ON.
16. After the problem has be repaired, install
11. With the volt/ohmmeter, check the follow- the machine case sides and top. Install
ing voltages between plug J16 pins at the the handle and the lift bail rubber gasket.
display board (without removing plug J16
from the display board):
pin 3
- pin 7
pin 7
pin 7
pin 7
12. Turn power switch SW1 to the OFF posi-

tion and disconnect input power to the
machine. Connect plug J30 into the pro-
tection board. Connect the five leads to
the main contactor.
If the voltages checked in step 11 were cor-
rect, go to step 14.
If any of the voltages in step 11 were not cor-
rect, go to step 13.
POWER WAVE 450

P82 P83 SQUARE WAVE TIG

WF2 RECEPTACLE WF1 RECEPTACLE PROTECTION BD
F-138
24V
TRIG 1
COMMON
COMMON
42V
24V
115V
COMMON
COMMON
42V
24V
115V
P82 TRIG 2
P83 TRIG 1
J92
J92
A
I
K
C
J
D
A
I
K
C
J
D
6
3
32D
32E
42C
102D
31C
106A
32B
32C
42B
102B
31B
105A
296
293
PROTECTION POWER
BOARD BOARD
5A
J34
J34
J38
3
2
INPUTS:
5
6
3
4
1
7
8
12
13
10
11
14
C.B.
W 33 32A 351 COMMON
2 1 1 3
U 333 356 42V
5 3 6 1
(42V)
J35 J43
N 334
3 4
(24V)
R 336
6 6
(115V) J33
J37
J37
J37
J37
4
2
3
1
AUXILIARY
372
373
374
TRANFORMER 1
DISPLAY
2
4
2
4
J13
J13 371
J12
J12
BOARD
OUTPUTS:
TRIG 2 TRIG 1 442
RS232 3 2 COMMON
POWER WAVE 450

POWER 443
2 3 +5VDC
444
6 6 -8VDC
446
9 9 -5VDC
DISPLAY
BOARD 447
10 10 +15VDC
POWER 448
1 11 +5VDC
449
7 12 COMMON
J16 J44
INTERNAL AUXILIARY SUPPLY
WIRING DIAGRAM
CONTROL
BOARD
226
6 6 -15VDC
FIGURE F.52 – INTERNAL AUXILIARY SUPPLY WIRING DIAGRAM
CONTROL 223
10 10 +15VDC
BOARD 224
POWER 11 11 +5VDC
225
12 12 COMMON
J22 J42
F-138
F-139 F-139
CALIBRATION PROCEDURES
POWER WAVE PC BOARD
REPLACEMENT CALIBRATION
PROCEDURES
If the display board is replaced, the display sensor cal-
ibration and a voltage calibration must be performed
for optimum performance. If the calibration is not
done the voltage may be accurate only to within 3
volts. If the sensor calibration is not done, the display
board may have some problems sensing the correct
overlay on power up.
WARNING
The display is shipped with the water cooler disabled.

If an internal water cooler is being used with the Power
Wave, you must use the Setup Overlay L9770-0 to
enable the water cooler before using the system.
If the control board is replaced, the voltage calibration

and current calibration must be performed for opti-
mum performance. If the calibration is not done, the
voltage may be accurate only to within 3 volts and the
current will be accurate only to within 15 amps.
POWER WAVE 450

F-140
NOTES
POWER WAVE 450

F-140
F-141 F-141
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD)
WARNING
TEST DESCRIPTION
This procedure recalibrates the eight overlay sensors of the Power Wave.
MATERIALS NEEDED
Power Wave Test and Calibration Overlay – L9660-255
Set-Up Overlay – L9660

POWER WAVE 450

F-142 F-142
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued)

FIGURE F.53 - SENSOR LOCATION BEHIND OVERLAY
1. LEADS 300, 301 TO PLUG J15 ON

DISPLAY BOARD
2. PIEZO-ELECTRIC ALARM BUZZER
PROCEDURE 6. If the calibration procedure is successful,

the display reads:
1. Turn the machine ON with no overlay in
place. The overlay ID number displayed CALIBRATION
should be 255. SUCCESSFUL
2. When the display reads SELECT A FUNC- After a few seconds the display changes to
TION, place the TEST overlay on the read:
machine.
INSERT CAL OVRLY
3. Press key #34 - OVERLAY CALIBRATE. PRESS ENTER . . .
The OVERLAY CALIBRATE light turns on
and for a few seconds the display reads: 7. Press key #133 - ENTER. the OVERLAY
CALIBRATE LED turns off, the machine
OVERLAY SENSOR exits the OVERLAY CALIBRATE function
CALIBRATION and the display reads:
Then the display changes to read: SELECT A FUNCTION
INSERT REF OVRLY 8. Turn the power switch SW1 to the OFF
PRESS ENTER . . .
position. To use the machine, place the
Insert set-up overlay appropriate overlay in position and turn
power switch SW1 to the ON position.
4. Press key #133 - ENTER. The machine will
begin to calibrate the eight overlay sensors. NOTE: Turn power switch SW1 to the OFF
5. If one of the sensors could not be calibrat- position and get the overlay that was
ed, the display reads: not recognized by the power wave.
Replace the TEST overlay with this
SENSOR X FAILED overlay and turn the machine ON. The
ENTER TO RETRY machine should recognize the overlay
Make sure the overlay is lined up properly and now. If it does not, the overlay is faulty.
press key #133 - ENTER. This will cause the
machine to try to calibrate the sensor again. If
a particular sensor continues to fail. Clean
sensor or replace display board.
POWER WAVE 450

F-143 F-143
QUICK VOLTAGE CALIBRATION
WARNING
PROCEDURE DESCRIPTION
This procedure is a quick way of calibrating the voltage sensing points (leads), provided that
the existing display board is capable of displaying the calibration numbers that are stored in
the display board.
MATERIALS NEEDED
A known “good” replacement display board
A Test and Calibration overlay L9660-255

POWER WAVE 450

F-144 F-144
QUICK VOLTAGE CALIBRATION (continued)

FIGURE F.54 - TEST AND CALIBRATION OVERLAY
PROCEDURE 5. Repeat the process by pressing the Voltage

Calibration function again. The next sens-
1. Before changing or disturbing the display ing lead may be selected by pressing the
board, power up the machine with the down Arrow Key (101). The above proce-
L9660-255 Test and Calibration overlay in dure must be repeated six times to obtain
place. See Figure F.54. and record the calibration number for six
2. Press the Voltage Calibration function (32). different voltage sensing points. These
The machine should display the following: points are the following:
VOLTAGE WIRE + Polarity (+67A)
+ POLARITY (+67A) + Polarity (+67B)
- Polarity (+21A)
3. Press the Enter Key (133) on the lower right - Polarity (+21B)
side of the overlay. The machine should + Polarity
display the following: - Polarity

ADJUST TO 30V 6. Install the “new” replacement display
CALIBRATION #=XX board.
NOTE: Here “XX” indicates a particular cali- 7. With the L9660-255 overlay installed, apply
bration number for a given voltage sensing power to the machine. Press the Voltage
point. Calibration function (32). Enter the re-
corded calibration numbers for each of the
six voltage sensing points. The calibration
WARNING numbers are entered by selecting the prop-
The machine’s output terminals will be electri- er sensing point (lead), pressing the Enter
cally “HOT” when the Enter Key is pressed. Key (133) and obtaining the display that
reads:
ADJUST TO 30V
4. Record the number displayed for the +67 CALIBRATION #=XX
wire and press the Enter Key (133) again.
The calibration number is changed using the
up/down Arrow Keys (100, 101). Press the

Enter Key when the desired number is dis-
played.
8. Repeat the process for all six sensing
points (leads).
9. Perform the Sensor Calibration Test.
POWER WAVE 450

F-145 F-145
FULL VOLTAGE CALIBRATION
WARNING
This procedure is necessary if the display board is replaced and the Quick Voltage Calibration
is NOT possible. The Full Voltage Calibration is also necessary if the snubber and/or control
boards are replaced.
MATERIALS NEEDED
A Test and Calibration Overlay L9660-255
A 300 amp, 30 volt resistive grid load. (A MIG welding load may be used if a grid load is
not available. Choose an argon rich 30 volt spray procedure.) See the topic Full
Voltage Calibration Using a Welding Arc in this section of the manual.
A calibrated DC voltmeter accurate to 30.0 volts +/- 0.1 volt.
A set of jumper leads to access the remote voltage sensing leads in the wire feeder
amphenol receptacles.
SETUP PROCEDURE
1. Using the jumper leads, connect 21A (H) and 67A (N), located in wire feeder receptacle
#1, to the machine’s positive output terminal.
2. Using the jumper leads, connect 21B (H) and 67B (N), located in wire feeder receptacle
#2, to the machine’s positive output terminal.
3. Connect the resistive grid load (or wire feeder) to the machine’s output terminals.
4. Connect the DC voltmeter to the machine’s output terminals. Do not connect the volt-
meter to the load. This avoids erroneous readings due to cable drop.
POWER WAVE 450

F-146 F-146
FULL VOLTAGE CALIBRATION(continued)

FIGURE F.55 - TEST AND CALIBRATION OVERLAY
PROCEDURE 6. With the machine loaded, monitor the refer-

ence voltage only (external voltmeter). It is
1. The voltage calibration numbers are stored the only important reading. Adjust the volt-
in the display board. They are program-
age using the Arrow Keys (100 and 101)
mable from the front panel using the Test
until the reference voltmeter reads 30.0
and Calibration Overlay.
volts. Press the Enter Key.
2. Change the PC board in question.
6a. If using a synergic 7 wire feeder, press
3. Install the Test and Calibration Overlay enter then adjust to the desired w.f.s Note
L9660-255 and power up the machine. See the gun will be electrically “hot” at this
Figure F.55. time.
4. Press the Voltage Calibration function (32).
The machine should display the following: CAUTION

VOLTAGE WIRE
+ POLARITY (+67A) WHEN LOADING THE MACHINE WITH THE
CASE PARTS REMOVED, BE CAREFUL NOT
TO OVERHEAT THE MACHINE.
5. Press the Enter Key (133) on the lower right
side of the overlay. The machine should 7. Repeat the process by pressing the Voltage
display the following: Calibration function again. The next volt-
age sensing point (lead) may be selected by
ADJUST TO 30V pressing the down Arrow Key (101). The
CALIBRATION #=XX above procedure must be repeated six
NOTE: Here “XX” indicates a particular cali- times to set the six sensing points (leads) to
bration number for a given voltage 30.0 volts. The six test points (leads) are
sensing point. the following:
+ Polarity (+67A)
WARNING + Polarity (+67B)
- Polarity (+21A)
The machine’s output terminals will be electri- - Polarity (+21B)
cally “HOT” when the Enter Key is pressed. + Polarity
- Polarity
8. If the display board is replaced or dis-
turbed, perform the Sensor Calibration
Test.
POWER WAVE 450
F-147 F-147
FULL VOLTAGE CALIBRATION USING A WELDING ARC

WARNING
This procedure is necessary if the display board is replaced and the Quick Voltage Calibration
or the Normal Full Voltage Calibration is NOT possible.
MATERIALS NEEDED
A Test and Calibration overlay L9660-255 (the test procedure can be done within this)
A Synergic 7 wire feeder.
A calibrated DC voltmeter accurate to 0.1 volts at 30.0 volts.
The proper welding wire and gas combination to produce a Spray Arc. For example,
0.035 L-50 wire with a 90% Argon and 10% CO2 blend of gas.
SETUP PROCEDURE
1. Connect a DC voltmeter to the machine’s negative output terminal and the conductor
block of the wire feeder.
2. Connect the Synergic 7 wire feeder to the Wire Feeder 1 amphenol on the back of the
Power Wave.

POWER WAVE 450

F-148 F-148

FIGURE F.55a - TEST AND CALIBRATION OVERLAY
PROCEDURE 6. Adjust the wire feed speed on the Synergic

7 to 500 IPM (some wire feed speed to get
1. The voltage calibration numbers are stored into the spray range).
in the display board. They are programma-
ble from the front panel using the Test and NOTE: When the Enter Key is pressed it will
Calibration Overlay. clear the wire feed speed to 200 IPM.
The wire feed speed must be adjusted
2. Change the display board in question. after pressing the Enter Key but before
3. Install the Test and Calibration overlay starting to weld.
L9660-255 (or do not insert any overlay into 7. Pull the trigger on the torch and start to
the machine) and power up the machine. weld. Hold a long stick out. This is not nor-
See Figure F.55a. If the -255 overlay is not mally a welding technique. The starting will
available, use Figure F.55a as a guide to see
be poor. The welding may be poor. Main-

which keys to press. tain a long, steady welding arc. While weld-
4. Press the Voltage Calibration function (32). ing, monitor the reference voltage only
The machine should display the following: (external voltmeter). It is the only important
reading. Adjust the voltage using the Arrow
VOLTAGE WIRE Keys (100 and 101) until the reference volt-
+ POLARITY (+67A) meter reads 30.0 volts. Record the number
5. Press the Enter Key (133) on the lower right on the display, “xx”. Press the Enter Key.
side of the overlay. The machine should Release the trigger on the torch.
display the following: 8. Repeat the process by pressing the Voltage
ADJUST TO 30V Calibration function (32) again. The next
CALIBRATION# = XX voltage sensing point may be selected by
pressing the down Arrow Key (101). Repeat
NOTE: Here “xx” indicates a particular cali- steps 5, 6, and 7 for the following test
bration number for a given voltage points.
sense point.
WARNING
The machine’s output terminals will be electri-
cally “HOT” when the Enter Key is pressed.
POWER WAVE 450

F-149 F-149
– POLARITY (+21A)
+ POLARITY
– POLARITY
NOTE: Do not attempt to weld for –Polarity

(+21A). Set the number to the same as
recorded for +Polarity (+67A). Also for
+Polarity and –Polarity, move the volt-
meter sense lead from the conductor
block of the wire feeder to the positive
output terminal on the front of the
machine.
9. Turn the machine off. Connect the

Synergic 7 to the Wire feeder 2 amphenol

on the back of the Power Wave machine.
10. Put the voltmeter sense lead back on the
wire feeder conductor block and repeat
the calibration process steps 5, 6, and 7
for the following test points:
+POLARITY (+67B)
–POLARITY (+21B)
NOTE: Do not attempt to weld for –Polarity
(+21B). Set the number to the same as
recorded for +Polarity (+67B).
POWER WAVE 450

F-150
NOTES
POWER WAVE 450

F-150
F-151 F-151
CURRENT CALIBRATION
WARNING
This procedure is necessary if the control and/or the shunt amplifier boards are replaced. The
current control is the most critical function in the Power Wave machine.
MATERIALS NEEDED
Test and Calibration Overlay L9660-255
A 300 amp, 30 volt resistance grid load
A small trimmer screwdriver
A calibrated DC ammeter accurate to read 300.0 amps +/- 1.0 amps.
A machine output triggering device such as the K941-1 Remote Control Kit.
SETUP PROCEDURE
1. Remove and install the replacement board in question.
FIGURE F.56 – PC BOARD REMOVED BUT STILL CONNECTED
Lay Control Board on top of machine.

Make sure it is snapped into the ground
plane assembly and insulated from the
case and other components.
Leads
POWER WAVE 450

F-152 F-152
CURRENT CALIBRATION (continued)
2. Locate the 10 turn trimmer potentiometer

located on the control board. It is the only CAUTION
trimmer on the board. If the trimmer is not
accessible with the control board installed, WHEN LOADING THE MACHINE WITH THE
then the board must be removed and laid CASE PARTS REMOVED. BE CAREFUL NOT
on the top of the PC board compartment. TO OVER HEAT THE MACHINE.
Be sure the control board is insulated from
the other boards and the case parts. All
wiring plugs must be connected to the con- 3. NOTE: If a wire feeder is NOT connected
trol board. See Figure F.56. to the Power Wave the machine
may not display output volts.
WARNING 4. Connect the resistance grid load to the
machine’s output terminals. Connect the

WHEN THE MACHINE CASE IS REMOVED reference ammeter in series with the grid
HIGH VOLTAGE POINTS ARE EXPOSED. load. See Figure F.57.
STAND DIRECTLY IN FRONT OF MACHINE
UNDER TEST.
EXPLODING PARTS CAN CAUSE INJURY.
FAILED PARTS CAN EXPLODE OR CAUSE
OTHER PARTS TO EXPLODE WHEN POWER
IS APPLIED. ALWAYS WEAR A FACE SHIELD
AND LONG SLEEVES WHEN SERVICING.
FIGURE F.57 – RESISTANCE GRID LOAD CONNECTIONS
POWER WAVE
– +
AMMETER
VOLT METER
RESISTANCE
GRID
LOAD
POWER WAVE 450

F-153 F-153
CURRENT CALIBRATION (continued)
FIGURE F.58 – TEST AND CALIBRATION OVERLAY

PROCEDURE
WARNING
1. Install the Test and Calibration Overlay and
apply power to the machine. See Figure The machine’s output terminals will be electri-
F.58. cally “HOT” when the trigger circuit is
2. Press the Manual Procedure Entry Key (64). activated.
The machine should display the following:
PROCESS 1 SETUP 5. Adjust the potentiometer until the reference

1-0 (external ammeter) reads 304 amps +/- 1.0
3. Toggle the Arrow Keys (100 and 101) until amps. The load voltage should be greater
the display reads: than 15 volts but less than 35 volts.
PROCESS 1 SETUP 6. Remove power to the machine.

1-6 7. If necessary re-install the control board.
4. Activate the external trigger device. 8. Replace the machine case parts.
(K941-1) and load the machine.
POWER WAVE 450

F-154
NOTES
POWER WAVE 450

F-154
F-155 F-155
T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the T1 auxiliary transformer for
maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver or socket wrench
Wire cutters

POWER WAVE 450

F-156 F-156
T1 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)

FIGURE F.59 - T1 AUXILIARY TRANSFORMER LOCATION
1. AUXILIARY TRANSFORMER T1
2. MOUNTING SCREW (2)
2
PROCEDURE 7. After you have completed the capacitor

1. Remove main input supply power to the boards, disconnect plugs P70, P71, and
machine. P73 that attach to the transformer. See
2. With the 3/8" nut driver, remove the 4 Figure F.59 for location.
screws that hold the handle to the machine. 8. With the wire cutters, cut any necessary
3. Remove the rubber gasket (cover seal) from cable ties (necessary for removal of the
the lift bail. transformer). Note the location of these
cable ties for reassembly.
metal screws from the case top. 9. With the 3/8" nut driver or socket wrench,
remove the two screws that mount the
5. With the 5/16" nut driver, remove the transformer to the machine base.
screws holding the right and left case sides. Remove the T1 auxiliary transformer.
out. 10. To install the T1 auxiliary transformer,
carefully position it onto the machine base
6. Perform the Capacitor Discharge Proce- and tighten the two mounting screws.
dure described earlier in this section of the Connect plugs P70, P71, and P73 to their
manual. respective receptacles on the transformer.
WARNING 11. Install the machine case sides and top.

Before continuing with the gasket.
POWER WAVE 450

F-157 F-157
WATER COOLER REMOVAL AND REPLACEMENT

For later model coolers (Inlet & Outlet on lower left of machine back)
Refer to IM645-A
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the machine water cooler
assembly for maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
9/16" Open end or box wrench
3/4" Open end wrench

POWER WAVE 450

F-158 F-158
WATER COOLER REMOVAL AND REPLACEMENT (continued)

FIGURE F.60 - WATER COOLER LOCATION
2
1
3
1. WATER COOLER ACCESS DOOR (ON

BACK PANEL)
2. WATER COOLING FITTINGS
3. CIRCUIT BREAKER
PROCEDURE
WARNING
NOTE: These instructions may vary slightly

with later model coolers. See instruc- Before continuing with the
tions included with cooler kit. test procedure, perform the
1. Remove main input supply power to the capacitor discharge proce-

screws that hold the handle to the machine. 7. After you have completed the capacitor dis-
3. Remove the rubber gasket (cover seal) from charge procedure for all four switch boards,
the lift bail. use the 5/16" nut driver to remove the water
cooler access door. See Figure F.60 for
4. With the 5/16" nut driver, remove the sheet location.
8. With the 3/8" open end or socket wrench,
5. With the 5/16" nut driver, remove the remove the two water cooler assembly
screws holding the right and left case sides. mounting screws. Slide the assembly to
Remove the case sides by lifting up and the left to better access the circuit breaker,
out. which will be removed in a moment.

6. Perform the Capacitor Discharge Proce- 9. With the 5/16" nut driver, remove the two
dure described earlier in this section of the sheet metal screws holding the lower case
manual. back panel.
POWER WAVE 450

F-159 F-159
WATER COOLER REMOVAL AND REPLACEMENT (continued)
10. With the 9/16" open end wrench, remove 15. To install the water cooler, slide the
the circuit breaker. assembly into the machine base. Make
sure the cooler fits under the retaining
11. Locate and disconnect plug J4, behind
clips. Connect the water lines to the back
the water cooler. Plug J 4, a large molex
panel and connect the plastic strain reliev-
plug, has two leads (H1A and H3A).
ers where they hold the water lines to the
Double-check that these are the leads
subframe.
feeding the plug; there is another large
molex plug in the same area that is not 16. Connect plugs 3 and 4, behind the water
connected to the water cooler. cooler assembly.
12. Disconnect Plug 3, a small molex plug 17. Attach the circuit breaker. Use the 9/16"
with four leads. This plug is also located open end wrench.
behind the water cooler.
18. Install the two 5/16" sheet metal screws
13. Slide out the water cooler assembly. Take that hold the lower case back panel.
care not to damage the reservoir tank and
19. Install the two 3/8" water cooler assembly
cooling coils.
mounting screws.
14. If complete removal is required, with the
20. Connect the water cooler lines to the back
3/4" and 11/16" open end wrenches, dis-
panel using the 3/4" and 11/16" wrenches.
connect the water cooler lines from the
machine back panel. Disconnect the 21. Set the tabs of the water cooler access
plastic strain relievers that hold the water door in place and secure the door with the
lines to the subframe. two 5/16" screws.
If disassembly of the water cooler is required, 22. Install the machine case sides and top.
refer to the Water Cooler Disassembly
gasket.
POWER WAVE 450

F-160
NOTES
POWER WAVE 450

F-160
F-161 F-161
WATER COOLER DISASSEMBLY
WARNING
DESCRIPTION
The following procedure will aid the technician in disassembly of the machine water cooler
assembly for maintenance or part replacement for early model coolers.
MATERIALS NEEDED
Pliers
5/16" Box wrench

POWER WAVE 450

F-162 F-162
WATER COOLER DISASSEMBLY (continued)

FIGURE F.61 - WATER COOLER DISASSEMBLY (EARLY MODEL)
2
3 1. RESERVOIR
2. TUBE SUPPORT BRACKET
3. ASSEMBLY FLOOR
PROCEDURE
WARNING

the lift bail.
out.
manual.
POWER WAVE 450

F-163 F-163
WATER COOLER DISASSEMBLY (continued)
Reservoir Removal Motor/Pump/Fan Assembly Removal

A. After you have completed the capacitor A. Perform the Reservoir Removal procedure.
B. With the 3/4" open end wrench, remove
boards, remove the water cooler assembly.
the two coolant hoses attached to the
Refer to the Water Cooler Removal and
motor/pump assembly.
Replacement Procedure in this section of
the manual. C. Remove the four wires leading from the
motor to the terminal block. Note the lead
B. Empty the coolant from the reservoir.
numbers and locations for reassembly.
Dispose of the coolant in a proper and
approved manner. D. With the Phillips head screw driver and the
5/16" box wrench, remove the four screws
C. With the Phillips head screw driver, remove
and nuts mounting the motor/pump/fan
the two screws holding the reservoir to the
assembly to the mounting platform.
cooling tube support bracket.
E. Carefully lift out the motor/pump/fan

D. With the Phillips head screw driver, remove
assembly.
the four screws holding the reservoir to the
floor of the assembly. F. Install the motor/pump/fan assembly by
carefully setting in onto the mounting plat-
E. With the pliers, carefully remove the two
form and attaching it with the four screws
coolant hoses from the reservoir.
and nuts. Connect the four wire leads from
F. Carefully slide out and lift the reservoir free the motor to the terminal block. Attach the
from the motor and fan blade. two coolant hoses to the motor/pump
assembly using the 3/4" open end wrench.
G. After repair, install the reservoir by careful-
ly setting it in place around the motor and 7. Install the reservoir according to the direc-
fan blade. With the pliers, install the two tions in the Reservoir Removal procedure.
coolant hoses to the reservoir. With the Install the water cooler assembly according
Phillips head screw driver, install the four to the Water Cooler Removal and Replace-
screws holding the reservoir to the floor of ment procedure in this section of the man-
the assembly and the two screws that hold ual.
it to the cooling tube support bracket.

Replace the old coolant with fresh coolant
and install the water cooler assembly into 9. Install the handle and the lift bail rubber
the machine according to the Water gasket.
Cooler Removal and Replacement
POWER WAVE 450

F-164
NOTES
POWER WAVE 450

F-164
F-165 F-165
T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the T2 auxiliary transformer for
MATERIALS NEEDED
5/16" Nut driver

POWER WAVE 450

F-166 F-166
T2 AUXILIARY TRANSFORMER REMOVAL AND REPLACEMENT (continued)

FIGURE F.62 - T2 AUXILIARY TRANSFORMER LOCATION
1. BASE
2. AUXILIARY TRANSFORMER T2 3
3. MOUNTING SCREW (2)
2
PROCEDURE 7. After you have completed the capacitor

1. Remove main input supply power to the boards, proceed to remove the T2 auxil-
machine. iary transformer. First you will have to
2. With the 3/8" nut driver, remove the 4 remove the water cooler; follow the Water
screws that hold the handle to the machine. Cooler Removal and Replacement
8. Disconnect the single molex plug
the lift bail.
attached to the transformer. See Figure
4. With the 5/16" nut driver, remove the sheet F.62 for location.
metal screws from the case top. 9. The 3/8" nut driver or socket wrench,
5. With the 5/16" nut driver, remove the remove the two screws that mount the trans-
screws holding the right and left case sides. former to the machine base. Remove the T2
Remove the case sides by lifting up and auxiliary transformer.
out. 10. To install the T2 auxiliary transformer,
6. Perform the Capacitor Discharge Proce- carefully position it onto the machine base
dure described earlier in this section of the and tighten the two mounting screws.
manual. Connect the molex plug to its receptacle
on the transformer.
11. Install the water cooler. Refer to the

WARNING Water Cooler Removal and
Replacement Procedure in this section
Before continuing with the test procedure, per- of the manual.
form the capacitor discharge procedure to
gasket.
POWER WAVE 450
F-167 F-167
FAN MOTOR REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the machine fan motor for main-
tenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
3/4" Open or box end wrench
Wire cutters

POWER WAVE 450

F-168 F-168
FAN MOTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.63 - FAN MOTOR LOCATION
1
1. MACHINE BACK
2. TERMINAL STRIP
3. FAN MOTOR AND MOUNTING BRACKET
PROCEDURE
WARNING

the lift bail.
use the wire cutters to cut any necessary
5. With the 5/16" nut driver, remove the cable ties (necessary for removal of the fan
screws holding the right and left case sides. motor) holding the fan motor leads togeth-
Remove the case sides by lifting up and er. Note the location of these cable ties for
out. reassembly.
6. Perform the Capacitor Discharge 8. Remove the fan motor leads from the ter-
Procedure described earlier in this section minal strip.

of the manual.
9. With the 5/16" nut driver, remove the water
cooler access door. Then remove the four
screws from the lower rear panel.
POWER WAVE 450

F-169 F-169
FAN MOTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.64 - MACHINE BACK SECURED TO LIFT BAIL.
2
1. MACHINE BACK
2. LIFT BAIL
11. With the 3/4" wrench, remove the lead 17. To install the fan motor, do the following:
connected to the rear positive (+) output Carefully position the fan motor into place
terminal. on the mounting bracket with the leads
toward the terminal strip. Install the flat

12. Swing the back panel up and secure it to
washers, split-ring lock washers, and nuts
the lift bail. See Figure F.64. Use heavy
to the motor mounting bolts. Carefully
string or wire. BE CAREFUL NOT TO
slide the fan blade all the way onto the
DAMAGE THE RS232 CONNECTOR OR
motor shaft. The side of the hub with the
THE WIREFEEDER RECEPTACLES.
metal clip goes toward the motor. Install
13. With the slot head screw driver, remove the clip so that it grips the rounded side of
the clip holding the fan blade onto the the D-shaped shaft, not the flat. Swing
motor shaft. the back panel back down, being careful
not to damage the RS232 connector or
14. Remove the fan blade by carefully sliding
the wire feeder receptacles. Install the
it off the motor shaft.
lead to the rear positive (+) output termi-
15. With the 11/32" nut driver or socket nal. Install the case back lower sides and
wrench, remove the two fan motor mount- the lower rear panel with the 5/16" screws.
ing nuts. Remove the split-ring lock Attach the fan motor leads to the terminal
washers and flat washers. strip and replace the tie wraps cut during
removal so that the motor leads are held
16. Remove the fan motor by sliding it out of

away from the fan blades.
the mounting bracket and free of the
machine. 18. Install the machine case sides and top.
NOTE: Repeat this procedure to remove the 19. Install the handle and the lift bail rubber
second fan motor if necessary. gasket.
POWER WAVE 450

