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POWER WAVE 355/405
TROUBLESHOOTING & REPAIR
F-5 F-5
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
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 1-800-833-9353(WELD).
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The machine does not have weld-
ing output.
1. Make sure the reconnect switch
is configured correctly for the
input voltage applied.
2. Primary current limit has been
exceeded. Possible short in
output circuit. Turn machine
off. Remove all loads from the
output of the machine. Turn
back on. If condition persists,
turn power off, and contact an
authorized Lincoln Electric Field
Service Facility.
3. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes
by the status LED.
4. If an error code is displayed
see Fault Code Explanations.
If thermal light is on, wait for
machine to cool.
1. Check the reconnect switch and
associated leads for loose or
faulty connections. See the
wiring diagram.
2. Perform the DC Bus Board
Test.
3. Perform the Main Switch
Board Test.
4. Perform the Power Board
Test.
5. Perform the Output Diode
Module Test.
6. The control board may be faulty.
7. The input filter capacitors may
be faulty. Check and replace if
necessary.
The POWER WAVE 355/405 will
not produce full output.
1. The input voltage may be too
low, limiting