F-170
NOTES
POWER WAVE 450

F-170
F-171 F-171
INPUT RECTIFIER REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier for mainte-
nance or replacement.
MATERIALS NEEDED
5 mm Allen wrench
10 mm Open end wrench
RTV Silicone sealant (Lincoln E2861)
Dow Corning 340 Joint Compound (Lincoln E1868)
S18491 M.O.V. Assembly (if necessary)

POWER WAVE 450

F-172 F-172
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)

FIGURE F.65 - INPUT RECTIFIER LOCATION
CR1
6
1. MAIN CONTACTOR
2. M.O.V. ASSEMBLY
3. SILICONE SEALANT
4. INPUT RECTIFIER
5. 5MM ALLEN SCREW
6. HEAT SINK PANEL
PROCEDURE WARNING

the lift bail.
peel the silicone sealant away from the
5. With the 5/16" nut driver, remove the M.O.V. assembly in order to expose the
screws holding the right and left case sides. heads of the screws that attach the three
Remove the case sides by lifting up and heavy leads from the main input contactor
out. to the input rectifier. See Figure F.65.
6. Perform the Capacitor Discharge 8. With the Phillips head screw driver, remove
the three heavy leads from the input

of the manual. rectifier.
9. With the Phillips head screw driver, remove
the positive (+) and negative (-) leads from
the input rectifier.
POWER WAVE 450

F-173 F-173
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
10. With the 5 mm Allen wrench and the 10 13. With the Phillips head screw driver, attach
mm open end wrench, remove the two the positive (+) and negative (-) leads to
screws mounting the input rectifier to the the input rectifier. Attach the three heavy
heat sink panel. leads and the M.O.V. assembly to the
input rectifier. Replace the M.O.V. assem-
11. When replacing the input rectifier, apply a
bly if it appears damaged.
thin, even coating of Dow Corning 340
Joint Compound (Lincoln T12837) to the 14. Apply silicone sealant to the M.O.V.
mating surfaces between the input rectifi- assembly connections.
er and the heat sink panel. Avoid applying
the compound to either the mounting
holes or the mounting hardware. 16. Install the handle and the lift bail rubber
gasket.
12. Mount the input rectifier to the heat sink
panel and tighten the two mounting

screws with the 5 mm Allen wrench and
the 10 mm open end wrench. Be sure to
tighten the screws evenly.
POWER WAVE 450

F-174
NOTES
POWER WAVE 450

F-174
F-175 F-175
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT

(CONTROL BOARD, POWER BOARD,
AND PROTECTION BOARD)
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the control, power, or protection
printed circuit boards for maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-176 F-176

(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)
FIGURE F.66 - PC BOARD REMOVAL
1
1. PC BOARD COVER
2. PC BOARD ASSEMBLY
3. RETAINER CLIPS
PROCEDURE
WARNING
the lift bail.
screws holding the printed circuit board

screws holding the right and left case sides. cover in place. Slide the cover forward and
Remove the case sides by lifting up and lift up to remove it.
out.
of the manual.
POWER WAVE 450

F-177 F-177

(CONTROL BOARD, POWER BOARD, AND PROTECTION BOARD) (continued)
10. When reinstalling the PC board, make cer-

CAUTION tain the tabs at the bottom of the board fit
into the slots on the compartment floor.
Be sure to follow the recommended static-free When the board is properly seated, the
methods for handling printed circuit boards. retainer clips will snap into the locked
Failure to do so can result in permanent dam- position.
age to the equipment.
11. Install the molex plugs removed earlier.
Be sure to fit the each plug into its respec-
tive receptacle on the board.
8. Remove the molex plugs from the PC board
you are removing. 12. Perform appropriate calibration procedure
per flowchart in Figure F.67.
NOTE: The plugs are numbered in order from
left to right. 13. Install the PC board cover and tighten the
two screws with the 5/16" nut driver.
9. Depress the two PC board retainer clips
located on the left and right sides of the 14. Install the machine case sides and top.
board. Lift the board by the clips to remove
it.
gasket.
FIGURE F.67 – PC BOARD REPLACEMENT CALIBRATION REQUIREMENTS
SHUNT CONTROL
DISPLAY SNUBBER
AMPLIFIER BOARD
BOARD BOARD
BOARD REPLACED
REPLACED REPLACED
REPLACED
IF POSSIBLE
QUICK
VOLTAGE CURRENT
CALIBRATION CALIBRATION
FULL
VOLTAGE
CALIBRATION
POWER WAVE 450

F-178
NOTES
POWER WAVE 450

F-178
F-179 F-179
DISPLAY BOARD REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the display board for mainte-
nance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver

POWER WAVE 450

F-180 F-180
DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.68 - DISPLAY BOARD REMOVAL
3
2
4
1
5
1. MOLEX PLUG HEADERS (8)
2. KEY PAD RIBBON CONNECTOR
3. LCD DISPLAY WINDOW
4. LCD CONNECTOR
5. MOUNTING PIN HOLE
NOTE: Before changing or disturbing the dis-

WARNING
play board follow the procedure outlined under

QUICK VOLTAGE CALIBRATION (Fig. F.54)
in this section. Before continuing with the
PROCEDURE capacitor discharge proce-
machine.
screws that hold the handle to the machine. CAUTION
3. Remove the rubber gasket (cover seal) from Be sure to follow the recommended static-free
the lift bail. methods for handling printed circuit boards.
4. With the 5/16" nut driver, remove the sheet Failure to do so can result in permanent dam-
metal screws from the case top. age to the equipment.


out. 7. After you have completed the capacitor dis-
6. Perform the Capacitor Discharge carefully remove the eight molex plugs from
Procedure described earlier in this section the lower portion of the display board.
of the manual.
POWER WAVE 450

F-181 F-181
DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)
8. Carefully remove the key pad ribbon con- 11. Reinstall the display board by carefully
nector from the right side of the display pressing it onto its mounting pins. Install
board. the LCD display connector, the key pad
connector, and the eight molex plugs that
9. Carefully remove the connector to the LCD
fit along the bottom portion of the display
display.
board.
12. After you have installed the display board
CAUTION (a new one or the old one), you must per-
form the Display Board Sensor
Do not touch the sensors located on the left
Calibration Test and necessary voltage
side of the display board when you handle it
calibration. Refer to this test in the test
for removal or replacement. Failure to do so
portion of this section of the manual.
can result in permanent damage to the sen-
sors. 13. After performing the Display Board
Sensor Calibration Test, install the

10. Carefully remove the display board from gasket.
the its mounting pins. Remove the display
board by lifting up and out.
POWER WAVE 450

F-182
NOTES
POWER WAVE 450

F-182
F-183 F-183
MAIN INPUT CONTACTOR (CR1) REMOVAL

AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the main input contactor for
MATERIALS NEEDED
5/16" Nut driver

POWER WAVE 450

F-184 F-184
MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)

FIGURE F.69 - MAIN CONTACTOR
A
L1
L3
L1 L2 L3
324
CR1 326
T1 T2 T3
T1
T3
PROCEDURE WARNING

the lift bail.
with the slot head screw driver, remove the
5. With the 5/16" nut driver, remove the three heavy leads from the output side of
screws holding the right and left case sides. the contactor.
out. 8. With the slot head screw driver, remove the
two small leads (L1A and L3A) from the
6. Perform the Capacitor Discharge Proce- input side of the contactor.
manual.
POWER WAVE 450

F-185 F-185
MAIN INPUT CONTACTOR (CR1) REMOVAL AND REPLACEMENT (continued)

9. With the slot head screw driver, remove 13. For replacement, mount the contactor to
the two small leads (T1 and T3) from the the vertical mounting panel with the two
output side of the contactor. 3/8" mounting screws and nuts.
10. With the slot head screw driver, remove 14. Attach all the contactor leads: coil leads
the two contactor coil leads (#324 and #324 and #326; small leads T1 and T3 to
#326) from the contactor. the output side; three heavy leads to the
output side; small leads L1A and L3A and
11. With the slot head screw driver and 3/8"
three input leads to the input side. Tighten
wrench, loosen the two mounting screws
all evenly with the slot head screw driver.
and nuts holding the contactor to the ver-
tical mounting panel. 15. Install the machine case sides and top.
12. Remove the contactor by lifting up and 16. Install the handle and the lift bail rubber
out. gasket.
POWER WAVE 450

F-186
NOTES
POWER WAVE 450

F-186
F-187 F-187
OUTPUT RECTIFIER BRIDGE REMOVAL

AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier bridge for
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
Wire cutters
This procedure takes approximately 1 hour 30 minutes to perform.

POWER WAVE 450

F-188 F-188
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)

FIGURE F.70 - OUTPUT RECTIFIER BRIDGE LOCATION
1. OUTPUT RECTIFIER BRIDGE

PROCEDURE WARNING
the lift bail.
cut all necessary cable ties (necessary for
5. With the 5/16" nut driver, remove the removal of the output rectifier bridge) on the
screws holding the right and left case sides. left side of the machine.

out. 8. Disconnect all necessary leads from the left
side of the output rectifier bridge (two
6. Perform the Capacitor Discharge heavy and two small leads). Place the fas-
Procedure described earlier in this section tener hardware back together to avoid loss.
of the manual.
POWER WAVE 450

F-189 F-189
9. Cut all necessary cable ties on the right 11. With the 7/16" wrench, remove the bolts,
side of the machine and disconnect all top and bottom, that connect the heat
necessary leads (two heavy and two small sink and glastic insulated angle mounting
leads) from the right side of the output piece at the middle. With the side bolts
rectifier bridge. Place the fastener hard- already removed, it is easier to access the
ware back together onto the lead ends to middle bolts.
avoid loss.
12. With the 7/16" wrench, remove the bolt,
10. On the right side of the machine, use the nut, and split-ring lock washer from the
7/16" open end wrench to remove the bolt tab connection at the bottom of the heat
that connects the heat sink at the top to sink. The input rectifier bridge can now be
the glastic insulated angle mounting removed. You may have to bend the bot-
piece. Then remove the carriage bolt that tom tab slightly in order to get it past the
holds the glastic insulated angle mounting main transformer.
piece at the bottom to the subframe.

Repeat the same procedure on the left
side of the machine. Save the shake-
proof washers and nuts for reassembly.
FIGURE F.71 – HEAT SINK REMOVAL
1
2
3
1. GLASTIC INSULATED ANGLE MOUNTING

PIECE (TOP)
2. BOTTOM TAB CONNECTION
3. GLASTIC INSULATED ANGLE MOUNTING
PIECE (BOTTOM)
4. HEAT SINK
POWER WAVE 450

F-190 F-190
FIGURE F.72 – CABLE TIE LOCATIONS

PRIMARY HARNESS ASSEMBLY (BLACK) SECONDARY HARNESS ASSEMBLY (WHITE)
13. For reassembly, attach the glastic insulat- 15. Install the machine case sides and top.
ed angle mounting pieces to the heat sink
first. Slide the bridge into position and

gasket.
then fasten the bottom tab to the sub-
frame with the bolt, split-ring lock washer
and nut. Then attach and tighten down
the top and bottom bolts that hold the
heat sink on both sides of the machine.
14. Reconnect the leads on both sides of the
bridge. Install new cable ties according to
Figure F.72.
POWER WAVE 450

F-191 F-191
FET MODULE REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the FET modules and main
transformer for maintenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
3/8" Socket wrench
1/2" Socket wrench

Wire cutters
This procedure takes approximately 3 hours 30 minutes to perform.

POWER WAVE 450

F-192 F-192
FET MODULE REMOVAL AND REPLACEMENT (continued)

FIGURE F.73 - FET MODULE LOCATION
3
1. FET MODULE
2. PIEZO ALARM BUZZER
3. FET MODULE LOCKING BAR
4. RESISTORS
PROCEDURE WARNING

the lift bail.
5. With the 5/16" nut driver, remove the screws holding the printed circuit board
screws holding the right and left case sides. cover in place. Slide the cover forward and
Remove the case sides by lifting up and lift up to remove it.
out.
6. Perform the Capacitor Discharge Proce- CAUTION
manual. Be sure to follow the recommended static-free

methods for handling printed circuit boards.
Failure to do so can result in permanent dam-
age to the equipment.
8. Remove the molex plugs from the PC

boards except the display board.
POWER WAVE 450
F-193 F-193

FIGURE F.74 - LIFT BAFFLE/BAIL REMOVAL
2
1. LIFT BAIL
2. LIFT BAIL BAFFLE
3. SUBFRAME STAND
3
9. With the wire cutters, cut all necessary 17. With the 3/8" wrench, remove the six
cable ties. resistors that are attached to the top of the
subframe (four on the top right, two on the
10. Disconnect the leads to the output rectifi-
top left). Note the physical placement and
er bridge. Cut all necessary cable ties.

wiring for reassembly; labeling is recom-

11. Disconnect two plugs from the snubber mended. Also loosen the bottom resistors
board. closest to the FET module assembly. This
will allow the capacitors to clear the resis-
12. Disconnect the output cable strap and pull
tors when the FET module assembly
it through and free from the lift bail baffle
slides forward for removal.
eyelet hole. Cut any necessary cable ties.
13. With the 3/8" nut driver, remove the two
sheet metal screw holding the ground
screws that hold the lift bail baffle. See
leads to the right rear of the subframe. On
Figure F.74. Remove the baffle.
the left side, unclip the cable tie holding
14. With the 1/2" socket wrench, remove the the leads. Let the back of the subframe
four bolts (two on each side of the swing out carefully; the harness will sup-
machine) from the lift bail. See Figure port it.
F.74. Slide the lift bail up and free of the
19. With the 5/16" wrench, remove the two
machine.
sheet metal screws holding the subframe
15. On the right side of the machine, cut any bottom support section. Note the green
necessary cable ties to free the wiring har- ground lead on the left side; be sure to
ness from the subframe. reconnect it during reassembly.
16. With the Phillips head screw driver, 20. With the 7/16" wrench, disconnect the
remove the screw that holds the piezo- heavy current-carrying flat copper strap
electric alarm buzzer in place. Cut the running from the shunt amplifier to the
cable tie that holds the wire. output rectifier bridge.
POWER WAVE 450

F-194 F-194
21. Remove the water cooler assembly in Replacement of the FET Module Assembly:
order to access the retainer clips that hold
27. Carefully set the assembly into the bottom
the bottom of the FET module assembly in
of the machine. The terminal label should
place. (Complete removal of the unit
face the front (toward the main trans-
should not be necessary.) Refer to the
former).
Water Cooler Removal and
Replacement Procedure in this section 28. Connect all leads to their appropriate ter-
of the module. minals on the assembly. Use the Wiring
Diagram for reference.
22. Remove the locking bar from the top of
the subframe where it secures the FET 29. Carefully position the subframe on top of
module assembly. Depress the top and the FET module assembly. Slide the
bottom retainer clips with the slot head assembly into place so that the retainer
screw driver so that the FET module clips snap into their slots, top and bottom.
assembly can slide forward. Fit the locking bar into place on top of the
subframe to secure the FET module
23. Slowly lift and remove the subframe, mak-
assembly.
ing sure no clips, cable ties, or lead con-
nections are still holding it.
24. With the wire cutters, cut all necessary
cable ties holding the FET module assem-
bly to the wiring harness. Using needle
nose pliers, disconnect the leads attached
to the FET module assembly (all red and
white leads should remain connected).
Refer to the Wiring Diagram to determine
which leads should be disconnected. The
main transformer and the reconnect mod-
ule must be free of the FET module
assembly. Also disconnect the thermostat
lead.
25. Carefully lift the FET module assembly

and remove it from the machine.
26. With the FET module assembly removed,
the main transformer, background choke,
and output choke are now easily accessi-
ble. Refer to the Main Transformer
Removal and Replacement Procedure
in this section of the module.
POWER WAVE 450

F-195 F-195
30. Install the water cooler assembly. Refer to 35. Slide the lift bail into place. With the 1/2"
the Water Cooler Removal and Replace- socket wrench, install the four bolts (two
ment Procedure in this section of the on each side of the machine) to secure the
module. lift bail. With the 3/8" nut driver, install the
two screws to secure the lift bail baffle.
31. With the 7/16" wrench, connect the heavy
Feed the output cable strap through the
current-carrying flat copper strap running
lift bail baffle eyelet hole. Replace any
from the shunt amplifier to the output rec-
necessary cable ties.
tifier bridge. With a 5/16" wrench, install
the two sheet metal screws holding the 36. Connect the two plugs to the snubber
subframe bottom support section. board.
Connect the green ground lead on the left
37. Connect the leads to the output rectifier
side.
bridge. Replace all necessary cable ties.
32. Swing the back of the subframe into
38. Install the molex plugs to the PC boards.
place. With the 5/16" nut driver, install the

Refer to Figure F.1, PC Board Connector
sheet metal screw holding the ground
Locations in this section of the manual.
leads to the right rear of the subframe. On
the left side, clip the cable tie to hold the 39. Install the printed circuit board cover with
leads. two 5/16" screws.
33. With the 3/8" wrench, install the six resis- 40. Replace any necessary cable ties for the
tors that are attached to the top of the wiring harness and other leads that were
subframe (four on the top right, two on the cut during disassembly.
top left) according to the markings you
made during disassembly. Also tighten
the bottom resistors closest to the FET 42. Install the handle and the lift bail rubber
module assembly. gasket.
34. With the Phillips head screw driver, install 43. Prior to applying full input power perform
the screw that holds the piezo-electric the Pre-Power Up Switch Board Test.
alarm buzzer in place. Replace the cable
tie that holds the wire.
POWER WAVE 450

F-196
NOTES
POWER WAVE 450

F-196
F-197 F-197
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
DESCRIPTION
The following procedure will aid the technician in removing the main transformer for main-
tenance or replacement.
MATERIALS NEEDED
5/16" Nut driver
3/8" Nut driver
3/8" Socket wrench
1/2" Socket wrench

Wire cutters
This procedure takes approximately 2 hours 30 minutes to perform.

POWER WAVE 450

F-198 F-198
MAIN TRANSFORMER/CHOKE REMOVAL AND REPLACEMENT (continued)

FIGURE F.75 - MAIN TRANSFORMER LOCATION
1. MAIN TRANSFORMER
PROCEDURE 7. After you have completed the capacitor dis-

1. Remove main input supply power to the perform the FET Module Assembly
machine.
Removal Procedure. Refer to the proce-

2. With the 3/8" nut driver, remove the 4 dure in this section of the manual. After the
screws that hold the handle to the machine. FET module assembly has been removed,
the main transformer and chokes are easily
3. Remove the rubber gasket (cover seal) from accessible.
the lift bail.
8. With the 3/8" socket wrench, remove the
4. With the 5/16" nut driver, remove the sheet four main transformer mounting bolts.
9. Disconnect the heavy leads between the
5. With the 5/16" nut driver, remove the main transformer and the choke assembly.
screws holding the right and left case sides. You will need to cut the cable ties on the
Remove the case sides by lifting up and insulating sleeve and slide the sleeve for-
out. ward to access the connection.
6. Perform the Capacitor Discharge 10. Lift the main transformer out. Remove the
Procedure described earlier in this section of background or output chokes if necessary
the manual. by removing any mounting bolts holding
WARNING the chokes to the machine frame bottom.

11. After reassembly test on high voltage
Before continuing with the test input and reconnect.
procedure, perform the capaci-
tor discharge procedure to avoid
electric shock.
POWER WAVE 450

F-199 F-199
PRE-POWERUP SWITCH BOARD TEST PROCEDURE

FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2
WARNING
DESCRIPTION
The following tests and procedures must be performed if the main power FET module has
been replaced in the Power Wave. These tests are necessary to ensure that the FET
module has been installed and connected properly.
This procedure takes approximately 2 hours to perform.
BEWARE:
ISOLATED POWER SUPPLIES AND METERING MUST BE USED: CATASTROPHIC PC
BOARD DAMAGE WILL OCCUR IF THE VOLTAGE SUPPLIES AND METERING ARE NOT
COMPLETELY ELECTRICALLY ISOLATED.
MATERIALS NEEDED
Calibration and Test Overlay L9660-255
Isolation transformer (for oscilloscope)
Isolation transformer 115vac @ 3 amps (min) circuit of figure #1
Isolation transformer 115vac @ 2 amps (min) circuit of figure #3
Variable transformer 3 amps (min)
Oscilloscope
*Current probe Tektronic P6201
or equivalent
Voltmeters
Fuse 5 amps (2).
P70 adapter
Female connector S18247-6
Male connector S18249-6
Male pin S8053-122
Female pin S8053-123
P23 adapter
Male connector S18247-6
Female pin S8053-123
Toggle switch (SPST)
*An alternate method of testing using an isolated oscilloscope may be used.
POWER WAVE 450

F-200 F-200

FOR REPLACEMENT OF SWITCH ASSEMBLY G2402-2 (continued)
FILTER CAPACITOR POLARITY across one of the 7.5K ohm bleeder resistors
TEST (R9 or R10). See wiring diagram.
1. Perform this procedure with the input power

removed. Perform the CAPACITOR DIS- 4. Attach the positive meter probe to wire #9
CHARGE Procedure to remove any charge and the negative meter probe to lead #12.
from the input filter capacitors. The resistance should slowly increase to a
value between 3K ohms and 3.5K ohms.
2. Configure the machine for 230VAC opera-
5. Repeat the procedure for the other bleeder
tion.
(7.5K ohm) resistor.
3. Attach the ohmmeter (set to 1 K ohm range)
FIGURE F.76 - AC SUPPLY LEADS
FUSE
PRIMARY 5A INPUT RECTIFIER: AC1 (T1)
ISOLATED VOLTAGE
115 VAC VARIABLE INPUT RECTIFIER: AC3 (T3)
0 115 VAC
SETUP THE POWER WAVE FOR WARNING

PRETEST
ALL AC SUPPLIES MUST BE ELECTRICALLY

1. Turn the input power switch to the OFF ISOLATED (Isolation transformers). THE
position. PRINTED CIRCUIT BOARDS WILL BE DAM-
AGED IF THE AC SUPPLIES ARE NOT
2. Unplug P73. See wiring diagram.
ISOLATED.
3. Install the L9660-255 Calibration & Test over-
lay into the Power Wave.
6. Monitor the filter capacitor voltage as per
4. Construct an isolated variable AC supply
Figure F.77.
circuit as shown in Figure F.76 using the
following equipment:
Isolation transformer 115vac @ 3 amps. WARNING
5 amp Variac.
WARNING: ALL METERS AND OSCILLO-
5 amp Fuse.
SCOPES MUST BE ELECTRICALLY ISOLAT-
5. Connect the variable AC supply leads to the ED (Isolation transformers).
Power Wave input rectifier terminals AC1 (T1),
and AC3 (T3). See Figure F.76. Make certain
the variac is at zero volts output.
POWER WAVE 450

F-201 F-201

FIGURE F.77 - FILTER CAPACITOR VOLTAGE
+ 9L R9
400 VDC
VOLTMETER 12L
+ 9M R 10
400 VDC
VOLTMETER 12M
WARNING WARNING
MAKE SURE FILTER CAPACITORS ARE ALL AC SUPPLIES MUST BE ELECTRICAL-
DISCHARGED LY ISOLATED (isolation transformers). THE
PRINTED CIRCUIT BOARDS WILL BE
DAMAGED IF THE AC SUPPLIES ARE NOT
1. Construct a 115VAC pretest power supply ISOLATED.
as per Figure F.78 using the following:
Switch (SPST)
Fuse (5 amp max)
P70 adapter
POWER WAVE 450

F-202 F-202

FIGURE F.78 - PRETEST POWER SUPPLY
PRETEST POWER 5A
SWITCH FUSE
ISOLATED
115 VAC
P70 P70
2 2
3 3
5 5
6 6
Connect the pretest power supply to plug P70 as 1. Release wire tension and pull gun trigger.
per Figure F.78. See wiring diagram.
2. Jumper pins C and D on wire feeder input con-
nector.
ARC START PW450 WITH WIREFEEDER
The arc start may be initiated by any of the follow- 3. Jumper pins D and E on front panel amphenol
ing methods: connector near welding output terminals.
POWER WAVE 450

F-203 F-203

ARC START FOR PW450 ROBOTIC 3. Leave plug J103 connected to the interface
1. Construct and connect an arc start circuit as board.
per Figure F.79.
2. Install leads and an arc start switch into plug
J103 pin 10 to pin 11 on the interface PC
board. Make sure the arc start switch leads
are long enough to reach outside of the
machine case.
FIGURE F.79 - SHUNT CONNECTIONS
1 500
2 501
3 542 TO
J34
4 543 P83
INTERFACE
5 R RECEPTACLE
6 U
7 B
INSTALL LEADS
8 539 AND SWITCH
J103 9 541
INTERFACE
BOARD 10 544
11 545 ARC START

SWITCH
12 512
13 522
14 67
15
16
PRETEST MACHINE CONNECTIONS

1. Make sure the machine shunt connections 2. Remove one wire from the output diode
are tight. heat sink thermostat. The thermostat LED
should turn ON. See Wiring Diagram
2. Connect the Power Wave output terminals
to a grid load. 3. Reconnect the wire to the output diode heat
3. Turn the grid OFF. sink thermostat. The thermostat LED
should turn back OFF.
PRETEST POWERUP
1. Turn on the pretest power switch. See 4. Turn off the pretest power switch See
Figure F.78. The Power Wave should beep Figure F.78.

and display “SELECT A FUNCTION”.
FET DRIVE TEST
THERMOSTAT TEST Construct plug jumper as per Figure F80.
1. Check the thermostat LED (upper right
hand corner of the Power Wave Display
Panel) it should be OFF.
POWER WAVE 450

F-204 F-204

FIGURE F.80 - PC BOARD RECEPTACLE
P 23
2
5
1. Unplug P23 and insert jumper plug into PC 5. Turn ON the arc start switch. See Arc Start
board receptacle. See Figure F.80. PW450 with wire Feeder or Figure F.79.
2. Turn ON the preset power switch. See 6. Attach the oscilloscope probes to each of the
Figure F.78. following eight test points. Each test point
should look like the oscilloscope picture in
3. Press the MANUAL PROCEDURE ENTRY
Figure F.81.
(64) key on the Calibration & Test overlay and
using the arrow keys (100) and (101) change
the Power Wave to “Process 1 Setup 1-1” WARNING
mode.
ALL METERS AND OSCILLOSCOPES MUST
4. Set the Oscilloscope for: BE ELECTRICALLY ISOLATED (isolation trans-
20 V/div. former).
20 uS/div.
POSITIVE PROBE NEGATIVE PROBE

#1 P40 pin 14 P40 pin 16
#2 P40 pin 9 P40 pin 11
#3 P40 pin 6 P40 pin 8
#4 P40 pin 1 P40 pin 3
#5 P41 pin 15 P41 pin 16
#6 P41 pin 9 P41 pin 10
#7 P41 pin 7 P41 pin 8
#8 P41 pin 1 P41 pin 2

POWER WAVE 450

F-205 F-205

FIGURE F.81 - FET DRIVE SIGNAL
0V
20V/Div 20uS/Div
SNUBBER SIGNAL TEST 6. Attach the oscilloscope to each of the follow-

1. Adjust the grid for a “light” load. ing eight test points. Each test point should
look like the oscilloscope picture in Figure
2. Turn ON the variable AC supply applied to the
F.82.
primary circuit. See Figure F.76.
3. Slowly increase the voltage until the filter WARNING
capacitor voltage is 25VDC. See Figure
F.77.
ALL METERS AND OSCILLOSCOPES MUST
4. Adjust the grid load to get 5 amps output from BE ELECTRICALLY ISOLATED Isolated
the Power Wave. DO NOT PULL MORE Transformer).

THAN 7-8 AMPS OUTPUT FROM THE
POWER WAVE.
5. Set the Oscilloscope for:
5 V/div/
20 uS/div.
POSITIVE PROBE NEGATIVE PROBE
R1 12E or 12L 401
R2 402 9E or 9L
R3 12F 403
R4 404 9F
R5 405 12G or 12M
R6 406 9G or 9M
R7 12H 407
R8 408 9H
Turn the variable AC primary supply to zero Once the filter capacitor voltage drops to zero,
volts and then turn it OFF. See Figure F.76. turn the arc start switch OFF. See Figure F.79.
POWER WAVE 450

F-206 F-206

FIGURE F.82 - SNUBBER SIGNAL
0V
5V/Div 20uS/Div
460VAC RECONNECT
1. Reconfigure the machine for 460VAC operation. 4. Slowly increase the voltage until the filter capac-
itor voltage is 25VDC. See Figure F.77.
primary circuit. See Figure F.76. 5. Adjust the grid load to get 5 amps output from
the Power Wave. DO NOT DRAW MORE
3. Turn on the arc start switch. See Arc Start
THAN 7-8 AMPS OUTPUT FROM THE
PW450 or Figure F.79.
POWER WAVE.
4. Slowly increase the voltage until filter capacitor
voltage is 25VDC. NOTE: Monitor both capaci- 6. Set the Oscilloscope for:
5 V/div.
tor voltages. If the two voltages are not within 5

10 uS/div.
to 8 VDC of each other STOP and check wiring
to the FET switch board assembly and also the
individual switch boards. See Figure F.77. WARNING
5. Adjust the grid load to get 5 amps output from
the Power Source. DO NOT PULL MORE ALL METERS AND OSCILLOSCOPES MUST BE
THAN 7-8 AMPS OUTPUT FROM THE ELECTRICALLY ISOLATED.
POWER WAVE.
6. Repeat the previous Snubber Signal Test by 7. Connect the positive oscilloscope probe to the
checking the eight test points. Power Wave positive welding output terminal
and the negative probe to the negative welding
output terminal. The output should look like the
OUTPUT SIGNAL TEST oscilloscope picture in Figure F.83.
1. Make certain the machine is configured for
460VAC operation.

primary circuit. See Figure F.76.
3. Turn ON the arc start switch. See Arc Start
POWER WAVE 450

F-207 F-207

FIGURE F.83 - OUTPUT SIGNAL
0V
5V/Div 10uS/Div
8. Turn the variable AC primary supply to zero OUTPUT TESTS SETUP

volts and then turn it OFF. See Figure F.76. The filter capacitors must be discharged
before continuing. Make sure the Power Wave
9. Once the filter capacitor voltage drops to zero,
is configured for 460VAC operation.
turn the arc start switch OFF. See Arc Start
1. Connect a power input cable to CR1. DO NOT
APPLY INPUT VOLTAGE AT THIS TIME.
PREPARE MACHINE FOR NORMAL 2. Connect the grid load to the Power Wave out-
OPERATION put terminals. Make sure the grid load is OFF.

1. Turn OFF the 115VAC pretest power circuit.

See Figure F.78 PRIMARY OVER CURRENT TEST
1. Connect a current probe to the oscilloscope
2. Make certain the filter capacitors are
and set it for:
completely discharged. Remove the variable
10 mV/div. (should be equal 10 mA/div.)
AC primary supply. See Figure F.76.
10 uS/div.
3. Remove the 115VAC pretest power circuit.
2. Put the current probe on lead 221 at J21
See Figure F.78.
pin 1. See Wiring Diagram
4. Reconnect plug P70.
3. Loosely assemble the sheet metal case to the
5. Remove the jumper plug in P23. See Power Wave.
Figure F.80
4. Apply input power to the machine and turn the
6. Reconnect P23. Power Wave power switch ON.
7. Reconnect P73.
POWER WAVE 450

F-208 F-208

FIGURE F.84 - PRIMARY CURRENT SIGNAL
0V
10V/Div 10uS/Div
5. Press the MANUAL PROCEDURE ENTRY PREPARE MACHINE FOR NORMAL

Key on the Calibration and Test Overlay and OPERATION.
change the Power Wave to “Process 1 Setup 1 1. Turn the power switch OFF and remove input
-8” mode. power to the machine.
6. Turn the arc start switch ON. See Arc Start 2. The input capacitors must be discharged
PW450 or Figure F.79. before continuing.
7. Adjust the output grid load to get 400 amps at 3. Remove the capacitor voltage monitoring
36VDC. The oscilloscope picture should look leads. See Figure F.77.
like Figure F.84.
4. Remove the power input cable from CR1.
*ALTERNATE TEST (without current probe) 5. Remove the output cables from the Power
1. Connect a transformer isolated oscilloscope Wave.
as follows:
Set oscilloscope for .2v/div and 10us/div 6. Remove the arc start switch circuit.
Probe J21 pin 1 wire #211 7. Enable the water cooler if it was enabled at the
Common J21 pin 5 wire #215 start of this test.
2. Observe a waveform similar to Figure F.84.
Equal amplitude and symmetry of the pulses is
important.
3. Check the capacitor voltages. The capacitor
voltages must be within eight volts of each
other.
4. Turn the arc start switch OFF. See Arc Start

PW450 or Figure F.79
5. Turn OFF the Power Wave and remove the
input power. Make sure the filter capacitors are
completely discharged. See Figure F.77.
POWER WAVE 450

G-1 G-1
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS
Electrical Diagrams Section................................................................................................Section G

Wiring Diagram ...........................................................................................................................G-2
Schematic Complete Machine ..................................................................................................G-3
Control PC Board Schematic (1 of 4).........................................................................................G-4
Control PC Board Assembly ......................................................................................................G-8
Display PC Board Schematic (1 of 2).........................................................................................G-9
Display PC Board Schematic (2 of 2).......................................................................................G-10
Display PC Board Assembly ....................................................................................................G-11

Power PC Board Schematic ....................................................................................................G-12
Power PC Board Assembly ......................................................................................................G-13
Protection PC Board Schematic ..............................................................................................G-14
Protection PC Board Assembly................................................................................................G-15
Square Wave Protection PC Board Schematic........................................................................G-16
Square Wave Protection PC Board Assembly .........................................................................G-17
Shunt PC Board Schematic .....................................................................................................G-18
Shunt PC Board Assembly.......................................................................................................G-19
Snubber PC Board Schematic .................................................................................................G-20
Snubber PC Board Assembly ..................................................................................................G-21
Switch PC Board Schematic....................................................................................................G-22

Switch PC Board Assembly .....................................................................................................G-23
RS232 Connections..................................................................................................................G-24
POWER WAVE 450

1/96
G-2 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - POWER WAVE 450
LEFT SIDE OF MACHINE

U V W G 1
THIS AREA VIEWED FROM LEFT SIDE OF MACHINE 302 2
DISPLAY BOARD CONTROL BOARD PROTECTION BOARD POWER BOARD 306 3

4
TO J17
1 75 1 201 1 321A 1 3W
(MACHINE SHOWN CONNECTED FOR 440-460V) TO SW1
5
TO SW1 6
2 750 2 202 2 2
GROUND GROUND 12G TO SWITCH BD #3 9G TO SWITCH BD #3 321B
L1A 303 7
3 277 3 203 TO 3 3 3R TO SW1 307 8
12M TO R10 9M TO R10
TO A SYSTEM GROUND PER
4 77
J20
4 204
J61
PLANE #1 4
PLANE #2 4
L3A
5 76 5 205 5 5
6 291 6 206 6 H1B 6 4W
NATIONAL ELECTRICAL CODE.
TO TO 20 P81
7 292 7 207 7 TO 7 200-208V
8 276 P82 8 208 8 8 4R SWITCH R5 R6
TO FUSE J10 9 275
J30 9 SW1 J40 9 3W 25 25
H2 TO TERM STRIP 220-230V F1 RS232
P83 BDS
5A SLOW
321B 10 294 10 CR1 10 25W 25W
H3 TO TERM STRIP
'A' 380-415V L1 L2 L3 CONNECTOR
J92 1 211 3 & 4 BLOW FUSE TO J32
11 11 T1 11 3R
12 2 212 12 12 H4 TO TERM STRIP
440-460V 324
321A 3 213
13 TO 13 13
TO J30 14 4 14 14 4W H5 TO TERM STRIP 32D A
J21 5 215 J36 B
15 15 15
TO J30 6 W
405 TO SWITCH BD #3 406 TO SWITCH BD #3 CR1
16 J50 16 T3 16 4R
7 RECONNECT SWITCH
H1B
(TOP) 8 R 9A TO SWITCH BD #1 102D C
1 453 1 12K 1 1W 326 106A D
9B TO SWITCH BD #2 9C TO SWITCH BD #3
3 1 H1
2 2 2 1R TO 277 E
OFF
LOAD TO 1 221 9K TO J31 TO J32
3 454 3 3 9D TO SWITCH BD #4 276 F
TERM STRIP 2 POS TO INPUT RECT. TO J30 T1 T2 T3 J10
4 TO 4 4 275 G
J11 3 12H TO SWITCH BD #4 9H TO SWITCH BD #4
T1
5 5 5 POS TO INPUT RECT. J28 221A H
TO CR1 6 J3 4 5W 6 6 32E I
LINE TO
ON
5 5R TO 12J TO J31 9J TO J31 J34
4 2 L3A 7 455 7 7 2W T3 31C J
6 226 TO J31 RECONNECT SWITCH
8 456 J22 8 8 2R J60 42C K
7 227 J42 9 SWITCH
J41 9 1W
TO J30
117A (R) L
L1A BDS 12C TO SWITCH BD #3
8 10 9J 10 12A TO SWITCH BD #1 118A (W) M
1R R7 R8
J44
OFF
1 9 1 & 2 12D TO SWITCH BD #4
TO CR1 11 11 25 25 12B TO SWITCH BD #2 167A N P82
SW1 J12
2 371 TO 10 223 12 12J 12 25W 25W 12K TO J31
3 11 224 13 13 TP4
POWER J37
NEG TO INPUT RECT.
WIRE FEEDER
4 374 12 225 14 9K 14 N.B.
N.D. NEG TO INPUT RECT.
15 2W
RECEPTACLE #2
TO 16 2R
1 1 TP5 TP6
1 321
2 372 TO 2 232 J39 2 TO 407 TO SWITCH BD #4 408 TO SWITCH BD #4
J13 OUTPUT
3
J23
3 233 3 323 CR1 1 VOLTAGE=200-230V VOLTAGE=380-460V
LCD J37 RECT. THERM J32
4 373 4 234 4 324 2 RECTIFIER
5 235 P71 AC1 AC2 AC3
DISPLAY 6 236
SWITCH THERM 5 3
1 261
6 326 4 C12 INPUT 32B A
2 262
5 221 TO MAIN TRANSFORMER LEFT SIDE RECTIFIER
B
6 226 R12
J14
3 264 TO 1 1 32A J42 7 J22
4 266 2 2 TO POS NEG NEG
J26 8 TO SWITCH BD #3 102B C
5 265 3 C13 TO
3 333 C. BREAKER 9 227 S3 105A D

6 263 4 J33
4 334 10 223 3T J10 77 E
5 P70 R13
5 11 224 76 F
6 6 336 J27
TO J19 1 300 TO 12 225 75 G
7
2 301 PIEZO J24 8
.0047/400V 10 2W POS NEG J34 121A H
J15 BUZZER 32C I
3 9 1 31C J60
1 356 31B J
4 10 2 2 TO SECONDARY PRIMARY
J43 42B K
11 3 42C 3 351
12 4 102D
J35 (TOP) (TOP) 111A (R) L
1 448 4 112A (W) M
D1
13 5 32D
2 443 TO 67 N P83
14 6 32E
3 442
7 106A 1 D2
4 J34 P82 TO
8 31B 2 442 3W 3W LEFT TOP WIRE FEEDER
5 TO CT J40
1 9 P83 3 443 D3 3R 3R
TO TO
J16
6 444 2 10 42B 4 5W 4T
RECEPTACLE #1
7 449 TO
J44 3 11 102B 5 5R F3,F4 TO R6
8 445 D4 F3 406 406
4 12 32B J16 CONN.
REAR OF MACHINE
6 444
9 446 5 J44
N.E. J25
13 32C 7
10 447 6 14 105A 8 445
J22 D5 TO PRIMARY 3T 3T N.C.
11 7 TO REC. SWITCH 12C
9 446
+ ELECTRODE
+
12 D6 TO R5
8 10 447 TO SWITCH BD #4
12G 12C
9 1 351 11 448 S4 TO REC. SWITCH 9C C3
1 302
10 2 12 449 D7 3B TO R6 9G 9C -
3 TO
TO TERM STRIP
2 J35
4 J43 D8
KEYPAD 3 1 261 5 TO TO CT 4T 4T TO TERM STRIP TOP
4 303 CONNECTION FOR
5 TO
2 262 TO 6 356
D9
S3,S4 S3,S4 TO R5
FAN
J17 3 263 CONN. 405 405
6 P81 J26 4 264 J14 D7-D10 SECONDARY PRIMARY
7 306 TO D10 LEAD 461 - TO J62
5 265 1 361 TO
8 307 6 266 2 362
TO CHOKE (BOTTOM) (BOTTOM) 4R 4R
CT J40
9 J36 3 211 D11
4W 4W SWITCH BOARD #3 TO TERM STRIP
10 J21 CONNECTION FOR
4 215
TO J18 1 111A BUS
F3,F4 TO TERM STRIP BOTTOM
D12 D1-D6
2 TO BAR #1 TO FAN
1 J27 3 1 371 TO TO CT TO
2 P83 TO D13
S1,S2
J40
3W 3W LEFT BOTTOM
4 112A 2 372 J12 CONN.
J37 4B 3R
3 3 373
SHUNT 3R TERMINAL STRIP
4 J13 D14 F4 P4
4 374
TO TO R8 TOP FAN
5 1 117A CONNECTION FOR 408 408
J18 S1,S2 TO P73
6 KEYPAD 2 TO D15 BOTTOM FAN
J28 D11-D14 H1
7 3 1
P82 TO
TO PRIMARY 3B 3B N.C.
8 4 118A 2 293 TO REC. SWITCH TO SW1 TO P4
9
J38 3 296
D16 12D
+
J92 TO R7 H1 H1A
10 4
12H 12D
TO REC. SWITCH
D17
TO CURRENT 9D C4 N.D.
CONNECTION FOR TO R8 9H 9D -
F1,F2
1 1 D18
F1,F2 TRANSFORMER TO REC. SWITCH TO P73
TO CONN. D15-D20
2 2 234
J39 TO CT 4B 4B H2 H2
3 3 232 J23 D19 4T
4 4 233
TO R7
5 4B 407 407
D20
FRONT OF MACHINE
6 1T TO 4R 4R
7 J40
TO TO SWITCH THERM 1B
8 4W
4W
SWITCH BOARD #4
J19
9 (TO SWITCH BDS) TOP FAN

LCD 237 TO P73
C16
10
BOTTOM FAN H3
11
R16 RECT. 361
12 2W
THERM
TO 2W RIGHT TOP TO REC. SWITCH TO P4
13 TO J36
J41 H3 HXA
14 2R 2R
362
15
TO F3,F4, 235 401 401 N.C.
16 N.D.
R11, WORK TO R1
TO TO
J21
TO J23
TO PRIMARY 2T 2T SWITCH
J20 C15 4T TO REC. SWITCH TO P73
TO REC. SWITCH
- THERM
4B H4 H4
R15 9A 9A
TO R2 TO J23
BUS BAR #1 1T 9E C1
GROUND
213
212
TO OUTPUT TO P82, P83, TO REC. SWITCH 236

1B 12A 12A
121A
221A
167A
.0047/400V 10 2W
+
RECTIFIER
461
201
499
462
464
467
204
208
205
202
207
203
206
ELECTRODE
67
(FROM TRANSFORMER) TO R1 12E

W
R
TO CT 1T 1T
400A
SHUNT TO R2 402 402
TO REC. SWITCH TO P73
12E TO SWITCH BD #1 9E TO SWITCH BD #1 9L TO R2 9M TO R6
11
TO H5 H5
12
13
14
15
16
10
10
1
1R
2
3
4
5
2
3
4
5
7
8
2
3
4
5
7
8
9
2
3
4
5
7
8
6
6
9
12L TO R9 9L TO R9 1R TO RECT. THERM

TO J62 J41
1W 1W SWITCH BOARD #1 237
TO CT
467 S1
- 1T
R1 R2 R9 R10
J50 J60 J61 J62
WORK SNUBBER BD 25 25 7.5K 7.5K
TO
25W 25W 25W 25W
J41
2W 2W RIGHT BOTTOM AUXILIARY TRANSFORMER
SHUNT AMPLIFIER 2R 2R TO
1 321
BOARD SECONDARY PRIMARY J32
FOOT TO R3 403 403
1 291
A 177A
TO J62 (TOP) (TOP) (24V)
4
2 292 323
AMPTROL/ B 176A 462
3 293 401 TO SWITCH BD #1 402 TO SWITCH BD #1 12L TO R1 12M TO R5 TO PRIMARY 2B 2B N.C.
C 175A TO J93 J92 TO J10,J38 P71
4 294
REMOTE H5
-
D 105B TO REC. SWITCH 6 H5
5 9B 9B
E 102C TO R4 (440-460)
CONTROL P1 F
6 296 TO SWITCH BD #1 9F C2
R11 W H4
TO REC. SWITCH 12B 12B 33 2 3 H4
RECEPTACLE
+
40 2T
TO R3 12F (380-415)
100W 1 F1 TO
TO
2 177A TO CT 1B 1B N H3 TERM
334 3 2 H3
3 176A J33 (24V)
(220-230) STRIP
4 175A 404 404 C. BREAKER
300 + PIEZO J93 5 102C
TO P1
12F TO SWITCH BD #2 9F TO SWITCH BD #2
TO R4 U H2
TO J62 333 5 4 H2
TO J15 6 TO (42V)
301 - BUZZER 464 J41
1R 1R (200-208)
7 105B
R H1
8
1W 1W SWITCH BOARD #2 336 6 1 H1
TO J33 (115V)
P70 P73
5A 32A TO CT
PROTECTION BD (SQUARE WAVE) N.D. R4
S2
R3
CIRCUIT 25 25 1B J12,J13,J15 J3,J4
J27,J28,J36 J14,J23,J26
25W 25W NOTES :
BREAKER 33 TO S3, S4 CONNECTION J37,J38,J39 J32,J33,J35 J11,J20,J21
TO J11
TO P70 N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED J43 J50,J92 J62,J93 J17,J18,J25,J61
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

1 2 1 3 1 4 1 5
SECONDARY PRIMARY
THE INTERCHANGEABILITY OF A COMPLETE BOARD,
453
454
455
456
TO
(BOTTOM) (BOTTOM)
HXB
HXB
403 TO SWITCH BD #2 404 TO SWITCH BD #2 THIS DIAGRAM MAY NOT SHOW THE EXACT
H1A
HXA
N.D.
WATER COOLER
COMPONENTS OR CIRCUITRY HAVING A COMMON
GND
3
4
5
6
CODE NUMBER. 3 4 4 6 5 8 6 10
N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.

456A
455A
454A
453A
P4 P3 TO SWITCH BD #2
J16,J22,J42,J44 J24,J31,J34 J10,J19,J30,J40,J41,J60
D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET.
2B 1 6 1 7 1 8
D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.
1
2
3
4
5
6
F2
MAIN CHOKE TO
1
2
3
4
5
6
TERM N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.

PROTECTION BD (SQUARE WAVE) COOLER
STRIP
CIRCUIT N.D. THESE ITEMS ARE ONLY USED ON A 450 MACHINE 7 12 8 14 9 16
BREAKER J4 J3 RIGHT SIDE WITH A WATER COOLER.

WATER COOLER N.E. TOROID DOES NOT APPEAR ON EARLIER MODELS. CONNECTOR CAVITY NUMBERING SEQUENCE
ELECTRODE + (VIEWED FROM COMPONENT SIDE OF BOARD)
499
TO J60
RIGHT SIDE OF MACHINE ELECTRICAL SYMBOLS PER E1537 8-28-98B
G3617-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 450

SCHEMATIC - COMPLETE MACHINE
TRIGGER 24V, 42V, & 115V FROM PROTECTION BD.
ARC & WORK VOLTAGES TO SNUBBER BD.
N 67 N 167A
H 121A H 221A
C 102B C 102D
FEEDBACK VOLTAGES
U V W
ARC & WORK VOLTAGES FROM WIRE FEEDER RECEPTACLES

FROM CONTROL BD.
D 105A D 106A
TO CONTROL BD.
J 31B J 31C
321A
DC SUPPLIES
H1B
(N.E.) 115V
FEEDBACK VOLTAGES FROM SNUBBER BD.

A 32B A 32D
FET GATE SIGNALS TO SWITCH BOARDS #3 & #4

K 42B K 42C 321B
42V ON H1
I 32C I 32E
P82
111A(R)
DC SUPPLIES TO SNUBBER BD.

L L 117A(R) WF2 RECEPTACLE
L1A L3A TO A SYSTEM GROUND PER
OFF
112A(W) 118A(W)
FROM CONTROL BD.

M M
FROM CONTROL BD.

E 77 E S1
WF2 WORK VOLT.FEEDBACK

277 G
WF1 WORK VOLT.FEEDBACK

SWITCH BOARD #3
WF2 ARC VOLT.FEEDBACK

WF1 ARC VOLT.FEEDBACK
POWER SWITCH
ELECT.VOLT.FEEDBACK
L3A
F 76 F 276 3R
(LEFT TOP) 3W
G 75 G 275 MAIN TRANSFORMER LEFT SIDE
406
NOISE_GND
B
+15 Va
B
-15 Va
L1A
L1 L2 L3
R6
TO WF1 RECEPTACLE
SERIAL LOOP COMMUNICATION 324 25/25
FOR WIRE FEEDERS 31B 8J34 115VAC,FROM 6J33

3T
P83 1J30 321A
9C 3T
WF1 RECEPTACLE 32B CR1 9C
207
201
12J34 0VAC,FROM 1J33
204
205
206
208
203
202
6J30 H1B
112A(W)
118A(W)
111A(R)
SOFT START
42B
117A(R)
10J34 42V,FROM 3J33 .047/1200
RELAYS 326
LCD DISPLAY 32C 13J34 0VAC,FROM 1J33 R10

C3
GROUND PLANE #1
125/40 125/40
GROUND PLANE #2
D7-D14 IN PARALLEL
T1 T2 T3 3500uF
(ON OUTPUT RECTIFIER ASBLY)

7.5K/25
10J61
1J61
9J61
6J61
5J61
7J61
8J61
2J61
11J30 T1
T1 450V
102B 11J34 24VAC,FROM 4J33 .047/1200
24VAC
16J30 T3 T3
105A 14J34 24VAC WHEN WF1
1J27
1J28
4J28
4T
4J27
TRIGGER CLOSE,TO 4J37
4J32 324
TO WF2 RECEPTACLE
12C
10/2
4T
31C 1J34 115VAC,FROM 6J33
6J32 R5 FEEDED 13J60 221A
TO 4J22
0VAC 326 TP4 25/25 SNUBBER BD.
40mA
RUN MODE
-15 Va 15J60 167A
.0047/400
32D 5J34 0VAC,FROM 1J33 THRU CT GND DIVIDER
TO SNUBBER BOARD 8J20 208 &
121A
FLYBACK
9J60
KEYPAD 40mA
40mA
42C 3J34 42VAC,FROM 3J33
TP5 TP6 405 BUFFER
8J60 67
5J20 205 1J40 3W
+18 Vd 11J60
32E 6J34 0VAC,FROM 1J33 4R 4W
+15 Va TO SNUBBER BOARD 4J20 204 9J40 3W
AC1 AC2 AC3 SNUBBER BOARD
102D 4J34 24VAC,FROM 4J33
NOISE_GND ELECT.VOLT.FEEDBACK 3J20 203 3J40 3R 6J62
INPUT RECTIFIER OUTPUT 320V 160J 320V 160J
WF1 ARC VOLT.FEEDBACK 2J20 202 11J40
106A 7J34 24VAC WHEN WF2
3R
TRIGGER CLOSE,TO 2J37 RECTIFIER
POS NEG NEG
206
10J18
WF1 WORK VOLT.FEEDBACK 6J20
5J18
6J18
1J18
2J18
3J18
4J18
8J18
7J18
9J18
6J40 4W
WF2 ARC VOLT.FEEDBACK 1J20 201 .047/400 .047/400
14J40 4W SWITCH BOARD #4

1 WF2 WORK VOLT.FEEDBACK 7J20 207
+5 Vb V 8J40 4R (LEFT BOTTOM) 3W 3R
2 302 1J17 RX A
499
10/2 .0047/400
3 306 7J17 TX 16J40 4R 2.7/10

1J14 261 1J26
D1-D6
.047/1200
4
2J17 408
5 Vc (RS232) WF1
+15 Va
5 IN PARALLEL
12C
9C
9D
TRIGGER
R8
6
9J17 5V=OPEN d 380-460V 2.7/10
GND GRS232 1.5V=CLOSE
25/25
7 303 4J17
5V 2J14 262 2J26 3J43 351 1J35 0 VAC,FROM 1J33 3B
8 307 8J17 +5 Vb RECONNECT PANEL 320V 160J
42VAC SUPPLY, FROM PROTECTION BD. 9D 3B
ISOLATED FET BANK A FET BANK A 9D
1J19 1J43 356 6J35 42VAC,FROM 3J33
208-230V
24V
WF1 TRIGGER
DRIVER 1J22 221 5J42
4J62
1J62
265
7J62
5J14 5J26
2J62
CIRCUIT
20 2J19
WF2
GATE SIGNAL .047/1200
TRIGGER
3J19 C4
GD 5V=OPEN
WIRE FEEDER REMOTE CONTROL
FREQ.MODULATED
12A
12K
12B
12D
3500uF
12J
4J19
9B
1.5V=CLOSE
9A
GD A
9K
234
9J
+5Vb 2J39 450V
461
5J19 4J14 266 6J26 .047/1200
P81 DIFFERENTIAL CAP.VOLT.
NEG MAIN CHOKE
ISOLATED DC SUPPLIES
< 25uS
ISOLATED
TRIGGER
(1250Hz WHEN CAP.BALANCED) 1J31 12K
FROM POWER BD.

6J19
+
CIRCUIT
RS232 CAP.VOLTAGE
(+)CAP3,4
24V
WF2 TRIGGER
+15 Va 10J22 223 10J42 +15 Va SENSING CIRCUIT 4B
7J19 CIRCUIT 10J31 9J
CONNECTOR ELECTRODE
8J19 -15 Va 6J22 226 6J42 -15 Va V (-)CAP1,2 12D
A NOISE_GND 12J31 12J 4B
232 R7 FEEDED
462
9J19 3J39
464
GD +5 Va 11J22 224 11J42 +5 Va
50uS POS
14J31 25/25
10J19
9K THRU CT
40mA
6J14 263 3J26 a_GND
SERIAL
12J22 225 12J42
11J19 OUTPUT DISABLE 407
3J14 264 4J26 233 4J39
12J19 COMM. 40mA NOISE_GND
a d VB (OV = RUN 1K R11
4R 4W 40/100
COUPLED TO 1J27 5V = DISABLE)
13J19
DEAD TIME
14J19
40mA
321B
15J19 COUPLED TO 3J26 5J22 5R 5R 5J44 40mA CURRENT SOURCE
467
16J19 e_GND RECONNECT PANEL
FROM 4J28 4J22 5W 5W 4J44 PROTECTION BD.
40mA GND
SERIAL LOOP SHUNT BOARD WORK

e
77 4J10 10V
CURRENT
200-208V
WF1
H2
76 5J10 WIPER +15 Va
+18 Vd 1J41 1W F1 5A
CAP.VOLT. & OUTPUT DISABLE SIGNALS TO CONTROL BD.

1J10 H3 220-230V SLOW BLOW
75 9J41 1W SHUNT BD.
GA
GND
FUSE
277 3J10 10V
SHUNT BD.GND
2J41 1R
FET BANK B H4 380-415V
WF2
FET BANK B
276 WIPER
+15 Va
8J10
-15 Va
DRIVER 7J22 227 9J42 10J41 1R
Iout
GATE SIGNAL (+) H5 440-460V
275 9J10 211 3J36
GA
POT.MAX 7J41 2W
(-)
294 10J10 10V 215 4J36 "A"
A
POT.WIPER 15J41 2W
291 6J10 WIPER
1J50
3J50
6J50
4J50
POT.MIN VB
8J41 2R
(-)
292 7J10 361 1J36
GA
TOP
16J41 2R FAN
362 2J36 (+)
RECTIFIED CT VOLT. TO CONTROL BD.

453 1J11 (+)
218
216
213
212
15 V SWITCH BOARD #1
454 3J11 (-) BOTTOM
d
FAN (RIGHT TOP) 2W 2R
455 7J11 PRESSURE
FREQ.MODULATED
FOOT AMPTROL REMOTE CONTROL
4J23 234
456 8J11 CAP.DIFFERENTIAL VOLT. 402
2J23 232
AC VOLTAGE FROM CT
H1 H2 R2
H3 H4 H5
WATER COOLER CONTROL
TERMINAL STRIP
GA 25/25 FEEDED
OUTPUT DISABE 3J23 233
374 4J12
0V
1T
2J12 NOISE_GND 9A 1T
371 24V THRU CT
WHEN WF1 TRIGGER 9A
FET GATE SIGNALS TO SWITCH BOARDS #1 & #2

OR FOOT AMPTROL
CLOSE .047/1200
RECTIFIED CT VOLT. (+) 1J21 211

371 1J37 H1 H1A H2 H2A H3 H3A H4 H4A H5 H5A C1
373 4J13 0V 24VAC WHEN WF1 OR R9
RECTIFIED CT VOLT. (-) 5J21 215 3500uF
374 4J37 FOOT AMPTROL TRIGGER CLOSE 7.5K/25
450V
372 2J13 24V
.047/1200
WHEN WF2 TRIGGER
CLOSE
+15 Va 213 AUXILIARY TRANSFORMER #1
(Io = 5mA AT 400A WELDING CURRENT)

3J21
12A 2T
373 3J37
SHUNT CURRENT TO CONTROL BD.

24VAC WHEN 321
DC SUPPLIES FROM CONTROL BD.

447 10J16 +15 Vb 6J21 216 PWR_DN 8J44 445 1J32 1
WF2 TRIGGER CLOSE 12A 2T
372 2J37 24VAC SUPPLY H5
R1
448 6 H5
1J16 +5 Vb -15 Va 2J21 212 FOR P71 (24V) 25/25
PROTECTION BD. (440-460)
ISOLATED DC SUPPLIES FROM POWER BOARD
446 9J16 -5 Vb 3J32 323 4

SHUNT CURRENT 8J21 218 +15 Vb 10J44 447 H4
5 401
FROM SHUNT BD. R (115V)
OUTPUT
444 6J16 -8 Vb +5 Vb 293 2J38 24VAC WHEN FOOT AMPTROL
115V (380-415)
11J44 448 CLOSE,TO 4J37
6J33 336 6
RECTIFIER
( 5mA AT 400A WELDING CURRENT)
(N.E.) 1R 1W
449 7J16 -5 Vb 296 3J38 24VAC FROM 4J33
9J44 446
H3
H4
443 D A U (42V)
2J16 +5 Vc (RS232) -8 Vb 6J44 444 42V 3J33 333 5 (220-230)
DISPLAY BD.GND GD GA NOISE_GND
b_GND
442 3J16
12J44 449 H2
H3
24VAC TO DISPLAY BD. WHEN TRIGGER CLOSE

2
3 H2
N (24V)
24VAC TRIGGER VOLTAGES
445 8J16 PWR_DN b

+5 Vc 3J44 443 24V 4J33 334 3 (200-208)
(XIRQ)
GRS232
c_GND
300 1J15 (+) 6J23 2J44 442 H1
SWITCH BOARD #2 10/2 .0047/400
W 1 H1
15V 0 1J33 33 2
301 2J15 (-) 5J23 c
DISPLAY BOARD CONTROL BOARD POWER BOARD PROTECTION BOARD P73 (RIGHT BOTTOM) 2W 2R
P70
D15-D20
-
236
235
+
IN PARALLEL
404
PIEZO
32A
R4
FOOT AMPTROL TRIGGER

BUZZER 25/25 FEEDED
237
1B
9B 1B THRU CT
9B
OUTPUT RECTIFIER SWITCH BD.
TSTAT TSTAT .047/1200
C2
3500uF
450V
CB .047/1200
ISOLATED DC SUPPLIES,TO DISPLAY BD.
5A
12B 2B
12B
2B
R3
25/25
DC SUPPLIES TO SHUNT BD.
SHUNT CURRENT FROM SHUNT BD.
403 MAIN TRANSFORMER RIGHT SIDE
1R 1W
CURRENT TRANSFORMER
4 PRIMARY LEADS 1T,1B,4T,4B

296
293
291
294
292
ARE FEEDED THRU CURRENT TRANSFORMER

1J92
4J92
3J92
6J92
2J92
362
361
454
456
455
453
P1
FOOT AMPTROL RECEPTACLE AUXILIARY TRANSFORMER #2 (N.D.)
1
NOTES :
5J3
6J3
3J3
4J3
N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED

H5
D 105B 7J93 6 H5A CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
(24V)
E 102C 5J93 (440-460) THE INTERCHANGEABILITY OF A COMPLETE BOARD,
A 177A 4 THIS DIAGRAM MAY NOT SHOW THE EXACT
2J93 H4
B 176A 3J93 5 H4A COMPONENTS OR CIRCUITRY HAVING A COMMON
4J93
W
(380-415)
WATER COOLER CODE NUMBER.
C 175A 2
(N.D.)
N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.
F H3A 5J4 D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET.
(REMOTE) 3
N (24V)
(220-230) D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.
N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.
PROTECTION BOARD H2
H3 N.D. NOT EXIST ON MACHINE WITHOUT WATER COOLER
2
3 H2A
U (42V) N.E. NOT EXIST ON PW350 & PW500
ELECTRICAL SYMBOLS PER E1537
5 (200-208)
H1
6
R (115V) 1 H1A 2J4 POWER WAVE
P5
MACHINE SCHEMATIC
G 2990
7-21-95E
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 450

SCHEMATIC - CONTROL PC BOARD #1
2241-1 G
+5V +15V
+15V
J22
10
1
C13 DZ4 X3 3
4.7 18V
32 Vdd 26 Vcc 44 20 20 14 24 24 14 14 2
4
35V 1W
C21 C27 C19
J22 X10 C20 C22 X13 C28 C18 C17 C16 C45
X15 0.1 0.1 X20 C29 X16 X5 C1 X1 X3 0.1
12 0.1 0.1 0.1 0.1 X12 0.1 0.1 X11 0.1 X26
50V 50V 0.1 0.1 50V
50V 50V 50V 50V 50V 50V NAND 50V
NOISE_GROUND 28F512 MC68HC11 PSD301 74HC573 50V 74HC573 54HC08 50V 54HC08
74AC646 74AC646 LM224
DZ3
C15
18V Vss GND 12 GND
4.7 16 1 34 10 10 7 7 7
1W 12 12 11
35V
D
-15V
J22
6
+5V D
J22
11
DA-AD[0:7]
DZ2 C10 C11
6.2V 4.7 0.1
1W (DSP1 DATA BUS)
35V 50V
+5V
DATA[0:15]
J22 NOISE_GROUND
3
22 24
BtoA SRC Vcc
+5V 6A: PARALLEL COMMUNICATION
2 AtoB SRC BtoA CLK 23
WRITE_1 (DSP1 PORT1)
(DSP1)
J22 3 DIR AtoB CLK 1
9 DIRECTION RD_LOW
221 (SHEET 2, X44)
DA-AD[0] 4 A0 OE 21
R328 OE_LOW
221 X11
DA-AD[1] 5 A1 B0 20 DATA[0]
47p R329
DA-AD[2] 221 6 A2 B1 19 DATA[1]
C3 R330
+5V 4.75K
100V DA-AD[3] 221 7 A3 B2 18 DATA[2]
10K R331
R3
R4
DA-AD[4] 221 8 A4 B3 17 DATA[3]
1 R332
Vss A0/D0 9 DA-AD[0]
DA-AD[5] 221 9 A5 B4 16 DATA[4]
R333
R5 DA-AD[1]
10K 19 /IRQ A1/D1 10

DA-AD[6] 221 10 A6 B5 15 DATA[5]
R334
R35
2.21K 2 MODB A2/D2 11 DA-AD[2]

DA-AD[7] 221 11 A7 B6 14 DATA[6]
R335
D 3 MODA A3/D3 12 DA-AD[3] 12 74AC646
J25 GND B7 13 DATA[7]
1 R34 R40 MODE_SLAVE C26
18 /XIRQ A4/D4 13 DA-AD[4]
/XIRQ 47p
475 1.00K +5V
7 EXTAL X10 A5/D5 14 DA-AD[5] 100V
DZ8
5.1V 10M 8 XTAL A6/D6 15 DA-AD[6]
D
1W
R6 52 VRH A7/D7 16 DA-AD[7]
+5V R110
1/2W 20 29 22 24
1.00K RxD OC3 BtoA SRC Vcc
+6 C6 RXD OUTPUT_ON (3)
Y2 0.1 31 OC5 A/D2 47 2 AtoB SRC BtoA CLK 23
D SLAVE WRITE_1 (DSP1 PORT1)
50V (DSP1)
28 OC2 A/D3 49 3 DIR AtoB CLK 1
C5 8.0MHz C4 RESET DIRECTION RD_HIGH
AD[0:15]
22p 130 22p (SHEET 2, X44)
30 OC4 A/D4 44 (SHEET 4) 4 A0 OE 21
MACHINE CONNECTED IN PARALLEL 1.00K
100V 100V D Vpp_CTRL THERMAL OE_HIGH
X12
R36
32 IC1 A/D5 46 5 A1 B0 20 DATA[8]
MODE_SLAVE
33 IC2 A/D6 48 6 A2 B1 19 DATA[9]
D SWITCH1 AD[0]
J25 34 IC3 A/D7 50 7 A3 B2 18 DATA[10]

2 R39 R38 SWITCH2
21 TxD A8 42 AD[8] 8 A4 B3 17 DATA[11]
1.00K 1.00K TXD
17 41 AD[9] +5V 9 16 DATA[12]
/RES A9 A5 B4
2.21K DZ9
R37
+5V 27 PAI A10 40 AD[10] 10 A6 B5 15 DATA[13]
5.1V (DSP 1) LATCH_READ
1W 44
+15V 43 A/D0 A11 39 AD[11] 1 /BHE Vcc 11 A7 B6 14 DATA[14]
I_CK
45 38 AD[12] R/W 2 43 12 74AC646 13 DATA[15]
A/D1 A12 R/W A19 GND B7
22 MISO A13 37 AD[13] 3 /RES PC2 42

RES C25
D 4.75K 23 MOSI A14 36 AD[14] AD[0] 21 PA0 PB5 6 47p
475 475 D2 24 35 AD[15] AD[1] 20 5 100V

SCK A15 PA1 PB6
R7
R27
CE_FLASH
R26
C7 Vdd
25 5 E AD[2] 19 11
INPUT COMMAND 1.0 /SS E PA2
X13
PB0
A14 D DATA[0:15]
X2 RES
35V 51 6 R/W AD[3] 18 10
J25 RES VRL R/W PA3 PB1
A15
3 +6 S-8054HN 26
Vdd AS 4 AS-LE AD[4] 17 PA4 PB2 9
C2 A16 1
Vss MC68HC11
C23 0.1 10K 10K 10K 10K AD[5] 16 8 3 9
DZ5 PA5 PB3
50V A17 X1
0.1 6.2V
2 8
AD[6] 15 PA6 PB4 7 X1 RD_HIGH (3)
R10
50V RD_FLASH BE 10
R2
R8
100 1W
R9
C49 C50 C51 34
AD[7] 14 PA7 GND
R25 22p 22p 22p
J25 12 12
D 100V 100V 100V 41
4
R28 3E: HC11 GND PC1
4 11
X1 RD_LOW (3)
AS-LE 13 AS PC0 40 6 13
100 5 X1
D AD[8] 31 4
D A8 PB7
D +5V
AD[9] 32 23 DA-AD[0] DA-AD[0] 2 19
3Ea: UNDER VOLTAGE LOCKOUT D
A9 A0/D0 D0 Q0
SWDK CONTROL SERIAL LOOP
74HC573
SLAVE REFERENCE VOLTAGE AD[10] 33 A10 A1/D1 24 DA-AD[1] DA-AD[1] 3 D1 Q1 18 PORT SWITCHES
SWWF
AD[11] 35 A11 A2/D2 25 DA-AD[2] DA-AD[2] 4 D2 X20 Q2 17
SWOP
+5V 4.75K
AD[12] 36 A12 A3/D3 26 DA-AD[3] DA-AD[3] 5 D3 Q3 16
N.C.
12 BE
R336
X5 11 AD[13] 37 A13 A4/D4 27 DA-AD[4] DA-AD[4] 6
D4 Q4 15
13
AD[14] 38 A14 A5/D5 28 DA-AD[5] DA-AD[5] 7
D5 Q5 14
J25
5
E
+15V AD[15] 39 A15 A6/D6 29 DA-AD[6] DA-AD[6] 8

D6 Q6 13
I_AD 100K E 22 E A7/D7 30 DA-AD[7] DA-AD[7] 9 D7 Q7 12
J25 R11 PSD301

R29 6 5 475 475 BE
4
X26 R30 R31 I_CK
267 C8 7 1 X3 6 11 LE
0.1 X5 3 5
OE
6 1
J25 50V AD[8] 2
R22 7
SLAVE DZ7
C24
267 A R109 5.1V R/W
DZ6 0.1 D
1W
Q2 15.0K 50V 32
AD[0] 12 A0 Vcc
R20 600mA 15V
40V 1W 1.00K AD[1] 11 31
A1 /WE
R108
10K
AD[2] 10 A2 NC 30
26.7 J25 A17
R24 8
D AD[3] 9 24
26.7 A3 /OE RD_FLASH
R21
A AD[4] 8 A4 X15 DQ0 13 DA-AD[0] DA-AD[0] 2 D0 Q0 19 AS1
26.7
D R23 74HC573
AD[5] 7 A5 DQ1 14 DA-AD[1] DA-AD[1] 3 D1 Q1 18 AS2
CONTROL
AD[6] 6 A6 DQ2 15 DA-AD[2] DA-AD[2] 4 D2 X16 Q2 17 AS3 VOLTAGE
J25
9
SENSE
AD[7] 5 A7 DQ3 17 DA-AD[3] DA-AD[3] 5 D3 Q3 16 AS4
J25 MATRIX
Vpp 10 +15V AD[8] 27 A8 DQ4 18 DA-AD[4] DA-AD[4] 6
D4 Q4 15 AS5
AD[9] 26 A9 DQ5 19 DA-AD[5] DA-AD[5] 7
D5 Q5 14 AS6
+15V
AD[10] 23 A10 DQ6 20 DA-AD[6] DA-AD[6] 8
D6 Q6 13 AS7
10K 10K 3Ee: 12 VOLT PROGRAMMING SUPPLY AD[11] 25 21 DA-AD[7] DA-AD[7] 9 12
OPTIONAL OUTPUT SLAVE CONTROL A11 DQ7 D7 Q7 AS8
AD[12] 4 2 BE
R14
R12
A12 NC A16
10K 9
AD[13] 28 A13 1
Vpp Vpp 4 8 11 LE
+15V X3
29 A14 3 DA-AD[0:7] X5 6 10
R18
A14 A15 A15 1 OE

OPTIONAL INPUT SLAVE CONTROL 16 5
Vss 22
/CE CE_FLASH
28F512
Vpp_CTRL R13 D46

10 D
10K X26
8 12 Q3 AD[9]
X26 600mA BE
9 14 12
10K 40V
9 X3 11
13 WR_REF
X5 8 13
1.00K
R16
Vpp AD[10] 10
R15
10K
3Ec: HC11 SUPPORT

R32
15.0K
A
R17
AD[0:15]
(HC11 ADDR/DATA BUS)

D
HC11 CONTROL - SHEET 1

15.0K
R19
GENERAL INFORMATION LAST NO. USED
R- 345 DZ- 35 TP- 5

NUMBERS NOT USED:
C- 156 Q- 34 OSI- 8
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
C9,12,14,58,71,72,74-76,78,82,89,92-94,99,131 LABELS D- 52 X- 93 Y- 2
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
A D1,3,6-9,44,45,48,49
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
DZ1,23-26,28,29 SUPPLY VOLTAGE NET
OSI1
POWER SUPPLY SOURCE POINT
Q1,11
R1,75-83,85,100-107,111-117,123-125,131-133,137, COMMON CONNECTION
139,140,172,176,190,265,267-269,272,320-326
TP1 FRAME CONNECTION
X4,6-9,17-19,22,23,31-36,40,47-49,51-53,57, EARTH GROUND CONNECTION

58-60,62,65-67,69,70,72-89 Y1
FILE: G2241_2A1
NOTES :
Ch’ge.Sht.No. EQUIP.
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
POWER WAVE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY ON HOLES SIZES PER E-2056
1-6-95B
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ON 2 PLACE DECIMALS IS + .O2
CLEVELAND, OHIO U.S.A. SUBJECT CONTROL SCHEMATIC
ON 3 PLACE DECIMALS IS + .OO2
NUMBER. 8-11-95C
ON ALL ANGLES IS + .5 OF A DEGREE SCALE NONE
SHT.
MATERIAL TOLERANCE ("t") TO AGREE 1-30-98B
DR. JRF DATE 11-25-92 CHK. SUP’S’D’G. NO. G 2241-1
WITH PUBLISHED STANDARDS
8-13-99B
POWER WAVE 450

2241-2 G
R338
R339
R337
R345
4.75K
4.75K
4.75K
4.75K
+5V
D
(DSP1 ADDRESS BUS)
28
8
A12 VCC (DSP1 DATA BUS)
ADDR[0:11] 20
16 16 14 14 20 20 20 20 16 28 28
7
A11 X46 A13 9
ADDR[10] 6 10 DATA[0:15] C70 C60 C62 C64

C65 C63 C42 C44
A10 A14 C68 C66 C67 C61 C43 C155 C156
C69 C59 X25 X39
1.0 X38 X43 X41
C130
X27 0.1 0.1 0.1
X42 X45 X46
ADDR[9] 5 A9 /WE
27 X44 X21 0.1 X28 X29 X30
35V 0.1 1.0 0.1 0.1
/WE 0.1 0.1 0.1 0.1 50V 50V 50V 0.1 0.1 0.1
ADDR[8] 4 22 0.1 74AC04 50V 0.1 35V TMS320E14 50V 50V CY7C199 CY7C199
A8 /OE 50V 50V SCHMITT 50V PAL16R4 50V 74AC573
/REN TMS320E14 50V 74AC153 74AC573 74AC573 74AC573 50V 50V 50V
50V NAND 50V
ADDR[7] 3 20 74AC139 74AC139
A7 /CE
RAM_SEL 34 3 10
34 3 8 8 7 7 10 10 10 10 8 14 14
ADDR[6] 2 A6 I/O 0 11 DATA[0]
ADDR[5] 1 A5 I/O 1 12 DATA[1]
ADDR[4] 26 A4 I/O 2 13 DATA[2]
ADDR[3] 25 A3 I/O 3 15 DATA[3]

D
ADDR[2] 24 A2 I/O 4 16 DATA[4]
ADDR[1] 23 A1 I/O 5 17 DATA[5]
ADDR[0] 21 A0 I/O 6 18 DATA[6]

14
GND I/O 7 19 DATA[7]
CY7C199 3D: ANALOG/DIGITAL CONVERTERS
+5V
3C: STATIC RAM

(DSP2 MISC. I/O BUS)
CURRENT A/D CONVERSION AD_DATA[0:15] Vcc
R342
R343
R344
R341
4.75K
4.75K
4.75K
4.75K
C47
RD_CUR 4 RD DB0 20 AD_DATA[0] 1.0
C48
X24 OUT
+Vref_I +5V CLK
I_AD
8 Vin DB1 19 AD_DATA[1] 35V 0.1
X14 50V (3)
D STROBE_AD
3 S/H DB2 18 AD_DATA[2] 25mhz
28
9 Vref+ DB3 17 AD_DATA[3] 16
8 1 GND
A12 VCC select a VCC
6 AVcc DB4 16 AD_DATA[4] DSP_REN
7
A11 X45 A13 9 15 select b Y2a 6 RD_DSP2
1 DVcc DB5 15 AD_DATA[5] DSP_WE
ADDR[10] 6
A10 A14
10
C35 C40
2 A0a Y1a 5
2 INT DB6 14 AD_DATA[6] DSP_A0 X43
18 0.1 C33 C34 D

ADDR[9] 5 A9 /WE
27 10.0K 14 A0b Y0a 4
/WE 15V 50V 18 0.1 7 Vref- DB7 13 AD_DATA[7]
R267
ADDR[8] 4 A8 /OE 22 DSP_A2 3 A1a Y0b 12 1 2 DSP2_W0
X21
/REN
15V 50V
5 CS DB8 12 AD_DATA[8]
ADDR[7] 3 A7 /CE 20 13 A1b Y1b
11
RAM_SEL 10 GND ADC1061 DB9 11 AD_DATA[9]
ADDR[6] 2 A6 I/O 0 11 DATA[8] 7 Y3a Y3b 9
ADDR[5] 1 12 DATA[9] 8 10 3 4
A5 I/O 1 GND Y2b +5V
X21 DSP2_W2
ADDR[4] 26 13 DATA[10] A D 74AC139
A4 I/O 2
ADDR[3] 25 A3 I/O 3 15 DATA[11]
ADDR[2] 24 A2 I/O 4 16 DATA[12]
R74
ADDR[1] 23 17 DATA[13] 10K
A1 I/O 5
+5V +Vref_V 3A: BUS DECODE DSP 2
16
+5V ADDR[0] 21 A0 I/O 6 18 DATA[14] VOLTAGE A/D CONVERSION 1 /Ea Vcc
14 15 7
GND I/O 7 19 DATA[15] /Eb Za
OE_LOW
CY7C199 1 DVcc DB0 20 AD_DATA[0] 3 I3a X44 S0 14
DIRECTION
J24 2 INT DB1 19 AD_DATA[1] 4 I2a I1a 5
RD_LATCH (DSP1, PORT1)
13 ADDR[0] X37
ADDR[0:11]
STROBE_AD
3 S/H DB2 18 AD_DATA[2] 12 I2b I0a 6
RD_LOW (PSD301)
ADDR[1]
4 RD DB3 17 AD_DATA[3] 13 I3b I1b 11
RD_LATCH (DSP1, PORT1)
ADDR[2] RD_VOL
C37 C38
V_AD
8 Vin DB4 16 AD_DATA[4] 1 select a VCC
16
2 S1 I0b 10
RD_HIGH (PSD301)
ADDR[3] 0.1 18 /REN 8
50V 15V 6 AVcc DB5 15 AD_DATA[5] 15 select b Y0a
4 GND Zb 9
OE_HIGH
ADDR[4] /WE 74AC153
C41 C39 10.0K 9 Vref+ DB6 14 AD_DATA[6] ADDR[0] 2 A0a Y1a 5
R268
J24 475 475 ADDR[5] X42
0.1 18 5 CS DB7 13 AD_DATA[7] 14 A0b Y2a 6 D
1 R50 R51 ADDR[6] 15V READ_0
50V
7 Vref- DB8 12 AD_DATA[8] 3 A1a Y0b 12
ADDR[7] DSP_A11
DZ11 10 GND ADC1061 DB9 11 AD_DATA[9] 13 11 6A: CONTROL DATA FLOW (DSP 1 <> HC11)
A1b Y1b
5.1V ADDR[8]
1W 7 Y3a Y2b 10 5 6
ADDR[9] X21 WRITE_0 DIRECTION HIGH.....HC11 -> DSP 1
8 9
GND Y3b
NOISE_GROUND ADDR[10] A D DIRECTION LOW......DSP 1 -> HC11
DSP_A2 74AC139
ADDR[0:11]
WRITE_1
DSP_A11
J24 475 475 (DSP1 ADDRESS BUS)
DSP_A0
2 R52 R49 RD_LATCH
5 6 9 12 13 14 20 21 25 26 27 28 O/D(0:15) 5 6 9 12 13 14 20 21 25 26 27 28
100K
R266
ADDR[0:11]
DZ17 3B: BUS DECODE DSP 1
A5
A0
A5
A0
A4
A3
A2
A4
A3
A2
A10
A10
A9
A8
A9
A8
A6
A6
A7
A7
A1
A1
A11
A11
5.1V
1W 33 1 20 33
Vcc1 Vcc2 4 /OE Vcc Vcc1 Vcc2 4 D
RD_DSP2
NOISE_GROUND 56 IOP0 D0 64 DATA[0] DATA[0] 2 D0 O0 19 O/D(0) O/D(0) 64 D0 IOP0 56 AD_DATA[0]
X28
55 IOP1 D1 63 DATA[1] DATA[1] 3 D1 O1 18 O/D(1) O/D(1) 63 D1 IOP1 55 AD_DATA[1]
J24 475 475
3 R44 R55
+15V
DZ12 52 IOP4 D4 60 DATA[4] DATA[4] 6 D4 O4 15 O/D(4) O/D(4) 60 D4 IOP4 52 AD_DATA[4]
5.1V
1W
10K
R262
45 IOP6 X38 D6 58 DATA[6] DATA[6] 8 D6 O6 13 O/D(6) O/D(6) 58 D6 X25 IOP6 45 AD_DATA[6]
NOISE_GROUND
(3) DIRECTION
44 IOP7 D7 57 DATA[7] DATA[7] 9 D7 O7 12 O/D(7) O/D(7) 57 D7 IOP7 44 AD_DATA[7] C31
4.75K
1.00K
J24 475 475 0.1
R70
R73
10
42 IOP8 CMP3 1 GND LE 11
WRITE_0
100K
R263
19 CLKOUT IOP8 42 AD_DATA[8] 50V
4 R45 R57
74AC573
41 IOP9 TXD 47 11 TCLK2/CLKX IOP9 41 AD_DATA[9] Q6
C52
DZ14 LATCH_READ 38 24 10 38
2N4401
IOP10 CLKIN TCLK1/CLKR IOP10
CLK D CLR_CAP
5.1V
37 19 1 20 24 37 J22
1W IOP11 CLKOUT /OE Vcc CLKIN IOP11
RD_DSP2 CLK RD_CUR
820p 1
+5V 18 /INT TMS320E14 D8 50 DATA[8] DATA[8] 2 D0 O0 19 O/D(8) O/D(8) 50 D8 TMS320E14 IOP12 32
STROBE_AD
NOISE_GROUND X27 50V D50
/REN
16 /REN (3) D9 49 DATA[9] DATA[9] 3 D1 O1 18 O/D(9) O/D(9) 49 D9 IOP13 31
R264
10K
1N4936
Q7
J24 475 475 /WE
15 /WE (3) D10 46 DATA[10] DATA[10] 4 D2 O2 17 O/D(10) O/D(10) 46 D10 IOP15 29 R69 2N4401
DSP 1 3A: DSP 2 OUTPUT_ON *
5 R48 R53 17 /RS D11 43 DATA[11] DATA[11] 5 D3 O3 16 O/D(11) O/D(11) 43 D11 /REN 16 D 1.00K FET BANK A
RESET DSP_REN
1.00K
1.00K
R179
R71
/WTD
23 /WTD D12 40 DATA[12] DATA[12] 6 D4 O4 15 O/D(12) O/D(12) 40 D12 IOP14 30
+5V
10K
R72
DZ15 RD_VOL
5.1V +5V
22 NMI/MC/MP D13 39 DATA[13] DATA[13] 7 D5 O5 14 O/D(13) O/D(13) 39 D13 /WE 15
DSP_WE
1W
RD_HIGH
66 CMP4/CAP2/FSX D14 36 DATA[14] DATA[14] 8 D6 O6 13 O/D(14) O/D(14) 36 D14 /INT 18
J22
CMP4/CAP2/FSR
CMP5/CAP3/FSX
CMP5/CAP3/FSX
NOISE_GROUND RD_LOW
67 CAP1 D15 35 DATA[15] DATA[15] 9 D7 O7 12 O/D(15) O/D(15) 35 D15 NMI/MC/MP 22 2
TCLK2/CLKX
TCLK1/CLKR
34 10 11 34
Vss1 Vss2 3 GND LE Vss1 Vss2 3
WRITE_0
J24 475 475 74AC573 A
C30
CMP2
CMP0
CMP2
CMP0
CMP3
/WTD
CMP1
CMP1
CAP0
CAP0
IOP12
IOP14
IOP15
IOP13
CAP1
R46 R56
6
AD_DATA[0:15]
RXD
RXD
C56
TXD
/RS
330p
330p 1 20
100V CLK Vcc
7 2 68 11 10 48 65 8 32 31 30 29 20 1 17 23 67 47 48 68 65 66 1 2 7 8 CLK
100V Vcc /OE READ_0
DZ13 2 I0 O3 19 CHA
5.1V DATA[0] 19 O0 D0 2 O/D(0) X39
CHB
1W X29 3 I1 O2 18 +15V
D D
DATA[1] 18 O1 D1 3 O/D(1)
4 I2 D3 17
R41
NOISE_GROUND D RESET CAP1
STROBE_AD DATA[2] 17 O2 D2 4 O/D(2)
5 I3 D2 16
RAM_SEL (3) DATA[3] 16 O3 D3 5 O/D(3)
J24 475 475
10K
6 I4 D1 15 11 10
7 R47 R54 OUTPUT_ON DATA[4] 15 O4 D4 6 O/D(4) X21

7 I5 D0 14
10K 10K 10K 10K 10K 10K DATA[5] 14 O5 D5 7 O/D(5) STROBE_AD (4) C32
4.75K
1.00K
D 8 16 O1 13
(2) 0.1
R68
R67
CLR_SHUNT CLR_CAP
DZ16 DATA[6] 13 O6 D6 8 O/D(6) OVR_CUR
50V
12
5.1V 9 12 X41 11
R60
17 O0
R59
R58
(FROM HC11)
R62
R63
OUTPUT_ON
DATA[7] O/D(7) 1 4
R61
12 O7 D7 9 FAULT 13 12
1W 10 Q5 13
X21
X41 3 X41 6 GND PAL16R4 OE 11
11 10 /XIRQ C53 2N4401
LE GND 2 5
NOISE_GROUND DSP2_W2 /WTD
74AC573 J22
475 475 7 D D
J24
820p
R42 R43 D D51
8 D 50V
20
Vcc /OE 1 READ_0 5: PAL Q4
1N4936
3Eb: WATCH DOG R64 2N4401
DZ10 DATA[8] 19 O0 D0 2 O/D(8) *
X30 1.00K
5.1V DATA[9] 18 O1 D1 3 O/D(9) FET BANK B
1.00K
1.00K
R180
R173
1W 3B: DSP 1 FUNCTION GENERATOR 10K
DATA[10] 17 4 O/D(10)
R65
J24 O2 D2
14 DATA[11] 16 O3 D3 5 O/D(11)
J22
DATA[12] 15 O4 D4 6 O/D(12)
8
NOISE_GROUND DATA[13] 14 O5 D5 7 O/D(13)
DATA[14] 13 O6 D6 8 O/D(14)
A * INDICATES CHANGE FROM "XRF" VERSION
DATA[15] 12 O7 D7 9 O/D(15)
+15V
11 10
LE GND
DSP2_W2
74AC573 2O: MAIN FET DRIVE
R- 345 DZ- 35
J24 C- 156 Q- 34
DATA[0:15]
9 O/D(0:15) RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 52 X- 93
J24 (DSP2 DATA BUS) DSP / FUNCTION GENERATOR - SHEET 2 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
10
J24
6B: PARALLEL COMMUNICATION COMMON CONNECTION
11
FRAME CONNECTION
J24
EARTH GROUND CONNECTION
12
FILE: G2241_2A1
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
POWER WAVE
NOISE_GROUND WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY ON HOLES SIZES PER E-2056
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
1-6-98B CONTROL SCHEMATIC
ON 2 PLACE DECIMALS IS + .O2
CLEVELAND, OHIO U.S.A. SUBJECT
NUMBER. 8-11-95C NONE
ON ALL ANGLES IS + .5 OF A DEGREE SCALE
SHT.
8-13-99B
POWER WAVE 450

2241-3 G
+15V
+5V +5V +15V +5V
+5V
+5V
+5V
2E: CURRENT MODE CONTROL 13
14 14 18 4
Vdd C152 4 4
C96 20 20 20
0.1 C81
0.1 X56
267 C151 50V 0.1
R274
O/D(0:15) C132 C97 X63 C98 X64 X54
C150 X92 C100 C101 50V C148 C83 C84
0.1 0.1 0.1 0.1
0.1 X71 0.1 0.1
X61 0.1 0.1 0.1
50V
50V C153 X90 X68 X55
50V 50V 54HC4066 50V 54HC4066 50V 50V 50V C87 50V 50V 50V MC1408
AD7545 33074A 0.1
33074A 33074A 0.1 74AC573 74AC573 74HC573
+2.5V 50V
AGND DGND 50V 3
7 7 2 11
3 11 11
20 + A
O/D(8) 2 D0 Vcc 1 C133 A 10 10 10
X91 +5V A 0.1

O/D(9) 3 D1 O7 12 8
X90 50V A A A D
1 13
REF TL431
/OE O6
6 - -5V
O/D(10) 4 17 -15V
D2 O2
D
100K
O/D(11)
R277
5 D3 O3 16 A -15V
6 D4 O4 15 R288
-5V
7 D5 O5 14 221K
33.2K
8 D6 01 18
12 1 V+ /Q OUT 8
9 D7 00 19 R278
14
200
R282
825
2 +IN Q OUT 7 OVR_CUR
2H: REFERENCE VOLTAGES
10 DSP2_W0 X61 R283
GND LE 11 X93
(DSP2, PORT2) 13 3 -IN GND 6
74AC573 10.0
C137 C138
4 V- LE 5
820p 820p
D R316
1 OUT1 RFB 20 50V 50V LT1016
20 R281
1 /OE Vcc 2 AGND VREF
19 A A
C95 -5V
R315
6.81K
O/D(0) 2 D0 LE 11 3 DGND Vdd 18 0.1
X68 1.00K
15 A 50V
O/D(1) 3 D1 O0 19 DB0 X54 /WR
17
R170 R172
O/D(2) 4 18 14 16
D2 O1 DB1 /CS CLR_SHUNT CURRENT MODE CONTROL, DISABLE THE +2.5V
10K 10K 1.00K
O/D(3) 5 17 13 7 (DSP2) FETS AS SOON AS SECONDARY CURRENT
R168
D3 O2 DB2 DB8
IS GREATER THAN A REFERENCE LEVEL
O/D(4) 6 16 12 6 10
D4 O3 DB3 DB9
R284 200 825 R169 Q14
2
O/D(5) 7 15 11 5 8
D5 O4 DB4 DB10 R286 10K X71 2N4403
X61 R287 R167
10K 1
O/D(6) 8 14 10 4 9
D6 O5 DB5 DB11 475
9 C139 C140 3
O/D(7) 9 D7 O6 13 DB6 DB7 8
820p 820p
10 AD7545
GND O7 12 50V 50V 10.0
A
R166
74AC573 R285
6.81K
O/D(0:15)
A
(DSP2 DATA BUS) GENERATE A REFERENCE LEVEL
+15V
C57 +2.5V -15V
1.00K 6.81K
22p 5
R314
R275 R276 100V
7 Q9
4.75K X71 R128 2N4401
C134 1.00K
C135 C136 Q33
6 CURRENT A/D
820p 8 9 475
330p 150p 2N4401 R280 X21 CLR_SHUNT REFERENCE
50V FILTER INCOMING 1.00K
100V 50V (DSP2)
SECONDARY CURRENT
R127
10.0
+Vref_I
R313
10K
R279
CLEARING NETWORK
A 33.2K
SECONDARY CURRENT REGULATION
SHUNT CONNECTION +15V +15V R129
CURRENT SIGNAL IN
10mA = 800A OUTPUT 10.0 1.00K
A
R312
R311
R130
3
33.2K
1
X61 R155 I_AD C79
R33
CURRENT FEEDBACK
26.7K 2 (2) TO CURRENT A/D 0.1
CLEARING NETWORK CLR_CAP 150
D10 50V
A
4.75K
R302
J21 (SHEET 2, X39) 1N914

1.00K
R156
4.75K A
8 R299 R154 V_LIMIT
Q13 +15V
150 +Vref_I
Q12 600mA R66
1A 40V D52 47.5K
100V 10.0 1N4936 10
4.75K C54 C85 R126 R310
R149
C88 Q8
R142
(HC11 ADDR/DATA BUS)

R153 820p 750 CURRENT FEEDBACK 22p 8
CURRENT FEEDBACK 0.27 681 4.75K X71 R122 2N4401 VOLTAGE A/D
50V 1N914 DA-AD[0:7] 100V +Vref_I
INTERGATOR 50V AMPLIFIER -5V 9 REFERENCE
475
D11 12 16
DZ27 A8 COMP
GAIN = 5.0 to 6.9 1.00K
R300
1.00K
1.00K
R152
15V DA-AD[0] 2 D7 Q7 19 11 A7 Io 4
R118
Q10 CW I_AD = 5.0V @ 800A OUTPUT R97 R96 10.0
1W 74HC573
R309
TRIM_DAC REFERENCE +Vref_V
R150
3
600mA DA-AD[1] 3
D6 Q6 18 Vee Vref+ 14
R171 R98 1.00K 1.50K VOLTAGE FEEDBACK
500
40V DA-AD[2] 4 17 10 13 2 33.2K
D5 Q5 A6 X56 Vcc 1.00K 1.50K *
1.00K
DA-AD[3] 5
D4 Q4 16 9 A5 Vref- 15 1.00K C73 1 R121
R94 X26 R120
X55 0.1
DA-AD[4] 6 D3 15 8 A4 R CON 1 3
Q3 10.0 1.00K
R308
50V
R307
A
2C: SECONDARY CURRENT SENSE 2D: CURRENT FEEDBACK DA-AD[5] 7 D2 Q2 14 7 A3 GND 2
DA-AD[6] 8 D1 13 6 A2 A1 5
Q1
A
MC1408 C77
DA-AD[7] 9 D0 12
Q0
0.1
1.00K A
J20 50V
3 R188 +_OUTPUT WR_REF
11 LE A
-_OUTPUT DA-AD[0:7] 1 OE
J20 1.00K (SHEET 1, X5)
2 R187 67A 2G: PROGRAMMABLE VREF
J20 1.00K
1 R189 67B D
J20 1.00K
6 R186 21A
J20 1.00K
7 R191 21B
CLAMP CIRCUIT FOR
TRANSIENTS ABOVE 5.0V
KELVIN VOLTAGE X63
3 POLE FILTER J21 SUPPLY RAIL
FEEDBACK SWITCH 2 R271 -15V
1 2
FIRST STAGE CUTOFF FREQ = 4.8 KHZ
100 +5V +15V V_LIMIT
MATRIX SECOND STAGE CUTOFF FREQ = 3.3 KHZ
13 J21
AS1 THIRD STAGE CUTOFF FREQ = 3.4 KHZ 3 R270 +15V
X63 1.00K
100
R301
VOLTAGE IDEALLY 8 9 DZ34
ALL GROUNDS MEET DZ35
EQUAL TO 10/210, 15V 26.7
15V 10K
R182
80V=3.81V 6 HERE AND ONLY HERE 1W
AS2 PRECISION 1W R185
RECTIFIER
X64 1.00K
GAIN = 2 J21 C105
3
R183
R289 2.21K 10K 10K 6 0.1
11 10
CONNECTED IN
1 12
Q15 50V
3.32K X92 R291 R293 R295 R297 GRAPHICS ONLY D15 13
12 2 22.1K 14 1N914 X71 R184 2N4403
AS3 332 X92 V_LIMIT J21 14
C141 C142 C143 V_AD
X64 13
1N914 1N914 4 475
0.1 .022 .0047 12 10.0
R305
UNITY GAIN
R273
D13 D14
50V 50V 50V DIFFERENTIAL AMPLIFIER D12 475
4 3
R177
R303 1N914
+15V D A NOISE_GROUND
5 6.81K J21 10.0
R306
AS4 7 I_AD
* *
A 33.2K * 100K 100K
X64
J20 R174 R175 R99
4 8 9 NOISE_GROUND NOISE_GROUND
6 9
AS5 5
R290 10K * X92 R178 V_AD
J20 2.21K 5.11K 33.2K * 100K
X63 8 (TO VOLTAGE A/D)
8 7 -15V
3.32K X92 R292 R294 R296 R298 R181 R141 150
10
4 3 6
332
C144 C145 C146
5
AS6 0.1 .022 .0047
* 2I: V LIMIT
-15V 50V 50V 50V 100K
X63 D16
R148
R147
475
R146
R304 475
1N914
11 10 6.81K
A
J20 12
5 AS7
X64
UNITY GAIN
NOISE_GROUND 1 2 AMPLIFIER
A NOTES :
13
AS8
1.00K
1.00K
1.00K
1.00K
1.00K
1.00K
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

DZ18 DZ19 DZ20 DZ21 DZ22 2F: VOLTAGE FEEDBACK WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
( )
CONTROLED BY
SHEET 1, X16
R135
NUMBER.
R92
R90
R89
R93
R91
5.1V 5.1V 5.1V 5.1V 5.1V

1W 1W 1W 1W 1W GENERAL INFORMATION LAST NO. USED
R- 345 DZ- 35
C- 156 Q- 34
D- 52 X- 93
A RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS
SUPPLY VOLTAGE NET
ANALOG CIRCUITRY - SHEET 3 POWER SUPPLY SOURCE POINT

3Ef: MULTIPLEXING THE V INPUTS
ARC
COMMON CONNECTION
FRAME CONNECTION

FILE: G2241_2A1
EQUIP.
UNLESS OTHERWISE SPECIFIED TOLERANCE
Ch’ge.Sht.No.
8-13-99B
THE LINCOLN ELECTRIC CO. TYPE
POWER WAVE
ON HOLES SIZES PER E-2056
1-6-95B CONTROL SCHEMATIC
4-21-95J SCALE NONE
ON ALL ANGLES IS + .5 OF A DEGREE
SHT.
MATERIAL TOLERANCE ("t") TO AGREE 8-11-95C
1-30-98B
POWER WAVE 450

2241-4 G
50V
SER_LOOP
C121
+15V
2700p
J26
3 DK+
R233
750
R231
1.00K
R134
681
Q26
R241
3.32K
R236
61.9K
500mA
300V
2K D29
R237
Q25
500mA C120
300V
Q28 820p
600mA
ON / OFF ON / OFF 40V 50V
SWITCH +5V SWITCH +5V
+15V TP3
26.7 150V
R235
45J
R232
1 5 10K
SWDK
10K 10K
+5.5V +5.5V V_LIMIT OCI7
R257
R255
2N4403
10K R240
CNY17-3
R222
DIS1 DIS2 Q27
(SHEET 1, X20) C122
1.3K
R238
D24 200 .0047
J26 J26 10K 2 6 4
1 5 1N914 D27
400V
R239
SWITCH1 SWITCH2
J23
(TO HC11) (TO HC11) 6 R221 THERMAL
1 5 1 5
D30
1.00K (TO HC11) D26
OCI4 OCI8 DZ31 C119
D22 CNY17-3 D42 CNY17-3 5.1V 0.1
1W LOW = NORMAL 56.2K
50V
2 6 4 2 6 4 HIGH = FAULT
R234
HIGH = TRIGGER OPEN C123
HIGH = TRIGGER OPEN
LOW = TRIGGER CLOSED 150p
LOW = TRIGGER CLOSED J23 D
J26 J26
5 R226 50V
R254
221K
221K
R219
D28
2 R220 6 R256 J26
681
150 150 D
4 DK-
R225 TURN ON/OFF DISPLAY/KEYPAD FROM SERIAL LOOP

D 10.0
MUST BE ISOLATED FROM MUST BE ISOLATED FROM D
NOISE_GROUND
50V
ALL OTHER SIGNALS ALL OTHER SIGNALS C124
+15V
2700p
2N: THERMAL OVERLOAD INPUT J27
1 WF+
2M: ON/OFF SWITCHES R194
750
*
Q29
R195
3.32K
R192
1.00K
R138
681
R243
61.9K
500mA
300V
+15V
2K
R261
Q17 D38
500mA
300V C106
Q16 820p
+15V R230 600mA
J22
5 40V
26.7K 50V
TP5
R229
150V
R227
26.7 R193 26.7
26.7K 45J
R242
50V
100K 3J23 INPUT FROM PROTECTION 10K
R223
C113 J23 1 5
3 R228 SWWF
2700p +5V FOR FAULT CONDITION
1N914 2N4403 OCI2
0V FOR NORMAL CONDITION 1.00K R249
R207
D47
R203
CNY17-3
3.32K
Q31
1.00K
681
R119
(SHEET 1, X20) C129

1.3K
R250
J23 9 CAP1 200 .0047
100K 4 R258 10K 2 6 4
D33
R209
X41 8 400V
R251
R218 1.00K 10
(TO DSP2)
750 D34
Q20 DZ32 DZ33 D39
600mA 5.1V 5.1V
Q24 C128 C127
40V 1W 1W
500mA 150p 150p
56.2K
Q21 300V 50V 50V
500mA
C110
R201
300V
J23 150p
1 NC VCC 8 2 R259 D
50V
D36
2 ANODE VB 7 681 J27
TXD R204 2N4403
Q22 3 CATH VC 6 R260 D +5V
4 WF-
(FROM HC11) 1.3K C114
R205
200 4 NC GND 5 10.0

10K
OCI5 820p J27
R210
J23 NOISE_GROUND
10K 1 2
50V
R202
10K
TURN ON/OFF WIRE FEEDER 1 FROM SERIAL LOOP
R319
D21 J27
3
2K D25
R224
FAULT
56.2K 1N4936
D23
2K: PROTECTION BOARD INTERFACE 50V
C109
DZ30
R208
C112 +15V
150p 5.1V C111 Q34 2700p

R317 2N4401 J28

1W
D 50V 0.1
50V 10K HIGH = NORMAL
1 OPT+
10K
TP2 LOW = FAULT
R318
150V
R196
+15V 45J
+5V 750
C118
R197
3.32K
R327
R199
1.00K
681
Q30 *
.0047
500mA
R245
61.9K
400V D
300V
+Vref_I
2K D37
R248
5.11K Q18
R206
3.32K
2L: GENERATE FAULT SIGNAL 500mA C108
4.75K
R216
R211
300V
Q19 820p
CT FEEDBACK * 600mA
RXD 26.7K D4
220 Primary Amps 40V
(TO HC11) 1N914 50V
R86
= 1.257 Volts
D18 D19 R84 TP4
Q23
47.5K * 26.7 150V
600mA R215 R213 J21 R198
5 D5 45J
R244
40V 1 R161 R87
2.67K 10K 1N914 1 5 10K
7 SWOP
8 VCC NC 1 4.75K 2.21K X61
2N4403 OCI3
3.32K 4.75K C91 6 R247
7 2 * CNY17-3
VB ANODE Q32
R212
C115 C117 .022 C125

R214
R165
R160
R164
R162
R163
(SHEET 1, X20) 1.3K
R252
10.0
10.0
10.0
10.0
10.0
150p 150p 6 VC CATH 3 * 200 .0047
10K C90 150K 10K 2 6 4
D32
50V 50V 400V
R158
R246
5 GND NC 4 330p
R159
OCI6 100V
150 PRIMARY OVER CURRENT
D17
J21 SHUTDOWN @ 214 AMPS D31
D41
R253
D20 5
221K NORMAL X61-7 @ MINUS RAIL
FAULT X61-7 @ PLUS RAIL
C116 C126 56.2K
R217
A
150p 330p
R200
C107
50V 100V
D40 150p
D
50V
D35
J28
D43
4 OPT-
D SER_LOOP 2J: PRIMARY CURRENT SENSE
J22
4
TURN ON/OFF OPT FROM SERIAL LOOP

SL
WIRE FEEDER TRANSMIT/RECEIVE FOR SERIAL LOOP J28
2
2B: SERIAL LOOP PORT SWITCHES J28

3
2A: SERIAL LOOP

* INDICATES CHANGE FROM "XRF" VERSION
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE GENERAL INFORMATION LAST NO. USED
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
R- 345 DZ- 35
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ELECTRICAL SYMBOLS PER E1537
C- 156 Q- 34
NUMBER. CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 52 X- 93

SUPPLY VOLTAGE NET
SERIAL LOOP / PROTECTION INTERFACE - SHEET 4 POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION

FILE: G2241_2A1
UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
POWER WAVE
ON HOLES SIZES PER E-2056
1-6-95B
CLEVELAND, OHIO U.S.A. SUBJECT CONTROL SCHEMATIC
ON 3 PLACE DECIMALS IS + .OO2 8-11-95C
ON ALL ANGLES IS + .5 OF A DEGREE SCALE NONE
SHT.
8-13-99B
POWER WAVE 450

PC BOARD ASSEMBLY-CONTROL
±.04
11.25
ITEM REQ’D PART NO. DESCRIPTION
11.05 D38 C129 C125
D37 D35 Q30 R223
R227
C113 ITEM REQ’D PART NO. DESCRIPTION
R248 R218 R150 1 S24073-2 5 0 0 , 1 / 2 W, T R I M M E R C1,C2,C6,C8,C11,C16,C17 54 S16668-11 .1/50
R261 R194 C109 R209
Q26 Q25 R196 R153,R160,R162,R163,R164 16 S19400-10R0 10 1/4W C18,C19,C20,C21,C22,C23
C124 Q17 C111
TP5 R245 C24,C27,C28,C29,C31,C32
Q29
R202 Q24 R165,R166,R225,R260,R305
R243 R244
Q18 R306,R307,R309,R312,R313 C34,C37,C40,C41,C42,C43
D43
R233
C122
R253
C126
TP4 R242 DZ30
D40
C106 C108 D32
J28
C44,C45,C48,C59,C60,C61
C114
R236
C121
C120 R316
D23
D41
R193 R198
Q21
R232 R235 D33 R155,R178,R220,R253,R256 6 S19400-1500 150 1/4W C62,C63,C64,C65,C66,C67
C118
C110 C107 D31 C112
TP3 D27 C123
D39 R299 C68,C69,C73,C77,C79,C81
R234 R201 R200 R208
R159 1 S19400-1503 150K 1/4W C83,C84,C95,C97,C98,C100
D26 D36
TP2
R217
D19
R214
R216
C116
C105,C111,C119,C155,C156
J27
R195,R197,R207,R211,R212 8 S19400-3321 3.32K 1/4W
D28 OCI7 OCI2 OCI3 OCI6
Q19
R237 OCI5 C3,C25,C26 3 S16668-2 47pF/100
Q20
Q23
R241,R289,R290
Q16
R224 R200,R201,R208,R234 4 S19400-5622 56.2K 1/4W C4,C5,C49,C50,C51,C57,C85 7 S16668-1 22pF/100
D29
Q28
D25 R204,R240,R247,R249 4 S19400-1301 1.3K 1/4W C7,C47,C70,C130 4 S13490-42 1.0/35
R211
R138
R192
D18
C10,C13,C15 3 S13490-25 4.7/35
R241
D21
D20
D17
R212
R213
R195
R197
C115
R205,R238,R250,R252,R282 6 S19400-2000 200 1/4W
R249
R250
R246
R252
C117
R247
R207
R215
R240
R239
R238
R251
R199
R327
R203
R119
R206
D30
D34
R210
R205
R204
R256
Q22
J26
Q31
Q32
OCI4 OCI8 R286 C30,C56,C90,C126,C135 5 S16668-8 330pF/100
D42
Q27
R206,R298 2 S19400-5111 5.11K 1/4W C33,C35,C38,C39 4 S13490-39 18/15
R220
R219 R254 R215 1 S19400-2671 2.67K 1/4W C52,C53,C54,C106,C108,C114 12 S16668-7 820pF/50
D22 R257 R255 R231 C68 C69 C6 C20 C22 C27 R217,R219,R254,R288 4 S19400-2213 221K 1/4W C120,C134,C137,C138,C139
R134 XX XXX XXX
XXXXXXXXXX
R110
XXXXXXXXXXXXXX
R28 XXXXXXXXXXXX R224,R237,R248,R261 4 S19400-2001 2.0K 1/4W C140
XXX
R3
R4
XXXXXXXXX
R25 C87,C91,C96,C101,C132,C133 15 S16668-5 .022/50
X
R236,R243,R245 3 S19400-6192 61.9K
C70
C23
X
R23
R26
R27
R20
DZ5
C141,C142,C144,C145,C148
R10
R273 1 S19400-2212 22.1K 1/4W
R9
R8
XXX
J25
R21 R61
C7
XXX
R276,R281,R285,R303,R304 5 S19400-6811 6.81K 1/4W C150,C151,C152,C153
R36 R63 X13
X10 C88 1 S13490-85 .27/50
Q2
R24 R62 R283,R287 2 S19400-8250 825 1/4W
C56
C51
C50
XX
R22 R58 X2 R291,R292 2 S19400-3320 332 1/4W C107,C110,C112,C115,C116 10 S16668-9 150pF/100
X38
XXXXXXX
DZ6
R37 R43 R328,R329,R330,R331,R332 8 S19400-2210 221 1/4W C117,C123,C127,C128,C136
X
R38 R59
X
R39 R54 C109,C113,C121,C124 4 S16668-4 2700pF/50
X
R333,R334,R335
R40 R60 XXXXXXXXX
X
R29
X
C118,C122,C125,C129 4 S13490-3 .0047/400
C2
TP2,TP3,TP4,TP5 4 T13640-11 45J
XXXXXXXXX
X
R56 XXXXXXXX
D2
C49
R7
R34 R35 R262
R2
X
XXXXXXX
XXXXXX
R53 X1 1 S17900-1 Q UA D 2 - I N P U T N A N D ( S S ) C143,C146 2 S16668-6 4700pF/50
DZ9 DZ8 R6 R5
R57 X2 1 M15102-3 UNDERVOLT. SENSING CIR. (SS) D2,D17,D18,D19,D20,D21,D22 27 T12199-1 1N4004
R47 DZ16 C3
R55 XXXXXXXXXXXXX D25,D26,D27,D28,D29,D30
X3,X5 2 S17900-13 QUAD TWO INPUT AND GATE (SS)
R344
R341
R342
R49
X15
C5
D31,D32,D33,D34,D35,D36
C4
X10 1 M15101-6 MPU (SS)
C155
R46 DZ13 R51 X1
X45
Y2
C21
R48 X11,X12 2 S19650-7 IC,CMOS,TRNSCVR,BUS (SS) D37,D38,D39,D40,D41,D42
C1
DZ15
R343
J24
R45 X13 1 s21291-5 R O M A S S E M B LY ( S S ) D43,D46

DZ14 D4,D5,D10,D11,D12,D13,D14 11 T12705-22 1N914
X14,X37 2 M15105-4 IC,CMOS,CONVERTER,A/D (SS)
X
R44 C45 XXXXXXXX
DZ12 X41 X15 1 M15104-6 MPU (SS) D15,D16,D24,D47
R52 C18
X46
C156
R42 DZ17 X16,X20,X55 3 S17900-25 I C , C M O S , L AT C H , 3 - S TAT E ( S S ) D23,D50,D51,D52 4 T12705-34 1N4936
C43
R336
R50 X21 1 S19650-1 HEX INVERTER (SS) DZ2,DZ5 2 T12702-40 1N4735
DZ10 C61 X3 X5
R222 X42
X24 1 M14428-2 C RY S TA L , ( M O D U L E ) , 2 5 . 0 M H Z DZ3,DZ4 2 T12702-45 1N4746A
R221 DZ11 R338
R339 X30 X25 1 S21292-5 I C , C M O S , M C U, D S P ( S S ) DZ6,DZ27,DZ34,DZ35 4 T12702-29 1N4744A
C44
DZ31
C42
C119 R345 X26 1 S15128-4 LM224 OP-AMP DZ7,DZ8,DZ9,DZ10,DZ11,DZ12 20 T12702-52 1N4733A
R229
DZ33
R337
C29
J23
C128 X21 X44 X20 X27,X28,X29,X30,X68,X90 6 S19650-5 I C , C M O S , L AT C H , 3 - S TAT E ( S S ) DZ13,DZ14,DZ15,DZ16,DZ17

R226
C127 D24 X38 1 S21293-3 D S P A S S E M B LY ( S S ) DZ18,DZ19,DZ20,DZ21,DZ22
R228
R259 C48 C66 X29 X39 1 S21294-1 I C , C M O S , P L D, G E N E R I C ( S S ) DZ30,DZ31,DZ32,DZ33
C60 C67
R258 X41 1 S17900-24 Q UA D S C H M I T T N A N D ( S S ) J20,J21 2 S20351-8 HEADER
C64
R230 R332 R331 J22 1 S20351-12 HEADER

5.63
C63
R180
X42,X43 2 S19650-3 1-OF-4 DECO/DEMUX (SS)
C28
DZ32
D51 X43 R333 R330 J23,J26 2 S20351-6 HEADER

POWER WAVE
X16 X44 1 S19650-6 IC,CMOS,MUX,4-INPUT (SS)

R64 X28 R334 R329 J24 1 S20351-14 HEADER
X24 X45,X46 2 M15104-11 I C,CMOS,EEPROM,FLASH (SS)
CONTROL
C53 R335 R328

X54 1 M15105-11 CONVERTER,D/A (SS) J25 1 S20351-10 R T. A N G L E H E A D E R
G2861-2
X56 1 M14513-4 IC,CONVERTER,D/A (SS) J27,J28 2 S20351-4 HEADER

X39
C84
R74
C26
C25
Q5 Q4 X11 OCI2,OCI3,OCI4,OCI7,OCI8 5 S15000-10 O P TO I S O L ATO R
X55 X61,X71,X92 3 S15128-18 Q UA D - O P A M P
C16
C65
X27 X63,X64 2 S17900-22 Q UA D A N A L O G S W I T C H ( S S ) OCI5,OCI6 2 S15000-23 6N136 OPTOCOUPLER

C47
R173
R260
R225
R68
R65
R67
C31
R41 Q2,Q3,Q4,Q5,Q6,Q7,Q8,Q9 17 T12704-68 2N4401

C32
X91 1 S15128-10 VO LTA G E R E F.

C130
XXXXXXXXXXX X93 1 S15128-21 I C , C O M PA R ATO R , H I - S P D, 5 - V Q10,Q13,Q16,Q19,Q20,Q23
X
X12 X56 Q28,Q33,Q34

X
C59
Y2 1 S16665-5 8.0 MHZ
C34
C73
C17
C30 X
Q12 1 T12704-73 IC PKG MOSFET (SS)

C83
X68
R179
R69
D50
Q14,Q15,Q22,Q27,Q31,Q32 6 T12704-69 2N4403

C52
C85
CAPACITORS = MFD/VOLTS
X
Q17,Q18,Q21,Q25 4 T12704-35 N P N T R A N S I S TO R
INDUCTANCE = HENRIES
XXX
X25
C81
Q24,Q26,Q29,Q30 4 T12704-47 .5AMP / 300 VOLT PNP
XXXXX
X14 RESISTANCE = OHMS
R171
C33
R267
R98
C148
R94
R2,R4,R8,R9,R10,R12,R13 52 S19400-1002 10K 1/4W
J22
C62
C38
X90
Q6 Q7 R14,R16,R18,R20,R32,R35
R41,R58,R59,R60,R61,R62
R263
XXXXXXXXXXXX
XXX
XXXX
R71
R70
R72
R73
DZ4
XXXX
R63,R65,R72,R74,R158,R169
DZ3
DZ2
C24
R11
R31
DZ7
R30
C39
C19
X54 R170,R172,R185,R193,R198
C150
C8
X XXXXXXXX X37
C35
R264
C40
C37
R202,R210,R213,R222,R235
R266
XXXXXXXXXXXX R239,R246,R251,R255,R257
R319
R271
Q34
R318 C41 R268 R262,R264,R267,R268,R279

DZ35
R274
C15
C10
C132
C133
R288
C13
R317 X93 X91 R32 R284,R295,R296,R297,R317

C11
R13
X26 R96 R318,R319

R108
R109
D47 R97
Q3
R3,R7,R68,R70,R142,R154 21 S19400-4751 4.75K

R161,R214,R216,R302,R310
R277
C140
R142
R282
R281
R278
R284
R287
R286
R285
R314,R336,R337,R338,R339
C138
C137
C139
R283
C54
R168
R126
R120
R172
R19
R14
R17
R12
R15
R279
R16
D5
R18
D46
J21
R341,R342,R343,R344,R345
C136
C135
R270
R299
R275
R276
Q33
R280
C134
DZ34
C57 R5,R37,R87,R293,R294 5 S19400-2211 2.21K 1/4W

C95
R6 1 T14231-2 10M 1/2W
R316
Q10
R11,R99,R141,R148,R175 10 S19400-1003 100K 1/4W

C101
R158
X61 R315
C87
C96
D11
D10
R86
R161 C88
C79
R311
Q14
R129
R167
R170
R169
R209,R223,R263,R266,R277
R127
R313
R312
R130
R310
R314
R163
C91
R15,R36,R38,R39,R40,R64 50 S19400-1001 1K 1/4W

R33
R164
Q9
R160 C145 R166 R67,R69,R71,R73,R89,R90

R300
R152
R156
R302
R153
R155
Q13
DZ27
R296
R294
D52
Q12 R84 C90 R91,R92,R93,R94,R97,R108

R165 R154 R150
R162 R159 R146 R128 R110,R118,R120,R127,R135
R66
R87 D4 R298 C100 X71
DZ18 R149 R152,R156,R168,R171,R173
C105
R191 R135 R179,R180,R183,R186,R187

R306
D12
D16
R188,R189,R191,R192,R199
R273
R174
R181
R148
R141
R175
R178
D13
R147
DZ19 X63
C146
C144
R292
D14
R99
R118
J20
R184
R121
R177
R307
R308
R309
R185
R183
R305
R122
R91 C142 R203,R221,R228,R231,R258

D15
R186
C77
R188 R89 C143 R275,R280,R300,R301,R308

C97 R297 R311,R315
R290
C98
R187 DZ22 R17,R19,R109 3 S19400-1502 15K 1/4W

R295 Q15
R304
C151
X92 R301
C152
C153
R291
DZ21 R93 X64 R21,R23,R24,R182,R227,R232 8 S19400-26R7 26.7 1/4W

R293 Q8 R182
DZ20 R92 C141 R242,R244
.20 R189 R90 R289 R303 R22,R29,R274 3 S19400-2670 267 1/4W
R25,R28,R270,R271 4 S19400-1000 100 1/4W
0 R26,R27,R30,R31,R34,R42 28 S19400-4750 475 1/4W
R43,R44,R45,R46,R47,R48
R49,R50,R51,R52,R53,R54
±.04 R55,R56,R57,R122,R128,R146
R147,R167,R177,R184
R33,R86,R229,R230 4 S19400-2672 26.7K 1/4W
0 8.00 R66,R84 2 S19400-4752 47.5K 1/4W
R96,R98 2 S19400-1501 1.5K 1/4W
R119,R126,R134,R138,R226 7 S19400-6810 681 1/4W
R259,R327
.20 4.00 7.80

R121,R129,R130,R174,R181 6 S19400-3322 33.2K 1/4W
R278
R149,R194,R196,R218,R233 5 S19400-7500 750 1/4W
11-12-99C G 2861-2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER WAVE 450
SCHEMATIC - DISPLAY PC BOARD (SHEET 1)
G 2239-1
+5V
+15V
J16
9 448 1 +5V
X5 8
10
26 Vcc 44 20 20 20 14 14 12 16 16 Vdd 3 3 11 10 C27 C22 C23 C29
Vdd Vdd 4 4 X11
0.1 0.1 1.0 0.1
C48 12 50V 50V 35V 50V
C57 DZ5 X8 DZ4 C50 C49 C56 C20 C12 C52 C55 X14 C54 X10 C25 C30
X7 X13 11 J16
0.1 0.1 5.1V X4 X9 X3 X11 X5 X16 X12 C39 C40 X5
449
5.1V X1 X2 13 13 12 7 W1
50V 50V 1W X11
1W 0.1 0.1 0.1 74HC04 0.1 54HC08 0.1 0.1 0.1 0.1 0.1 0.1
MC68HC11 PSD301 74HC573 74HC573 74HC573 74HC4040 74HC151
MC14489 MC14489 0.1 0.1
50V 50V 50V 50V 50V MC6850CS 50V 50V 50V 50V 50V LM224 LM224 C26
50V 50V C28
0.1
Vss GND GND Vss Vss 1.0 GA
1 12 34 10 10 10 7 7 1 8 8 14 14 GD 50V GD
11 11 3 4 35V
X11
J16
-5V 446 9 -5V
12
GA 5 6
14 X11 J16
GD X1 447 +15V
10
13
C21
GD C19
LED15 0.1 1.0
50V
FROM POWER BOARD

35V
-5V
LED19
16 J16
7 4
Q2 Vcc D0 443
FULL DUPLEX RS232 COMMUNICATION LINK 74HC151
2 +5RS232
LED18 1 Q12 Q3 6 3 D1
C37 C38
0.1
PIEZO BUZZER CIRCUITRY
15 Q11 X12 Q4 5 2 D2 Y 5
LED34 1.0
35V 50V
14 Q10 Q5 3 1 D3
+5RS232 LED13
+5V X14 J16
9 2 15
Q1 Q6 D4 442 3
LED30 +15V
10 /C Q7 4 14 D5 6
/Y GRS232
J17 5 16
1 X15 750 LED14 11 13 13
R Q8 D6
J15
R43
LED32 8 12 12 1 J16
C18 GND Q9 D7
6.81K + 444 6 -8V
18 74HC4040
R42
10K D21 PIEZO
LED16 11 A0
15V +10RS232 BAUD0 C41
R41
BUZZER C44
J15 _
20 18 1 6 LED33 GD 10 A1 1.0 0.1
BAUD1 Q15 2
A2 35V 50V
9
2 C1+ C1- 17 OCI7 4 LED17 BAUD2 600mA
C17 GND Vdd
C16 Q3 H11L2 7 STROBE 40V
Rx J15
18 X15 18 40V PIEZO R115 3
2 5 LED29 J15
15V 4 Vss 19 15V 600mA GD 3.32K
Vcc
+5RS232 LED12 4
C2+ C2-
(POWER DOWN)
R114
10K C70 J16 475 475
1 3 C14
LED31 445
R47
22.1K 8 R33 R34 XIRQ
330p GD
GRS232 C15 LED11 +5V
50V
18
15V LED28 DZ2 C24
-10RS232
BI-DL[0:15] GD J16 5.1V 0.1
LED4
11
R48
50V
RECEIVE GRS232 4.75K 1W
LED27
J17 X16
3 LED10 1
VSS /IRQ 7 IRQ
J17 J17
5 2 +5RS232 3 RxCLK R/W 13 R/W
11 10
X15 J17 4 22 BI-DL[0]
LED7 LED24 TxCLK D0
6
23 /DCD D1 21 BI-DL[1]
J17 J17 /DCD
10 4
GRS232 5 20 BI-DL[2]
/RTS D2
LED22 -5V
LED8 6 19 BI-DL[3]
GRS232 Tx TxData D3
ISOLATED POWER & SIGNALS Rx

2 RxData D4 18 BI-DL[4]
LED21 24 /CTS 17 BI-DL[5]
LED5 D5
2.67K
+5RS232
BI-DL[6] TEMPERATURE
R14
14 E D6 16 1.00K
Tx R3
+5V
10 15 BI-DL[7]
COMPENSATION
+5V LED25 CS1 D7
+5RS232
LED6 11 8 BI-DL[15] 301
RS CS0
J17 9 12
R13
9 X15 12 9 6
750 VCC /CS2 /CS_RS232 D2 R71
R54
J17 MC6850CS X1 R49
4.75K 267 8 LED2 LED23 7
4.75K
R57
6.81K 4.75K
R56
BI-DL[11] 5
R53
22.1K 10K BI-DL[14]

GD
R51
R55
Q6 LED3 LED26
1 6 1 6
600mA E 2 J19
+5V
40V 4 13 8 J17 OCI5 4 X1 R70 5 Vo
OCI8 X15 7
/DCD 1
H11L2 LED9 LED20 P1
H11L2 Q5 1.00K
C45 +5V 3
C46 10K 40V CW DZ7
2 5 330p 2 5
330p 600mA 8.2V
R7 R5 R72
R52
50V
R73
50V GD 1W
10K
10K 100K 133K 4.75K
R58
GD
4 d BANK5 17 4 d BANK5 17
1.00K
RESET
X10 X13
TRANSMIT
R66
GRS232 GD
5 c BANK4 16 5 c BANK4 16
Vdd
9
X1
LCD
6 3 6 3 8
-5V
b Vdd b Vdd
DATA CARRIER DETECT GRS232 RES X17 C60
L1 DISPLAY
7 a BANK3 15 7 a BANK3 15 0.1 10
S-8054HN 50V
GD 12 DATA IN 13 10 /ENABLE 13 GD
MOSI BANK2 OC5 BANK2 C59 -8V 2 -LEDB
Vss .39mH J19 P1
10 /ENABLE 9 19 h 9 0.1
OC5 BANK1 BANK1
50V
14 19 14 2
Vss h Vss e RS_LCD R68 R61 6 RS
1 20 20 1
J19 P1
f g g f 100 100
GD DZ6
2 e DATA OUT 18 12 DATA IN DATA OUT 18
RST 5.1V
8 Rx CLOCK 11 11 CLOCK Rx 8 1W
MC14489 MC14489
R62 7 R/W
SCK
J19 P1
1.50K 1.50K MAIN PROCESSOR 4.75K
R35
R17
GD
L2
1 9 BI-DL[0]
Vss A0/D0
LED 10K 25 10 BI-DL[1] R50
150
1 +LEDB
R30 /SS A1/D1 .39mH
150 J19 P1
GD
DRIVE GD
10K 2 MODB A2/D2 11 BI-DL[2] R59
+5V R40 150
10K 3 MODA A3/D3 12 BI-DL[3] R60
R39 150
18 /XIRQ A4/D4 13 BI-DL[4] R63
XIRQ 150
8 XTAL X7 A5/D5 14 BI-DL[5] R64
150
10M 7 EXTAL A6/D6 15 BI-DL[6] R65
BI-DL[0:15] 1/2W 150 +5V
1K 52 VRH A7/D7 16 BI-DL[7] R67
+5V R240
R38
24 SCK A8 42 BI-DL[8] 44
J18 SCK BI-DL[0] 23 GD
P1 19 D0 2 BI-DL[0] BI-DL[0] 2 D0 Q0 19 A0/D0 Vcc 4 VDD
1 R9 Q0 INFRA1 C36 23 41 BI-DL[9]
74HC573 74HC573 MOSI MOSI A9 J19 P1
J18 75.0 BI-DL[1] BI-DL[1] 3 18 0.1 BI-DL[1] 24 A1/D1 PA0 21
P1 18
Q1 D1 3 D1 Q1
INFRA2 4.9152MHz BI-DL[10] 9 D0
3 R8 10K 22 MISO A10 40
50V R31 BI-DL[2] 25 20 J19 P1
P1 J18 75.0 17 4 BI-DL[2] BI-DL[2] 4 D2 X3 Q2 17 A2/D2 PA1
5 R10 Q2 X9 D2 INFRA3 Y1 21 19 IRQ 10 D1
TRN TxD /IRQ J19 P1
J18 75.0 BI-DL[3] BI-DL[3] 5 16 BI-DL[3] 26 A3/D3 PA2 19
P1 16 Q3 D3 5 D3 Q3 C33 GD 11 D2
7 R4 INFRA4 20 RxD A11 39 BI-DL[11]
C32 REC BI-DL[4] 27 18 J19 P1
75.0 15 6 BI-DL[4] BI-DL[4] 6 D4 15 22p A4/D4 PA3
Q4 D4 Q4 INFRA5 22p BI-DL[12] 12 D3
TRIM1 100V
27 PAI A12 38
RS_LCD J19 P1
C10
BI-DL[5] 100V BI-DL[5] 28 17

C8
C9
C5
14 7 BI-DL[5] 7 D5 Q5 14 A5/D5 PA4

TRIM2 Q5 D5 INFRA6 28 OC2 A13 37 BI-DL[13] X8 13 D4
BAUD0 BI-DL[6] 29 16 J19 P1
13 Q6 D6 8 BI-DL[6] BI-DL[6] 8 D6 Q6 13 A6/D6 PA5
TRIM3 INFRA7 29 36 BI-DL[14] 14 D5
BAUD1 OC3 A14 J19 P1
BI-DL[7] 9 12 BI-DL[7] 30 A7/D7 PA6 15
12 Q7 D7 9 BI-DL[7] D7 Q7
INFRA8 GD BI-DL[15] 15 D6
TRIM4 30 OC4 A15 35
BAUD2 BI-DL[8] 31 A8 PA7 14 J19 P1
E 16 D7
CRYSTAL TRIG1
43 A/D1 E 5
BI-DL[9] 32 A9 PB0 11 J19 P1
11 LE LE 11 45 6 R/W /E_LCD R36 8 E
GD LE_KEY LE_INFRA TRIG2 A/D2 R/W 34 J19 P1
BI-DL[10] 33 A10 GND
OE OE 1 AS 100
1 47 A/D3 AS 4
SPTIG 12 10
GND PB1 PIEZO 100 DZ3
R37
49 A/D4 /RES 17 RST
GD SPWF2 BI-DL[11] 35 9 5.1V
A11 PB2 /OE_KEY
GD 44 A/D5 A/D8 50 1W
SPWF1 SENSE BI-DL[12] 36 A12 PB3 8 3 VSS
WATER
46 A/D6 IC1 32 J19 P1
THERMAL BI-DL[13] 37 A13 PB4 7
/PB4 GD GD
C34 C31 C35 48 A/D7 IC2 33
PRESSURE BI-DL[14] 38 A14 PB5 6
0.1 0.1 0.1 FAN /E_LCD
1 2 1 31 OC5 IC3 34
A G K Q /PB4 X11 50V 50V 50V OC5 FLAG BI-DL[15] 39 A15 PB7 4
X5 3 26 /PB7 +5V
LE_KEY (2) Vdd VRL 51
2 MC68HC11 E 22 E PC0 40
/CS_RS232
E
R/W 2 R/W /CSI 43
4
+5V GD
6 AS 13 AS PB6 5 10.0K
B H N R X5 LE_INFRA R28
9 8 5
+5V
/PB7 X11 RST 3 /RES PC1 41 10.0K
R29
1 /BHE PC2 42 10.0K
+5V R32
PSD301
6.81K
R25
C I L S
1.00K
1.00K
1.00K
1.00K
1.00K
1.00K
R24
R12
R16
R11
R2
R6
GD
R27
J18
P1 2 19 BI-DL[0]
D J O T 2 R22 D0 Q0 1.00K LAST NO. USED

J18 75.0 74HC573 C1
GENERAL INFORMATION
R26
P1 3 D1 Q1 18 BI-DL[1] 267 R- 240 D- 24 DZ- 28
4 R21 0.1
P1 J18 75.0 4 17 BI-DL[2] ELECTRICAL SYMBOLS PER E1537 C- 101 X- 17 TP- 1
R20 D2 X4 Q2 50V
6
J18 75.0 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED) LED- 34 Q- 29 OCI- 18
P1 5 D3 Q3 16 BI-DL[3]
E M U
8 R18 RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS
P1 J18 75.0 6 15 BI-DL[4]
R23 D4 Q4 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
9 GD SUPPLY VOLTAGE NET
P1 J18 75.0 7 14 BI-DL[5] R99-R106 ARE NOT ASSIGNED
10 R19 D5 Q5
75.0 8 13 BI-DL[6]
D6 Q6
C11
COMMON CONNECTION
C7
C4
C2
C6
C3
F P V 9 12 BI-DL[7]
D7 Q7
FILE NAME: G2239_1DA FRAME CONNECTION
+5V
SHEET 1 OF 2 EARTH GROUND CONNECTION
GD 11 LE
1 OE Ch’ge.Sht.No. EQUIP.
/OE_KEY NOTES : THE LINCOLN ELECTRIC CO. INVERTEC V400
TYPE
KEYPAD INTERFACE GD
1-6-95B
CLEVELAND, OHIO U.S.A. SUBJECT DISPLAY/KEYPAD PCB SCHEMATIC
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY 12-8-95E
SCALE NONE
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE SHT.
NUMBER. DR. DB DATE 1-26-94 CHK. SUP’S’D’G. NO. G 2239-1
POWER WAVE 450

SCHEMATIC - DISPLAY PC BOARD (SHEET 2)
G 2239-2
+15V
R194
100
100 +5V +5V

+5V +5V +5V
J11
R195 2
+15V
DZ24 C97 200
R196
15V 0.1 THERMAL FAN
1W 50V 150 150 150 150 150
R105
R104
R152
R154
10K
R110
R201
J11
1.00K GA R197 4
J11 THERMAL
5 R203 100
3 1 3 1 3 1 3 1 3 1
R206
DZ26 C99
10K
R205
5.1V 0.1 75.0 OCI10 OCI12
OCI17 OCI18 OCI11
1W 50V OPTEK OPB706 OPTEK OPB706
681 OPTEK OPB706 OPTEK OPB706 OPTEK OPB706
J11
6 R204 4 2 4 2 4 2 4 2 4 2
FAN Q29 SENSE SENSE SENSE SENSE SENSE
DZ25
R202
600mA
10.0 GD R198 Q24 Q13
40V 15V Q22 Q23 Q9
681 1W 600mA 600mA 600mA 600mA 600mA
INFRA4 R176 INFRA5 R182 INFRA6 R177 INFRA7 R179 INFRA8 R103
40V 40V 40V 40V 40V
6.81K 6.81K 6.81K 6.81K 6.81K
C98
R200
R178
R180
22.1K
R199
R175
R174
R102
330p GA
GA 75.0
100V 22.1K 22.1K
22.1K C88 22.1K C89 C90 C91 22.1K C68
GD
GD GD GD GD GD
+15V NOTE: 8 MULTIPLEXED SIGNALS (UNDER SOFTWARE CONTROL) ARE SAMPLED AT THIS NODE
SENSE
(9)
4 +15V
+5V +5V +5V
R158
R156
R157
R161
J16 47.5K 133K 33.2K 10.0K
R207
1.50K R46
J11
5 1
1.00K TRIM4
+t 56 TRIM1 TRIM3
J16 C95
R139
J11 PRESSURE TRIM2
7 R208 150 33.2K
0.1 150 150
R153
C100 WATER COOLER
R150
R151
DZ27 50V
R159
R127
R137
R138
0.1 10K 1.50K 3.32K 33.2K 6.81K
5.1V
R211
50V
1W 681 J11
R141
J11 3 6.81K
R142
R136
R133
8 R210 12 3 1 3 1 3 1 6.81K 6.81K 6.81K
J16 OCI14 OCI15 OCI16

R209
GD OPTEK OPB706 Q17 Q20 Q18 Q19

10.0 OPTEK OPB706 OPTEK OPB706
2N4401 2N4401 2N4401 2N4401
4 2
Q28 4 2 4 2
DZ23 SENSE
GA WATER 600mA SENSE SENSE
R190
R140
R126
R134
R135
15V C77 C75 C78 C79
40V 22.1K 22.1K 22.1K 22.1K
475 1W Q26 Q25 Q27
600mA 600mA 600mA
INFRA1 R121 INFRA2 R183 INFRA3 R185
40V 40V 40V
6.81K 6.81K 6.81K
C96
GA
22.1K
R192
75.0
R181
R191
R122
R184
330p
100V 22.1K
22.1K C94 22.1K C93 C92 GD
+15V
GD
10K
R212
GD GD GD +15V
1.00K
J10 FLAG J14
15 R213 6
DZ28 C101
5.1V 0.1
R109
26.7
1W 50V 50V
100K
R106
C69
2700p
R123
3.32K
1.00K
1.00K
R132
R101
GD
100K
R108
R107
750
J10 Q12
16 +15V
REFERENCE CIRCUIT 600mA
Q10
+5V 40V
500mA
Q11 300V
500mA
4.75K
300V
475 R160 1 NC VCC 8
3
Q21 2 1
+10V R155 X2 TRN 7
2N4401 2 ANODE VB
1 2N4403
J10 R111
14 Q14 3 CATH VC 6
2
1.3K C62
J10
R112
200 4 NC GND 5
3 10.0 1.00K 10K
820p
R124
R130
OCI13
R113
J10 10K
4 L3 50V
+5V +5V
R86
R145
J10 681 D20
10 R129
.39mH R227 DZ8
+t 56 C76
33.2K
0.1 R83 1.00K
J13
50V 2 R228 R74 221
DZ15 100K
R79
4.75K
R81
1N4936
+10V 1.00K +t 56 D4 D23

15V
475
R125
R167
R131
100K 47.5K 3.3V C72 DZ11 D10

1W
R128
R87
10.0 3.32K 2K D22
R89
DZ10 1W GD 150p 5.1V C65
20V R229 50V 1W 0.1
J14
5W TRIG2 50V
3.32K 5
R238
100K
10K 1 5
D6 R230
R77
OCI2 J14
3.32K
C61 D3 CNY17-3 4
GA R231 20
3.32K 50V
R239
DZ9
100K 2 6 4
TP1
D7 20V R232
5W +15V 150V
J10 3.32K 45J
12 +5V
R234
221K
R80
J10 10
R148 J13 C74
6 475 475 4
8 .0047
100K X2 R149 R143 SPTIG D5 Q7
C81 400V
600mA
R146
DZ17 9
100K J13
0.1 10V C80 DZ16 C82 40V 5.11K
1 3.32K
+10V
R118
50V 1W 0.1 5.1V 0.1 24VAC ISOLATED TRIGGER CIRCUIT
4.75K
R147
R85
R84
50V 1W 50V J13
3 10K REC
R78
1.00K
R225
100K GA GD
TO REMOTE 10K POTENTIOMETERS
D11 D12
6 - PIN Q16
600mA R117 R116
REMOTE GD 40V
2.67K 10K
R226
8 VCC NC 1
100K
3.32K 4.75K
7 VB ANODE 2
R120
C71 C73
R119
J10 150p 150p 6 VC CATH 3
11
+5V 50V 50V
5 GND NC 4
J10 12
8 R165 +5V OCI3
681 D8 150
14
100K X2 R163 R173 SPWF2
R214 DZ14
13
DZ20
R88
C85 475 475 221K
R94 1.00K
R168
R100
0.1 100K 10V J12
+10V DZ19 4.75K D14
1W C83 C67 2 R215 R93 221 C64 C63
50V
R95
R90
0.1 5.1V 0.1 +t 56 150p 330p
R169 D19 D24 475
50V 1W 50V 3.3V 50V 100V
1.00K DZ13 3.32K 1W D9
20V R216 TRIG1
100K J14
R44
14 - PIN 5W
3.32K
1
1 5 D13
D17
GA REMOTE GD
R217
10K
3.32K OCI4 J14
R99
C66 D15
2
CNY17 J14
100K R218 20
R45
3
DZ12 3.32K 50V 2 6 4 WIRE FEEDER COMM.
20V R219 GD
J10 D18 5W
2 3.32K
R220
R97
221K
J10 5
5 R166
J12
7 4
100K X2 R162 R171 SPWF1
D16 Q8
C86 6
DZ18 475 475 600mA

0.1
R172
10V DZ21 40V GENERAL INFORMATION

50V 100K C84 C87 LAST NO. USED
1W J12
R164 0.1 5.1V 0.1 1 24VAC ISOLATED TRIGGER CIRCUIT 10K
R- _ D- _ R- _
1.00K 50V 1W 50V ELECTRICAL SYMBOLS PER E1537
R98
C- _ C- _ C- _
J12 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
3
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- _ D- _ D- _
J10
GA 14 - PIN
1 NOTES : SUPPLY VOLTAGE NET
L4 REMOTE
J10 .39mH GD POWER SUPPLY SOURCE POINT
7 GD N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
J10 COMMON CONNECTION
9 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
R170 NUMBER. FILE NAME: G2239_1DA FRAME CONNECTION
J10
13
+t 56
SHEET 2 OF 2 EARTH GROUND CONNECTION
THE LINCOLN ELECTRIC CO. TYPE INVERTEC V400
1-6-95B
CLEVELAND, OHIO U.S.A. SUBJECT DISPLAY/KEYPAD PCB SCHEMATIC
12-8-95E
SCALE NONE
SHT.
DR. DB DATE 1-17-94 CHK. SUP’S’D’G. NO. G 2239-2
POWER WAVE 450

PC BOARD ASSEMBLY-DISPLAY
G 2862-1
ITEM REQ’D PART NO. DESCRIPTION ITEM REQ’D PART NO. DESCRIPTION
R50,R59,R60,R63,R64,R65 16 S19400-1500 150 1/4W C1,C12,C20,C21,C22,C24,C25 45 S16668-11 .1/50
R67,R88,R104,R105,R110 C26,C27,C29,C30,C31,C34
R150,R151,R152,R153,R154 C35,C36,C38,C39,C40,C41
R51,R102,R114,R122,R126 16 S19400-2212 22.1K 1/4W C48,C49,C50,C52,C54,C55
R134,R135,R140,R174 C56,C57,C59,C60,C65,C67
R175,R178,R180,R181 C76,C80,C81,C82,C83,C84
±.04 R184,R191,R199 C85,C86,C87,C95,C97,C99

R73 1 T10812-41 10K 1/2W TRIMMER C100,C101
12.00 R79,R95 2 S19400-2210 221 1/4W C2,C3,C4,C5,C6,C7,C8,C9 23 S16668-5 .022/50
R80,R90,R97 3 S19400-2213 221K 1/4W C10,C11,C68,C70,C75,C77
11.75 R85,R115,R120,R123,R127,R216 15 S19400-3321 3.32K 1/4W C78,C79,C88,C89,C90,C91
R217,R218,R219,R220,R229 C92,C93,C94
R230,R231,R232,R234 C14,C45,C46,C63,C96,C98 6 S16668-8 330pF/100
R89 1 S19400-2001 2.0K 1/4W C15,C16,C17,C18 4 S13490-39 18/15
R109 1 S19400-26R7 26.7 1/4W C100,C101
R111 1 S19400-1301 1.3K 1/4W C32,C33 2 S16668-1 22pF/100
R112,R196 2 S19400-2000 200 1/4W C61,C66 2 S13490-73 20/50
R118 1 S19400-5111 5.11K 1/4W C62 1 S16668-7 820pF/50
C64,C71,C72,C73 4 S16668-9 150pF/100
R128,R130,R202,R209 4 S19400-10R0 10 1/4W C69 1 S16668-4 2700pF/50
R129,R137,R139,R158 4 S19400-3322 33.2K 1/4W C74 1 S13490-3 .0047/400
D2,D3,D4,D5,D6,D7,D8,D9 22 T12199-1 1N4004

D11,D12,D13,D14,D15,D16
D17,D18,D19,D20,D21,D22
R156,R167 2 S19400-4752 47.5K 1/4W D23,D24
R198,R204,R210,R214,R227 5 S19400-6810 681 1/4W D10 1 T12705-34 1N4936
TP1 1 T13640-11 45J DZ2,DZ3,DZ4,DZ5,DZ6,DZ11 12 T12702-52 1N4733

DZ16,DZ19,DZ21,DZ26,DZ27
W1 1 CJ000001 E2387-#20-2.00 (JUMPER) DZ28

DZ7 1 T12702-55 1N4738A
XXXXXXXX
XXXXXXXX
X1,X2 2 S15128-4 LM224 OP-AMP DZ8,DZ14 2 T12702-53 1N4728A
X3,X4,X9 3 S17900-25 IC,CMOS,LATCH,3-STATE (SS) DZ9,DZ10,DZ12,DZ13 4 T12702-25 1N5357B
8.27 X5 1 S17900-13 QUAD TWO INPUT AND GATE (SS) DZ15,DZ23,DZ24,DZ25 4 T12702-29 1N4744A
X7 1 S23996 HC11 MICROPROCESSOR(SS) DZ17,DZ18,DZ20 3 T12702-27 1N4740
X8 1 S21290-4 ROM ASSEMBLY(SS)
XXXXXXXX
XXXXXXXX
X10,X13 2 S20496-1 LED DRIVER (SS) J10 1 S18248-16 HEADER
16
X11 1 S17900-2 HEX INVERTER (SS) J11 1 S18248-8 CONNECTOR
X12 1 S17900-6 12 STAGE BINARY COUNTER (SS) J12,J13,J15 3 S18248-4 HEADER
X14 1 S17900-26 SELECT/MULTIPLX(SS) J14 1 S18248-6 HEADER
X15 1 S20353-1 IC,CMOS,DRVR/RCVR,EIA232 J16 1 S18248-12 HEADER
X16 1 S20603-1 IC,CMOS,ACIA,2.0MHZ,68B50P J17 1 S18248-10 HEADER
X17 1 M15102-3 RESET I.C. UNDERVOLT. SENSING CIR. (SS) J18 1 S19365-10 RT. ANGLE HEADER
J19 1 S18899-16 ST. HEADER
Y1 1 S16665-6 CRYSTAL,QUARTZ,4.9152MHZ
XXXXXXXXXX
XXXXXXXXXX
L1,L2,L3,L4 4 T12218-9 .39mH
LED2,LED3,LED4,LED5,LED6 32 T13657-3 GREEN LED

LED7,LED8,LED9,LED10,LED11
1
XXXXXXXX XXXXX LED12,LED13,LED14,LED15
6.00 CAPACITORS = MFD/VOLTS
XXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXX
INDUCTANCE = HENRIES LED16,LED17,LED18,LED19
RESISTANCE = OHMS LED20,LED21,LED22,LED23
XXXXXXXXXX
XXXXXXXXXX
LED25,LED26,LED27,LED28
LED29,LED30,LED31,LED32
LED33,LED34
LED24 1 T13657-4 YELLOW LED
X
X
X
XXXXXXXX XX
X
X
OCI2,OCI4 2 S15000-10 OPTO ISOLATOR

XXXXXXXXX XX
X
OCI3,OCI13 2 S15000-23 6N136 OPTOCOUPLER

4.73
X
X
X
OCI5,OCI7,OCI8 3 S15000-19 IC,OPTOISOLATER

X
XXXX
X
XXXXXXXXXXXXXXX
OCI10,OCI11,OCI12,OCI14 8 S15000-24 OPTOSENSOR,REFLECTIVE

OCI15,OCI16,OCI17,OCI18
XXXXXXXXXXX
Q3,Q5,Q6,Q7,Q8,Q9,Q12,Q13 23 T12704-68 2N4401

Q15,Q16,Q17,Q18,Q19,Q20
Q21,Q22,Q23,Q24,Q25,Q26
XX XXXXXXX XX
Q27,Q28,Q29
V400 DISPLAY KEYPAD
Q10 1 T12704-47 .5AMP/300V PNP

Q11 1 T12704-35 NPN TRANSISTOR
Q14 1 T12704-69 2N4403
R2,R6,R11,R12,R14,R16,R24 23 S19400-1001 1K 1/4W

R27,R66,R70,R101,R124,R131
R132,R147,R164,R169,R203
R208,R213,R215,R228,R240
R3,R117 2 S19400-2671 2.67K 1/4W
R4,R8,R9,R10,R18,R19,R20 13 S19400-75R0 75 1/4W
R197
R5,R161 2 S19400-1333 133K 1/4W
R7,R44,R45,R87,R106,R108 17 S19400-1003 100K 1/4W
R125,R146,R148,R165,R166
R168,R172,R225,R226,R238
R239
R13 1 S19400-3010 301 1/4W
1.23
G2862-1
R17,R35,R159,R207 4 S19400-1501 1.5K 1/4W

R25,R42,R53,R103,R121,R133 16 S19400-6811 6.81K 1/4W
.95 R136,R138,R141,R142,R176
R177,R179,R182,R183,R185
R26,R57 2 S19400-2670 267 1/4W
R28,R29,R30,R31,R32,R39 24 S19400-1002 10K 1/4W
R40,R41,R47,R52,R55,R58,R77
.25 R78,R86,R98,R99,R113,R116
R157,R201,R205,R211,R212
0
R33,R34,R74,R93,R143,R149 12 S19400-4750 475 1/4W
R155,R162,R163,R171,R173
R190
R36,R37,R61,R68,R194,R195 7 S19400-1000 100 1/4W

0 R197
R38 1 T14231-2 10M 1/2W
R43,R54,R107 3 S19400-7500 750 1/4W
±.04 R46,R83,R94,R145,R170 5 S18380-1 PTC THERMISTOR
.25 4.50 9.00 R48,R49,R56,R62,R71,R72 11 S19400-4751 4.75K

R81,R84,R100,R119,R160
9-27-96K EQUIP.
1-6-95B 3-21-97D THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
2-10-95F 1-7-2000E CLEVELAND, OHIO U.S.A.
8-11-95C SUBJECT DISPLAY/KEYPAD P.C. BOARD ASSEMBLY
SCALE FULL
G 2862-1
12-8-95E SHT.
DR MP DATE 9-22-94 CHK DRS REF. G2407-1 SUP’S’D’G
1-26-96 NO.
machine.
POWER WAVE 450
SCHEMATIC - POWER PRINTED CIRCUIT BOARD
2240 G
INVERTER POWER SUPPLIES

PRIMARY SWITCHING CIRCUIT GND VOLTAGE USE TRANS BRD
N.B.
N.C. J43
2 d 18Vd FET DRIVER T1 FET
D1 D2
N.B. 1K 1K 1K
+5Va WELD & CURRENT CONTROL
8A 8A
R130
R139
5W 5W 5W VOLTAGE
400V 400V a +15Va WELD & CURRENT CONTROL T2 CTRL
R1
FEEDBACK
J43
3 C1 C2
Vcc(+15) -15Va WELD & CURRENT CONTROL
L3 D5 D6
3900 3900
42VAC
C42
TP1 80V 80V
1N4936 1N4936 +5Vb DISPLAY KEYPAD
1mH
.0047 320V Q13 +15Vb DISPLAY KEYPAD
3000V 160J 1A D7 D8 b T3 D/K
J43
1
100V
C3
1N4936 1N4936 -5Vb DISPLAY KEYPAD
Vcc(+15)
DZ2 4.7
C40 C41 TP2 TP3 D3 D4 35V
-8Vb DISPLAY KEYPAD
15V
.0047 8A 8A 1W c +5Vc RS 232
R196
320V 320V 26.7
3000V .0047 400V 400V +5Vref 1
N.C. 3000V
160J 160J T4 D/K
J43
4 e 40mAe CURRENT SOURCE
C7 Q1 20t
R70
R67
R68
R69
0.1 R12 600mA D 200 200 200 200
D10 C6
D9 50V 40V Q5 2
1N4007 0.1 100 1 1 1
1N4007 G 18A
50V
R17 200V Vcc(+15)
267
R59
C4
S Vcc(+15)
26.7 20t 20t 20t 20t
4.7
40V C9 3
R198
35V 3 3 3
R56
SWITCH_GND 475 100 4.75K 10K R13 600mA
DZ3 .001 4
R9
Q2
R5
15V 400V
100 3
14 13 12
Vref Ot C 1W 20t 4t 20t 20t
4 8
DT CON C1 5 5 5 5 C15
11 C13 C14 X2
1
1+IN C2 T1 T3 T4 X1 0.1
T2 0.1 1.0
3 9 PRI. PRI. PRI. TL494 50V
COMP IN E1 PRI. 50V 35V LM2901
100 18.2K Vcc(+15)
2 12
22.1K 1-IN Vcc
C5
12
R57
4.7 15 10 7
2-IN X1 E2
R2
D58
35V TL494
R6
7 6
1N4936 GND Rt Q6
Q3
R64
R65
R66
18A
R63
5
D46 16 2+IN Ct 200 200 200 200
R14 600mA 200V

D
2.21K 1.00K 1.00K 40V
100
G
1.00K C8
R18
R7
R10
.0047
R16
S
R11
50V 26.7
500 40V
R8
C10
CW R15 600mA
C16 DZ4 .001
Q4
0.1 100 1W 400V
Vcc(+15) 50V 15V
10K
PWR DN Vcc(+15)
R61
100
R195
12.1K
R30
12.1K
R31
D30
DISPLAY KEYPAD
1.00M OVERCURRENT
R34
1.00K PROTECTION
R177 D28 L9
+5Vb
D47 1N4936
R22
R23
10K 10K
X7 +15Vb
1N4936 1mH IN OUT
5 7
R185 +15Vb R24 C32
D27 2.43K 2.43K 2.43K 2.43K 60mA
2 CNY17-3 9 1 C166 0.1
47.5K X2 X2 10K C30 GND
0.1 50V
R170
1 5
R167
R168
R169
OCI1
68.1K
4 14 6
D29 4.7
Q15 X2 R25 +5Vref 50V
DZ5 1N4936 35V
C175
R180
8
R35
2N4403 10K
10K 4.75K
R184
12V C11
0.1 10
1.0 D33
R27
1W
R4
R3
50V 100 100 1.00M .5
2 6 4 10 35V
R19
+5Vref X2 R26 C12 5W D31 L10
13 9t
Vdd
.022 1N4936
1.00K
R29
10K
X3 RES 11 50V 9 X8 +5Vb
1mH IN OUT
R55
R76
10K PWR_DN
S-8054HN C165 C34 200mA
221K D32 C33
R28
13.7K SWITCH_GND 0.1 0.1
Vss D12 8t 1N4936 35V GND
D11 50V 50V
1000
CR1 CR2 T3 8
b 12Vdc 12Vdc SEC.

b
8t
DZ6
6.2V C35 C36 C37
100K
1W 7 4.7 0.1 0.1
Q12 35V 50V 50V
R21 2N4401
D35
9t 100
DZ17 1N4936
Q7 6 R190
2N4401 6.2V C178 D60 GND
1W
1N4936 L11
D34 CR2
R32 R33 4 8 IN OUT
X9 -5Vb
100K 100K 1mH
b 15mA
D36
100 D20
R186 -8Vb
C176
N.D. J42 J44 250mA
D18 L6 Vcc(+15) 1 1
1N4936 CR1 +15Va
X4 J42 J44
1mH 4 8 IN OUT
4.75K 4.75K 4.75K 4.75K TESTVa 2 2
380mA
C21
WELD & CURRENT CONTROL c
C20
R137
R135
R138
R136
GND N.D. J42 OPTIONAL 13VDC FAN J44

C139 0.1
D19 4.7 +5Vb 3 +5Vc 3
0.1 50V 301
1N4936 35V
50V TESTVa
N.D. J42 R193 J44
-8Vb 4 4
R110 D39
100 D23
10 J42 e 301 J44
R191 gate 1 5 40mAe 5
C177
D21 1N4936 L12
9t 3A L7 J42 J44 +5Vc
CR1 +5Va D37
600V -15Va 6 -8Vb 6
13 9
IN OUT X10
X5 1mH IN OUT
9
.22mH 1.00K 1.00K 1.00K
J42 J44 30mA
D22 C22 C140 350mA N.B. Used on -1A N.C. Used on -1B C39
C23 7 7
D38 C38
R164
R162
T2
R163
3A 4.7 0.1 GND 0.1
SEC.
8t
600V 35V 50V ADJ
0.1
1N4936
4.7 C159
50V
RS232
243 50V J42 J44 35V 0.1
N.C. Used on -1B PWR_DN
8 8 8 50V
R86
2.21K 2.21K 2.21K C25 J42 J44

8t C141 0.1 gate 2 9 -5Vb 9 c
C24
R142
R144
R145
R187
R188
R143
0.1 50V
R150
1.50K 1.50K
R83
4.7
50V J42 J44 10
7 35V GND
+15Va 10 +15Vb 10
100
D24 L8 2.21K 2.21K 2.21K
1N4936 -15Va 15t
9t J42 J44 R194
C189 301
X6 +5Va 11 +5Vb 11 9
6 1mH IN OUT a T4 1N4936
7 L119 L116 R192
50mA SEC. CR2 150 40mAe
D40
J42 J44 13 9
12 12 R107 R109
D25 30t .39mH Q111 1mH
301 40mA @ 27V
1N4936 6 R156 100V
a b
1A 60mA limit
D26 D41 150
1N4936 C102
C190
CURRENT SOURCE
2 DZ115
.1
150V
1A/20.4usec max 100V
Q8 5.1V
J41 J40 1W
D13 4A FET DRIVER SUPPLY 18Vd 18Vd
1N4936 C191
R104
R105
R108
R157
1 1
R106
R103
3A
L4
100V FET DRIVE 1 FET DRIVE 2 D42
18.2K 18.2K 18.2K 18.2K 18.2K
18Vd J41 J40 0.1 18.2K
600V 9 9 L120
50V
D
3 3
T5 J41 T6 J40
.22mH 2 3
D59
1 GATE 1 GATE .39mH
1N5402 J41 J40
G
4 4 D43
1.50K 10 1.50K 11
R92
R93
D14 1N4936 e
C18 C27 DRIVE J41 C29 DRIVE J40
3A 2 4.7 5 7 4.7 5 6
2.67K DZ7
600V
R37
150V 35V 35V

1W 2 GATE J41 2 GATE J40 NOTES :

C26 C28
15 14
D17 15V 0.1 Q10 0.1 Q11
R39
10 4.75K 1.3K J41 J40 N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
1N4936 50V 4A
6
50V 4A
6
R36
gate 1
100V
8 gate 2
100V
8 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY GENERAL INFORMATION LAST NO. USED
DZ16 J41 J40 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
R197
C19
T1 2.21K 16 16 ELECTRICAL SYMBOLS PER E1537 R-198
4.7 27V DZ10 DZ13 NUMBER.
SEC. R80 J41 J40 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED) C-191
19t Q9 35V 5W 27V 27V
3 2
3.32K 500mA 5W 5W RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D-60
DZ9 DZ12
300V J41 J40 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
15V 15V
R88
R89
6 C17 10K 4 10K 4 SUPPLY VOLTAGE NET

2.7 1W 1W
D16 DZ11 J41 DZ14 J40 POWER SUPPLY SOURCE POINT
3A 50V 27V
5
27V
5
600V DZ8
5W J41 5W J40 COMMON CONNECTION
R40
15V 4.75K
6 7
1W FRAME CONNECTION
J41 J40
11 10
FILE: G2240_1D2 EARTH GROUND CONNECTION
J41 J40
12 12
D15
3A
d
J41
13 d
J40
13
THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
600V d
1-6-95B SCHEMATIC, POWER P.C. BOARD
J41 J40 CLEVELAND, OHIO U.S.A. SUBJECT
14 15
a (cosmetic trace connecting ground planes) 3-29-96L NONE
SCALE
SHT.
7-9-99F
DR. DB DATE 6-26-94 CHK. RM SUP’S’D’G. NO. G 2240
POWER WAVE 450

PC BOARD ASSEMBLY-POWER
G 2163-1 ITEM REQ’D PART NO. DESCRIPTION

C1,C2 2 S13490-141 3900/80V
C3,C4,C5,C19,C20,C22,C24 12 S13490-25 4.7/35
C27,C29,C30,C35,C38
C6,C7,C13,C15,C16,C21,C23 23 S16668-11 . 1/50

C25,C26,C28,C32,C34,C36
±.04 C37,C39,C139,C140,C141
8.00 C159,C165,C166,C175,C191
C8 1 S16668-6 4700pF/50
POWER WAVE POWER C9,C10 2 S13490-76 .001/400
7.80 G2163-1
C11,C14
C12,C176,C177,C178,C189
2
5
S13490-42
S16668-5
1.0/35
.022/50
J44 J42 J41 J40 C17 1 S13490-40 2.7/50
J43 C18,C102 2 S13490-68 2/150
C33 1 S13490-121
R76
C40,C41,C42 3 T11577-58 .0047/3000V
OCI1
R180
C42
C41
C190 1 T11577-26 .1/100
X3
R55
CR1,CR2 2 S13929-8 RELAY, 12V DC
C39
TP2
TP1
R130 D1,D2,D3,D4 4 S18395-22 DIODE HS ASBLY
R35 D9
X10 D5,D6,D7,D8,D17,D18,D19 23 T12705-34 1N4936
D10 D24,D25,D27,D28,D29,D31
C32 C40 D32,D34,D35,D37,D38,D40
R31
TP3
R30 T5 T6 D41,D42,D43,D58
D60 R195 D9,D10 2 T12199-2 1N4007
R139
R1 D11,D12,D20,D23,D26,D30 12 T12199-1 1N4004
D33,D36,D39,D46,D47,D60
D39
X7
D13,D14,D15,D16,D21,D22 6 T12705-59 600V/3A
R93 R92
D30
R109
R192
R110
R193
C159 D59 1 T12705-14 DIODE
C28 DZ2,DZ3,DZ4,DZ7,DZ8,DZ9 7 T12702-29 1N4744A
R88
C30 DZ12
DZ9
C166 D4 D1 C26
C29
Q15
Q10 Q11 DZ5 1 T12702-19 1N4742A
R177
R34
C37 C35 C27 DZ6,DZ17 2 T12702-40 1N4735
C15
R185 DZ14 DZ10,DZ11,DZ13,DZ14,DZ16 5 T12702-17 1N5361B ZENER DIODE

Q13
C38
DZ10 DZ115 1 T12702-52 1N4733A

C175 DZ13 J40,J41 2 S20351-16 HEADER
R184 DZ11 J42,J44 2 S20351-12 HEADER
X9
C36
D36
C25
L116
DZ5 J43 1 S20351-4 HEADER

Q111 DZ12 L3,L6,L8,L9,L10,L11,L12,L116 8 T12218-12 CHOKE
D2 D3 DZ2 C12
R89 L4,L7 2 T12218-11 INDUCTOR
C34 D33 R29
X2
R23 L119,L120 2 T12218-9 .39mH
C165 R25 C11 OCI1 1 S15000-10 OPTO ISOLATOR
C3
R170 R24 R27 Q1,Q3,Q7,Q12 4 T12704-68 2N4401
C24
DZ16
XXXXXXXXXX
Q2,Q4,Q15 3 T12704-69 2N4403
D59
R169 R28
R197
XXX
X6
XX
X8
Q8 Q5,Q6 2 T12704-61 TRANSISTOR (SS)
C21
C23
R168 R26
XX
R156
R8
R107 R167 R21 D27
D47
XX
XX
R22 X4 X5 Q9 1 T12704-35 NPN TRANSISTOR
XXXX XXXXXX
XX
R157 R4 Q8,Q10,Q11 3 T12704-80 TRANSISTOR-NMF
4.00 R61
XXX
R3 R59
R194
R108
R190
Q13 1 S18395-19 PNP TRANSISTOR H.S. ASBLY
C190
R106 DZ6 C6 C5 Q111 1 T12704-37 TRANSISTOR-P
XX XXXXXX
R105 D26 DZ7
XX
R150
R1,R130,R139 3 T14648-19 1K 5W
R83
R86
R5 R57 R196
R104
DZ17 C19
CR2
C16 R56 R9 C141 R37 R2,R103,R104,R105,R106, 7 S19400-1822 1 8.2K 1/4W
C1
R103 D20
C189
R198
C33
R108,R157
R162 R187 D23
L8
R33 D58 R135 C18 R3,R4,R12,R13,R14,R15,R56 13 S19400-1000 100 1/4W
R163 DZ115
R7 R188
XX
R32 C139 C140 R57,R61,R186,R190,R191,R194
R143
XX
R164 C191 R6 C7
XX
R39 R40 R5,R35,R36,R40,R135,R136 8 S19400-4751 4.75K
Q12 R142 R136
C178
XX
D12 R2 C22
XXXX
XX R137,R138
X1
C4 R144 R137 DZ8
XXX
XXX C8 R6 1 S19400-2212 22.1K 1/4W
R145 R138 Q9
XX
XXXX R10 R7,R11,R16,R26,R34,R162 8 S19400-1001 1K 1/4W
Q7 R16
L4
C20
XX
R163,R164
XX
R11
XX
R19
R8 1 T10812-62 500 1/2W TRIMMER
R80
R36
XX
C177
D46
C176
XXX XXXXX
C17
R9,R22,R23,R24,R25,R29,R31 11 S19400-1002 10K 1/4W
XXXX XXXXXX
C13
L7
C102
D11 D17 R76,R88,R89,R180

L119
L120
R12
R13
R14
R15
R10,R142,R143,R144,R145 8 S19400-2211 2.21K 1/4W
L10
L11
C14
L9
R187,R188,R197
XX
L12
L6
C2
R17,R18,R196 3 S19400-26R7 26.7 1/4W
R191
XXX
R19 1 T12300-80 5 WATT 0.5 OHM RESISTOR

Q3
CR1
R21,R32,R33 3 S19400-1003 100K 1/4W
D15
D16
D13
D14
XX
R186
R27,R177 2 S19400-1004 1M 1/4W
XX
X
XX
Q1 R28 1 S19400-1372 13.7K 1/4W

XXX C10
X
XX
D22
D21
XXX
XXX R30,R195 2 S19400-1212 12.1K 1/4W
XXXX Q4 R37 1 S19400-2671 2.67K 1/4W
D42
D43
D19
D34
D35
L3
D40
D41
C9
D31
D32
D29
D28
D38 Q2 R39 1 S19400-1301 1.3K 1/4W
D24
D25
R18
D18
DZ4
R55 1 S19400-2213 221K 1/4W
D37
Q6
R59 1 S19400-2670 267 1/4W
R17
DZ3
R63,R64,R65,R66,R67,R68 8 S19400-2000 200 1/4W

R69,R70
Q5
R67
R68
R69
R70
R80 1 S19400-3321 3.32K 1/4W

R83,R92,R93,R150 4 S19400-1501 1.5K 1/4W
R63
R64
R65
R66
R86 1 S19400-2430 243 1/4W
D8
D6
D7
D5
T2
T1
T4
T3
1 1 1 1 R107,R156 2 S19400-1500 150 1/4W
R109,R110,R192,R193 4 S19400-3010 301 1/4W
.20 R167,R168,R169,R170
R184
4
1
S19400-2431
S19400-6812
2.43K 1/4W
68.1K 1/4W
R185 1 S19400-4752 47.5K 1/4W
R198 1 S19400-4750 475 1/4W
0 T1 1 M16744-1 TRANSFORMER
T2 1 M16744-4 TRANSFORMER
T5,T6 2 T12737-7 PULSE TRANSFORMER
TP1,TP2,TP3 3 T13640-18 160J
X1 1 M15458-3 PWM CONTROLLER,IC
X2 1 S15128-11 14 PIN QUAD COMPARATOR
0 .20 5.63 X3 1 M15102-3 RESET I.C. UNDERVOLT. SENSING CIR. (SS)
11.05 11.25±.04 X4 1 S18395-8 REGULATOR ASSEMBLY

X5 1 S18395-7 S15128-15 ON S18104-5
X6 1 S15128-12 IC - VOLT REG
X7 1 S15128-6 IC - VOLT REG
X8 1 S18395-13 5V REG. ASBLY

X9 1 S15128-7 IC - VOLT REG
X10 1 S15128-5 IC - VOLT REG
RESISTORS = OHMS
Ch’ge. Sht. No. EQUIP.

1-6-95B THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
3-29-96K CLEVELAND, OHIO U.S.A.
3-29-96L SUBJECT POWER P.C. BOARD ASSEMBLY
SCALE FULL
G 2163-1
7-25-97K SHT.
7-9-99F DR FM DATE 3-9-94 CHK DB/FV REF. SUP’S’D’G NO.
machine.
POWER WAVE 450
SCHEMATIC - PROTECTION PRINTED CIRCUIT BOARD
G 2451
D15
AUXILIARY WIRE FEEDER 1 WIRE FEEDER 2 POWER BD DISPLAY BD AMPTROL

R1 24VAC
+24V
150
J33
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J34
J33
J33
J33
J33
J33
J35
J35
J35
J35
J35
J35
J37
J37
J37
J37
J38
J38
J38
J38
X4
R2 IN OUT
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 1 2 3 4 1 2 3 4
150
L1 D11 D13
R134
R3 ADJ 221
1
150 J36 .39mH
J32 C10 C12
FROM CURRENT R4 3
24VAC FROM TP2 3300
115V
4.7
TRANSFORMER
150 AUXILIARY 2 50V 50V
35V
R5 J32 15J
24V
TRANSFORMER
1N4936
1N4936
L2 C11
150 R162
R135
R136
D3
D1
3 6.81K 10K
42V
J36 C1 J32 .39mH
+t
START
1
.25 D12 D14
50V
TO CONTROL BD START
4
J36
2
1N4936
1N4936
105
D2
D4
POWER SUPPLY
106
J36
4
SECONDARY - 4000V ISOLATION FROM PRIMARY CIRCUITS
TO LOAD SIDE OF CONTACTOR
J30
J30
J30
J30
J30
J30
J30
J30
+24V 16 11 2 3 4 5 7 8
2
1
CR2 200 200 200 200 200 200
R150
R129
R160
R132
CR1
R151
R161
24 VDC
24 VDC 20W 20W 20W 20W 20W 20W

+24V
+24V
C13
.0027 50V D19 1
HIGH VOLTAGE DIVIDERS +10Vp 2
ENABLE
CAP1 FAULT SOFT START
J31 4 CR1 4 CR2
47.5K
R54
33.2K
R58
5 FAULT DISABLE PRIMARY - 2500V ISOLATION
R47 UPPER CAP 10K SOFT START
R51
J31 3 3
10K
33.2K VOLTAGE MONITOR FROM ALL CIRCUITS
12 2 SOFT START DISABLE R137
R46 NO FAULT 3
Q9
1 475 X7 A R60 2N4401
X5 A 1
3
CW 3 Vupcap 5.11K
267K
X6 A R52 2
267K
R40
R43
R44
1
D16 D18 10K C24
2K
VOLTAGE 2
68.1K
15.0K
Q6
R55
18
R59
R61
C29 22.1K
MONITOR 1 C26 600mA 15V
SOFT START
15.0K
+10Vp 40V
R53
GAIN = .016 V/V
R50
15.0K
267K
267K
R45
R42
R41
10K
UNDER VOLTAGE &
6 1 9 10 12 13 14 15
VERIFY CHARGE
Vfault
R48
J30
J30
J30
J30
J30
J30
J30
J30
22.1K
J31 Vupcap > 170 VDC
14 R6
TO LOAD SIDE OF INPUT SWITCH
1.00K
2 5 +24V
J31 X6 B
7
3
D17 24VAC
J31 6 V < 170V
4
DISABLE RM
J31
C14
R49
6
8.25K V > 170V
J31 .0027 50V
R128
ENABLE RM 3.32K 3.32K
R138
7
J31
J31
R75 R140
START
10 10K +24V
33.2K +24V 200
6 1 6
R74 TO CONTACTOR COIL
R141
C36 26.7
X5 B
7
OCI5 MT2 OUTPUT
R157
1.00K
Vupcap or 0V 0.1
3043 TRI1
CW 5 D35 ENABLE 50V J32 DISABLE
267K
267K
R68
R72
R71
RUN MODE G 6
R130 2 4 MT1 C25
2K
R83
133K .1
VOLTAGE
3.32K
R155
4.75K
R154
DISABLE
3.32K
J32 J39
400V
RUN MODE 5 R13 4
MONITOR 2 R79 CAP2 FAULT
R139 J32 100
GAIN = .016 V/V 13
150K
RUN MODE DISABLE R82
267K
4
R73
R70
R69
267K
10K R76 10
Q12 1.00K
14 475 X7 C R85 2N4401
150K X5 D 8
10
12 22.1K
R77 X6 C R80 9
Vlowcap 8
C16 +24V 1 5
D21 D22
R84
8 150K 10K 133K
J31
9
Q11
100
C34 DZ15 TO CONTROL BD
15.0K
OCI4
LOWER CAP 20V
R86
1.00K
FAULT
R11
9 150K C27 600mA RUN MODE 0.1 6.2V
R78
C15 CNY17-3
15.0K
J31 40V 50V 1W
VOLTAGE MONITOR
R81
11 .0027 50V 2 6 4
J31 NO FAULT
13
R92
J31 33.2K
ENABLE
GND
J31 OUTPUT
R104
R12
1 10K
33.2K DISABLE
9 56.2K
R103 D24 R89 OUTPUT
5
8
X5 C 68.1K X7 B
Vupcap + Vlowcap 7
CW 10
C35
267K
R100
267K
R101
OR Vlowcap
R97
R91
6
475 150p
2K
50V
VOLTAGE
22.1K
R152
SECONDARY - 4000V ISOLATION FROM PRIMARY
MONITOR 3
15.0K
R93
Vfault C17
GAIN = .016 V/V
267K
R102
267K
56.2K
10K
R98
R99
R90
18
R95
15V
15.0K
Q14
C28 Q17
600mA
12 2N4401
15.0K
R96
R142 40V
14
+10Vp 22.1K X8 D
R113 13
R153
15.0K
R119 R143
100K
1.50K V/F CONVERTER 22.1K
+24V
+24V R116
10K J39
R144
2
22.1K
13 R9 2
C31
R112 2.43K X8 A
1 6
R127
1.82K
14
33.2K X8 B 100
10K X6 D R159 R117 +10Vp J39
3 7 9
+10V PREC. R111
12
681 2.43K R124 X8 C 1
5 8
+10Vp DZ13
+10Vp
10V 10
R108
R109 R110
1W R120
3.32K
3.32K
D28
R7
100K 100K DZ14

1.50K 1 5 TO CONTROL BD
6.2V
R114
+10Vp 100K 1N4936 1W
1.00K
C32
R8
OCI3
CNY17-3
R158 Q15 2 6 4
1.0
R105
1A
R115
1K 100K CAP DELTA 1W 100V J39

Q16
CW C18
1A
3 GND
(ADDS GAIN + 0.27
100V
12
50V R123 X7 D
SHIFTS Fc)
14
C30 2.21K R125 GND
R10
4.7 13
2.21K
R106
2.67K 35V +24V DZ11 56.2K GENERAL INFORMATION

DZ12
R122
LAST NO. USED

15V
2.21K
+ 15V
R126
1
1W ELECTRICAL SYMBOLS PER E1537 R- 162 Q- 17
2.21K
1W DZ- 15
8 C- 36
X9 C33 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
CAP DELTA MONITOR
REF TL431 150p RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 35
6 - 50V SECONDARY - 4000V ISOLATION FROM PRIMARY DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
R107
1.00K
4 4 4 4 FREQ RANGE 0-2.5KHz POWER SUPPLY SOURCE POINT
CAP1=CAP2 Fc=1.25KHz COMMON CONNECTION

C20 C21 C22 C23
X5 X6 X7 X8
CAP1>CAP2 F<1.25KHz FRAME CONNECTION
LM224 LM224 LM224

33074A CAP1<CAP2 F>1.25KHz FILENAME: G2451_2DA EARTH GROUND CONNECTION
NOTES :
EQUIP.
11 11 11 11 DEADBAND +/- 375 Hz N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE Ch’ge.Sht.No.
THE LINCOLN ELECTRIC CO. TYPE INVERTEC
1-6-95B
GAIN .25 KHz/V NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
CLEVELAND, OHIO U.S.A. SUBJECT PROTECTION PC BOARD SCHEMATIC
NUMBER. 10-27-95G
SCALE NONE
SHT.
1-10-97D
DR. TEL DATE 12-26-91 CHK. TEL SUP’S’D’G. NO. G 2451
POWER WAVE 450

PC BOARD ASSEMBLY-PROTECTION
G 3196-1 ITEM REQ’D IDENTIFICATION

PART NO.
C1 1 T11577-50 4 . 0 M F D , 5 0 V C A PA C I T O R
C10 1 S13490-92 3300 / 50
C11,C20,C21,C22,C23,C26 11 S16668-5 .022/50
C27,C28,C29,C31,C32
C12,C30 2 S13490-25 4.7/35
C13,C14,C15 3 S16668-4 2700pF/50
C16 1 S13490-97 100 / 20
.20 5.63 11.05

C17,C24 2 S13490-39 18 / 15
C18 1 S13490-85 .27/50
C25 1 T11577-57 0.1/400
C33,C35 2 S16668-9 150pF/100
C34,C36 2 S16668-11 .1/50
CR1,CR2 2 S15122-4 R E L AY
±.04
8.00 D1,D2,D3,D4,D28 5 T12705-34 1N4936
D11,D12,D13,D14,D15,D16 13 T12199-1 1N4004
PROTECTION
7.80 D17,D18,D19,D21,D22,D24
D35
Q9
G3196-1 DZ11,DZ12 2 T12702-29 1N4744A
R60
R61 R72 R44 DZ13 1 T12702-27 1N4740
R45 R101 DZ14,DZ15 2 T12702-40 1N4735
R83
R73
C22
C29 R84 J30 1 S20351-16 HEADER
R59 J31,J34 2 S20351-14 HEADER
R58 C20 J32,J33,J35 3 S20351-6 HEADER
C16 R102
R54 C13 R79 J36,J37,J38,J39 4 S20351-4 HEADER
R55 R82 R76
X7 R47
R77 X4 L1,L2 2 T12218-9 . 39mH
C24 D35 R46
D15
X5 R78
R135
R136
R134
R92 R130 R74
C12
R161
R151
R132
R160
R129
R150
OCI3,OCI4 2 S15000-10 O P T O I S O L AT O R
R93 Q11 R75 R103 OCI5 1 S15000-11 3043
R137 C14 R104
R152 Q17
R153 R81 C15 Q6,Q9,Q11,Q12,Q14,Q17 6 T12704-68 2N4401
C11
Q6 C28 C27 Q15,Q16 2 T12704-73 IC PKG MOSFET (SS)
Q12
R53 R96 R90

C26 R1,R2,R3,R4,R5 5 S19400-1500 150 1/4W
R95 C17 R6,R8,R11,R107,R139,R157 6 S19400-1001 1K 1/4W
Q14
R91 C21
R7,R108,R128,R138,R154 6 S19400-3321 3.32K 1/4W
R52 R155
R89
R112 C10
R128
R138
D18 D24 R85 R9,R13 2 S19400-1000 100 1/4W
R159
R86 R50 R10,R12,R90 3 S19400-5622 56.2K 1/4W
D22 R80 DZ13
R51 R40,R41,R42,R43,R68,R69 12 S19400-2673 267K 1/4W
R113 R70,R71,R97,R98,R99,R100
R49 R115 R44,R72,R101 3 T10812-73 2K 1/2W TRIMMER
R116 R48 X6 R114 R45,R73,R102 3 S19400-5621 5.62K 1/4W
C23 R7 R111 R46,R51,R52,R74,R80,R103 9 S19400-1002 10K 1/4W
R108
R111,R112,R136
R110
R144 D17 R47,R58,R75,R92,R104,R124 6 S19400-3322 33.2K 1/4W
R119
R120 D16 R48,R59,R85,R142,R143,R144 7 S19400-2212 22.1K 1/4W
D12
D14
C31
D11
D13
R117 X8 R152
D21
R124 R107 R157 R49 1 S19400-8251 8.25K 1/4W
4.00
R143
R109 R50,R53,R61,R81,R86,R93 9 S19400-1502 15K 1/4W
R123 C36
D28 R106 CR1 R95,R96,R153
R122 X9 R54 1 S19400-4752 47.5K 1/4W
R142 TP2
DZ11 R55,R89 2 S19400-6812 68.1K 1/4W
R105 OCI5 R60 1 S19400-5111 5.11K 1/4W
Q15 R125
R158 C30 R76,R77,R78,R79 4 S19400-1503 150K 1/4W
R100
R82,R91,R137 3 S19400-4750 475 1/4W
DZ12
R43
R71
C18 R83,R84 2 S19400-1333 133K 1/4W
R126 R139 D19 R105 1 T10812-68 1K 1/2W TRIMMER
R106 1 S19400-2671 2.67K 1/4W
Q16
R155 R109,R110,R113,R114,R115 5 S19400-1003 100K 1/4W
L1
L2
R154 R127 R116,R117 2 S19400-2431 2.43K 1/4W
R140
R141
TRI1 R119,R120 2 S19400-1501 1.5K 1/4W
R11 C32
R42
R70
R99
R122,R123,R125,R126 4 S19400-2211 2.21K 1/4W
C34 R8
R127 1 S19400-1821 1.82K 1/4W
D4
XXXXXXXXXXXXXXXXXXXXXXXXXXXX CR2 R129,R132,R150,R151,R160 6 T14900-1 200 20W
D3
XXXXXX
XXXXXX
R161
OCI4 OCI3 D2 R130 1 S19400-4751 4.75K
D1
R41
R134 1 S19400-2210 221 1/4W
R69
R98
XXXXXXXXXXXXXXXXXXXXXXXXXXXX C1 R135 1 S19400-6811 6.81K 1/4W
R5
R4 R140 1 S19400-2000 200 1/4W
R3 R141 1 S19400-26R7 26.7 1/4W
R2 C25 R158 1 T12300-79 1 W AT T 1 O H M 1 % R E S I S T O R
DZ15
DZ14
C35
C33
R13
R12
R10
R9
R1 R159 1 S19400-6810 681 1/4W

R162 1 S18380-4 PTC THERMISTOR
R40
R68
R97
R6
R162 XXXXXXXXXXXXXXXXXXXXXXXX
TP2 1 T13640-15 15J
XXXXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXX TRI1 1 S18395-9 S15161-27 ON S18104-5
XXXXX
XXXXX
X4 1 S18395-7 S15128-15 ON S18104-5
X5,X6,X7 3 S15128-4 LM224 OP-AMP
XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXXX
J39 J38 J37 J36 X8 1 S15128-18 QUAD-OP AMP
X9 1 S15128-10 V O LTA G E R E F.
J35 J34 J33 J32 J31 J30
.20 INDUCTANCE = HENRIES
RESISTORS = OHMS
0
±.04
0 11.25
XA
THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
1-9-98D CLEVELAND, OHIO U. S. A. PROTECTION P.C. BOARD ASSEMBLY
8-27-99B SUBJECT
G 3196-1
SCALE FULL
SHT.
DR. DRS DATE 2-27-97 CHK. DRS REF. G2453-2 NO.
machine.
POWER WAVE 450
SCHEMATIC -SQUARE WAVE PROTECTION PRINTED CIRCUIT BOARD
M 16115
L4
J23 J22
1 5
.39mH
C4
.0047
3000V
L5
J23 J22
2 4
.39mH
C5
.0047
3000V
L1
J23 J22
3 1
.39mH
C1
.0047
3000V
L2
J23 J22
4 2
.39mH
FRANCE
C2
.0047
3000V
L6
J23 J22
5 6
.39mH
CANADA
C6
.0047
3000V
L3
J23 J22
7 3
.39mH
AUSTRALIA
C3
J23 .0047
8
3000V
R- _
C- _
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- _

SUPPLY VOLTAGE NET

NOTES :
COMMON CONNECTION
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION
NUMBER.

5-29-90SPA THE LINCOLN ELECTRIC CO. TYPE SQUARE WAVE TIG 350
CLEVELAND, OHIO U.S.A.
SUBJECT PROTECTION P.C. BOARD SCHEMATIC
SCALE NONE
DR MK/DRS DATE 1-12-90 CHK GM/BS REF. SUP’S’D’G

SHT.
NO. M 16115
POWER WAVE 450

PC BOARD ASSEMBLY-SQUARE WAVE PROTECTION
M 16062-1
AICF ITEM REQ’D PART NO. IDENTIFICATION
C1, C2, C3, C4, C5, C6 6 T11577-58 .0047/3000 V

L1, L2, L3, L4, L5, L6 6 T12218-9F .39 mH
J22 1 S18248-6 HEADER
J23 1 S18248-8 HEADER
+.05
-.02
3.60
3.40 SQUARE WAVE B

PROTECTION
±.12 L6
M16062-1
3.10
L4
L5
J23
C4
C5
C1
L1
L3 L2
C2
J22
±.12 C3
.60
C6
.20
±.12
.20 .50 3.40 +.05

3.60 -.02
0

12-8-89B THE LINCOLN ELECTRIC CO. TYPE SQUAREWAVE TIG 300 & 350
11-30-90B CLEVELAND, OHIO U.S.A.
SUBJECT PROTECTION P.C. BOARD ASSEMBLY
SCALE DOUBLE
DR FV DATE 9-8-89 CHK DEC REF. L8088-1 SUP’S’D’G

SHT.
NO. M 16062-1
machine.
POWER WAVE 450
SCHEMATIC - SHUNT PRINTED CIRCUIT BOARD
S 21151
+15V
R10 3
J50
100
7 DZ1
C2 15V
0.1 1W
VOLTAGE TO CURRENT
50V
X1
50mV = 5mA 1
TO
SHUNT J50
DIODE OP27
C3 DZ2 G
BRIDGE
PADS IN 0.1 15V
GRAPHICS 4 50V 1W
ONLY R5
-15V
392K R11 6
J50
J50 100
5 R1 R2 1 NULL X1 NULL 8
511 7
4.75K 2 INPUT - V CC
Vin C1
3 INPUT + OUT 6
4
J50 VEE NC 5
2 R3 R4 OP27
511 4.75K
R9
R6
562 1.30K
TO NEGATIVE G
OUTPUT STUD
500
R7
CW
-Vin * 74.51
Iout = A
(R7 + 392)
R8 4
J50
392K
NOTES :
LABELS FILE: S21151_2BA
GENERAL INFORMATION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
ELECTRICAL SYMBOLS PER E1537 FRAME CONNECTION
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING SUPPLY VOLTAGE NET
THE INTERCHANGEABILITY OF A COMPLETE BOARD. CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION
THE LINCOLN ELECTRIC CO. TYPE INVERTEC V400
1-6-95
11-21-97G
SHUNT AMPLIFIER PCB SCHEM.
SCALE NONE
SHT.
DR. DB DATE 2-7-94 CHK. SUP’S’D’G. NO. S 21151
POWER WAVE 450

PC BOARD ASSEMBLY- SHUNT
M 17150-2
ITEM REQ’D PA R T N O DESCRIPTION
C1 1 S16668-5 .022/50
C2,C3 2 S16668-11 .1/50
.13 DZ1,DZ2
J50
2
1
T12702-29
S18248-6
1N4744A
HEADER
R1,R3 2 S19400-5110 511 1/4W

R2,R4 2 S19400-4751 4.75K
R5,R8 2 S19400-3923 392K 1/4W
+.04
R6 1 S19400-5620 562 1/4W
- R7 1 S16296-3 500 1/2W TRIMMER
1.75
R9 1 S19400-1301 1.3K 1/4W
1.63
R10,R11 2 S19400-1000 100 1/4W
AMPLIFIER
X1 1 S15128-13 PRECISION OP AMP IC
R1
DZ2
C1
M17150-2 SHUNT
R8
R4
R3
C3
R2
R5
X1
J50
DZ1
R11
R10
C2
R6
R9
R7
0
+.04
-
0 2.25

11-21-97G THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
4-20-2000D
SUBJECT SHUNT AMPLIFIER P.C. BD. ASSEMBLY
SCALE FULL
DR LJB DATE 11-4-97 CHK J.J. REF. M17150-1 SUP’S’D’G

SHT.
NO. M 17150-2
machine.
POWER WAVE 450
SCHEMATIC - SNUBBER PRINTED CIRCUIT BOARD
M 16761
+15V
D5
J60 12
67A 8 R3 R10 J61
(67) 14
100K 100K X1 6
(202)
.5W .5W +15V 13
D4 R20
J60 10.0K 10
67B 15 R11 R12 J61
+15V 8
(167A) 100K 100K 7
X1 (201)
.5W .5W 9
D3
J60 5 R21
TO CONTROL BOARD
21A 9 R14 R8 J61
(121A) 7 10.0K
100K 100K X1 10
(206)
.5W .5W +15V 6
D2 R22
J60 10.0K 3
21B 13 R17 R9 J61
(221A) 1
100K 100K X2 8
(207)
.5W .5W +15V 2
D1
J60 5 R23
+OUTPUT 11 R6 R4 J61
(499) 7 10.0K
100K 100K X2 9
(203)
.5W .5W 6
DZ1 DZ3 DZ5 DZ7 DZ9

R24
5.1V 5.1V 5.1V 5.1V 5.1V
1W 1W 1W 1W 1W 10.0K J61
5
(205)
10K 10K 10K 10K 10K
C5 C6 C7 C8 C9
R15
R16
R13
R7
820p 820p 820p 820p 820p
R1
COSMETIC TRACE (J62-4 TO J61-5)
50V 50V 50V 50V 50V +15V
J61
4 4
DZ2 DZ4 DZ6 DZ8 DZ10 R18 1
+15V
5.1V 5.1V 5.1V 5.1V 5.1V 100 (204)
1W 1W 1W 1W 1W C13 C12
X2 0.1
X1 0.1
50V 50V
33074A 33074A J61
R19 2
-15V
11 11 (208)
100 J61
J62 (462) 3
J62
1 2 4
L3 1
(461) X1
C3 J61
TP3 2
.0047 2.7 2.7 DZ11 DZ12 3
320V C10 C11
R5
R2
400V 10W 10W 15V 15V
J60 160J 0.1 0.1
1 1W 50V 50V 1W
CHASSIS R11
J62 TP2 10
J60 6 40/100W
320V
2
160J 8
J60 X2
C2 C4
3 TP1 9
.0047 .047
J60 320V
400V 1200V
4 160J
J60 J62 GENERAL INFORMATION
J62 (464) 12 LAST NO. USED
5
7 4
-OUTPUT
J60 14 ELECTRICAL SYMBOLS PER E1537 R- 24 DZ- 12
(467)
6 C1 X2 C- 13
J60 .1 13
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 5
7 1000V
J62 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
J60 8 SUPPLY VOLTAGE NET
10
BACKGND
(468) POWER SUPPLY SOURCE POINT
J60 J62 NOTES :
12 5
COMMON CONNECTION

J60 J62
14 3 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION
J60 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
16 NUMBER. FILE: M16761_1BA
Ch’ge.Sht.No.
EQUIP.
THE LINCOLN ELECTRIC CO. INVERTER WELDERS
1-6-95A TYPE
CLEVELAND, OHIO U.S.A. SNUBBER P.C. BD. SCHEMATIC
SUBJECT
SCALE NONE
SHT.
DR. DB DATE 1-31-93 CHK. DB SUP’S’D’G. NO. M 16761
POWER WAVE 450

PC BOARD ASSEMBLY- SNUBBER
ITEM REQ’D PART NO. IDENTIFICATION
C1 1 S20500-1 .1/1000
SNUBBER P.C. BOARD ASSEMBLY

C2,C3 2 S13490-3 .0047/400
L 9579-1
INVERTER WELDERS
C4 1 S13490-112 .047/1200
C5,C6,C7,C8,C9 5 S16668-7 820pF/50
3.08 C10,C11,C12,C13 4 S16668-11 . 1/50
SHT.
NO.
D1,D2,D3,D4,D5 5 T12199-1 1N4004
±.04 DZ1,DZ2,DZ3,DZ4,DZ5,DZ6 10 T12702-52 1N4733A

DZ7,DZ8,DZ9,DZ10
SUP’S’D’G
4.05 DZ11,DZ12 2 T12702-29 1N4744A
SNUBBER
L9579-1 C13
J60 1 S18248-16 HEADER
3.85
R23
J61 1 S18248-10 HEADER
TYPE
D2
EQUIP.
REF.
SUBJECT
J62 1 S18248-8 CONNECTOR
R13
R15
DZ10
R16
R1
R7
DZ8
C5
C8
C7
C9
C6
DZ6
X2
CHK DB
R1,R7,R13,R15,R16,R20,R21 10 S19400-1002 10K 1/4W
THE LINCOLN ELECTRIC CO.

R22,R23,R24
R24
D1
R2,R5 2 T14649-7 2.7 10W
DATE 2-25-94
R3,R4,R6,R8,R9,R10,R11,R12 10 S20620-1003 100K 1/2W
DZ2
FULL
DZ4
DZ7
DZ3
DZ1
DZ5
DZ9
C4 R2 R5 R14,R17
SCALE
R18,R19 2 S19400-1000 100 1/4W
D5
DR JLV
D4 TP1,TP2,TP3 3 T13640-18 160J
C12
X1,X2 2 S15128-18 QUAD-OP AMP
R10
R12
R9
R4
R8
D3
X1 CAPACITORS = MFD/VOLTS
R21
R20
R22
C1
xxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxx
C3 C2
DZ11
R11
R17
R14
C10
Ch’ge. Sht. No.

DZ12
TP1
R19
R3
R6
TP2
TP3
1-6-95A
C11
UNLESS OTHERWISE SPECIFIED TOLERANCE
WITH PUBLISHED STANDARDS.

t AGREE
R18
ON ALL ANGLES IS .5 OF A DEGREE

ON 3 PLACE DECIMALS IS .002
ON HOLE SIZES PER E2056
ON 2 PLACE DECIMALS IS .02
MATERIAL TOLERANCE (" ") TO

.45 J61 J62
J60
0
NOT TO BE REPRODUCED, DISCLOSED OR USED

OWNED BY THE LINCOLN ELECTRIC CO. AND IS
THIS SHEET CONTAINS PROPRIETARY INFORMATION
WITHOUT THE EXPRESS PERMISSION OF

±.04

0 5.00
.20 3.05 4.80

L 9579-1
CAD
machine.
POWER WAVE 450
SCHEMATIC-SWITCH PRINTED CIRCUIT BOARD
SWITCH P.C. BOARD SCHEMATIC
L 10611
COMMON CONNECTION
INVERTER WELDERS
SUPPLY VOLTAGE NET
DZ- 10
FRAME CONNECTION
Q- 12
A- 2
LAST NO. USED
SHT.
NO.
R- 42
D- 10
C- 8
D4
1N4936
LABELS
W
221
D2 Q2
R4
SUP’S’D’G.
100
R3
1N4936 D3
1A
100V 1N4936
R35
47.5
UNLESS OTHERWISE SPECIFIED)

IRFD110
SUBJECT
UNLESS OTHERWISE SPECIFIED)
1
EQUIP.
22.1K
TYPE
Q7 1/2W
R15
R16 600mA DZ6
(UNLESS OTHERWISE SPECIFIED)

40V
DRS
2N4403
1.00K
POSITIVE
6.2V 1W
9 INPUT
CHK.
D9
R14
1.00K
B
1N4936
R12

Q6
Q3 DZ1
600mA
C1
1A 40V
10-28-96
C1 C2 C3 C4 C5
10V
NONE
2N4403 R8 G1 A1
100V

DZ5 1W
SNUBBER
MFD ( .022/50V
GENERAL INFORMATION
6.2V 10.0
1/4W
IRFD110 G2
A2
Q5
RESISTOR
1W DZ4
G3 A2
600mA R17
15V M16100-23
1 40V G4
1W
SCALE
Q4 10.0 M16100-23
2N4403
DATE
600mA 1/2W
1A, 400V
R11
FILE: L10611_1AA
RESISTORS = Ohms (
G5
DZ3 E1 E2 E3 E4 E5
40V R6 C1
10V 1W 15.0K
2N4401
CAPACITORS =
10.0
R10
20
402 406
DIODES =
D5
--- ---
JP/FM
475 475
R42
R18
R9
1N4936
404 408
R13
C2 10.0
2700p
50V R33
100 C3
DR.
R7
1.50K 10.0 .047
1200V
C7
R5
1 TRANSFORMER
R -
3 PRIMARY
C2

A2
M16100-23
A2
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

D1
R38 R39 INPUT
39.2K 39.2K
1N4936 FILTER
W R41 R40
CAPACITOR
7-18-97
39.2K 39.2K
Ch’ge.Sht.No.
XA
221
D6 100
R1
Q1
R2
1N4936 D7
1A C2
1N4936
100V
R36
47.5
IRFD110
A1
1
22.1K Q11 1/2W
R22
M16100-26
R23 600mA DZ9
A2
40V
2 TRANSFORMER
2N4403 -
1.00K 6.2V 1W 4 PRIMARY
D10
R21
1.00K 1N4936 A
R20
Q9
NUMBER.
Q10 DZ2
600mA C4
C5 .047
1A 40V
10V C1 C2 C3 C4 C5 1200V
100V 2N4403
DZ8 1W R19 G1
NOTES :
6.2V
IRFD110 Q8 10.0 G2 A1
1W DZ7
600mA 401 405
N.A.
15V G3
Q12 1 40V
1W
R26 M16100-26 --- ---
1/2W 2N4403 10.0
G4
403 407
R28
600mA
DZ10 G5
40V E1 E2 E3 E4 E5
10V 1W 15.0K R25
2N4401
R32
10.0 A1
20
D8
475 475 SNUBBER
R29
R37
1N4936 R27
R31
C8
A1
2700p
10.0 RESISTOR
50V R34 M16100-26
R30
100
1.50K 10.0 C1
R24
C6
R 12 NEGATIVE
INPUT
L 10611
POWER WAVE 450

PC BOARD ASSEMBLY-SWITCH
G 2390-1
ITEM REQ’D PART NO. DESCRIPTION
A1 1 M16100-8 ELECTRONIC MODULE (SS)
A2 1 M16100-7 ELECTRONIC MODULE (SS)
B1,B2,B3,B5,B6,B7,B9,B10 10 T13157-6 TAB TERMINAL

B11,B12
C1,C5,C6,C7 4 S16668-5 .022/50

C2,C8 2 S16668-4 2700pF/50
21B 11B 9B 01B 3B 7B 5B 6B 2B 1B C3,C4
{ 2 S13490-112 .047/1200
6.50 D1,D2,D3,D4,D5,D6,D7,D8,D9 10 T12705-34 1N4936

D10
DZ1,DZ2,DZ3,DZ12 4 T12702-27 1N4740

DZ4,DZ7 2 T12702-29 1N4744A
DZ5,DZ6,DZ8,DZ9 4 T12702-40 1N4735
R3 3C R1
C1
4C Q1,Q2,Q3,Q10 4 T12704-73 IC PKG MOSFET (SS)
{
D4 D1 Q4,Q12 2 T12704-68 2N4401
C5
D2 Q5,Q6,Q7,Q8,Q9,Q11 6 T12704-69 2N4403
D6
R1,R3,R5,R24 4 S19400-1000 100 1/4W

R14 R23
R2,R4 2 S19400-2210 221 1/4W
R6,R8,R9,R17,R19,R25,R26 10 S19400-10R0 10 1/4W
R16 R21 R27,R33,R34
R38,R39,R40,R41 4 S19400-3922 39.2K 1/4W
Q11
R7,R30 2 S19400-1501 1.5K 1/4W
Q12
Q7
Q4
R10,R32 2 S19400-1502 15K 1/4W
R11,R15,R22,R28,R43,R44 8 S19400-2R00 2 1/4W
R45,R46
R13 R31
R12,R14,R20,R21 4 S19400-1001 1K 1/4W

R5 R24 R13,R31 2 S19400-20R0 20 1/4W
R16,R23 2 S19400-2212 22.1K 1/4W
D5 D8
R18,R29,R37,R42 4 S19400-4750 475 1/4W
DZ5 DZ8 R35,R36 2 S19400-47R5 47.5 1/4W
R7 R30
R12 R20
R4 R2 CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
DZ6
R15
R43
R22
DZ9
R45
Q2 Q1
B8 B4
A1
DZ12
R11
R28
R46
R44
DZ3
Q3 Q10
A2
R33 R34
R9 R27
2.41 R6 R25
R17 R26
R8 R19
C7 C6
R18 R29
R42 R37
DZ4 DZ7
R35 R36
D3 D7
Q6
Q5
Q8
Q9
R41
R38
R39
R40
D9 D10
DZ1 DZ2
C2 C8
R10 R32
G2390-1 V400 SWITCH

0
0 4.13 8.25
Ch’ge. Sht. No. 9-22-2000 EQUIP.

1-6-95B THE LINCOLN ELECTRIC CO. TYPE INVERTER WELDERS
5-19-95F CLEVELAND, OHIO U.S.A.
8-25-95A SUBJECT SWITCH P.C. BOARD ASSEMBLY
SCALE FULL
G 2390-1
7-25-97F SHT.
DR JLV DATE 2-16-94 CHK R.M. REF. L8982-1 SUP’S’D’G
7-25-97J NO.
machine.
POWER WAVE 450
G-24 G-24
ELECTRICAL DIAGRAMS
POWER WAVE RS 232 CONNECTIONS
9 PIN RS 232 J17 MOLEX

FROM PC NULL CONNECTOR POWER WAVE
INTERNAL WIRING DISPLAY BOARD
MODEM
CABLE #302
DCD 1 1 1
RD 2 2 TD 2
TD 3 3 RD 3
DTR 4 4 RTS #303 4
GND 5 5 CTS 5
DSR 6 6 DSR 6
RTS 7 7 GND #306 7
CTS 8 8 DCD #307 8
RI 9 9
20DTR
22RI
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC
Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for
reference only. It may not be totally applicable to your machine’s specific PC board version. This dia-
gram is intended to provide general information regarding PC board function. Lincoln Electric discour-
ages 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.
POWER WAVE 450
SVM ERROR REPORTING FORM
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 col-
umn 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
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99

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INVERTEC POWER WAVE ™ 450

10513, 10514, 10515, 10516, 10520, 10607, 10608, 10609, 10610

Need Help? Call 1.888.935.3877

For Service outside the USA:

SVM112-B | Issue D­ate 01, Feb

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

• Semiautomatic DC Constant Voltage (Wire) Welder.

5.e. Also see item 1.b.

prévenir tout risque d’incendie dû aux étincelles.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

5. Toujours porter des lunettes de sécurité dans la zone de

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair.................................................................................................Section F

Electrical Diagrams ..............................................................................................................Section G

POWER WAVE 450

Technical Specifications .............................................................................................................A-2

Input Power Connections ...........................................................................................................A-4

POWER WAVE 450

INPUT -THREE PHASE ONLY

Input Voltages: 200 230 400 460 575

Constant Open Continuous Process

Circuit Voltage Current Range Current Ranges

RECOMMENDED INPUT WIRE AND FUSE SIZES

230/50-60 60% 76 4 (25) 8 (10) 100

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° to 40°C -50° to 85°C

POWER WAVE 450

Read this entire installation section before you LIFTING

SAFETY PRECAUTIONS HIGH FREQUENCY PRECAUTIONS

tion of the rating plate.

SELECT SUITABLE LOCATION

The Power Wave may be used outdoors. Power Wave

Power Wave machines cannot be stacked.

face. The machine may topple over if this procedure

wire sizes. Fuse the input circuit with the recom-

INPUT POWER CONNECTIONS

FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR

NOTE: Turn main input power to

mthe machine OFF before perform-

POWER WAVE 450

FIGURE A.3 – FRONTPANEL/BACK PANEL

To operate at 200-208 VAC: OUTPUT CONNECTIONS

1. Open the reconnect/input access door. ROUTING

Refer to the Accessories section of this manual for

POWER WAVE 450

Controls and Settings .................................................................................................................B-5

Setup Overlay ...........................................................................................................................B-17

Over Current Protection .....................................................................................................B-23

POWER WAVE 450

ELECTRIC SHOCK can kill.

• Insulate yourself from the work and ground.

FUMES AND GASES can be

WELDING SPARKS can cause

• Do not weld on containers that have held com-

ARC RAYS can burn.

HOT COOLANT can burn skin.

POWER WAVE 450

RECALL FROM MEMORY key RECALL and the appro-

SVM112-B | Issue Date 01, Feb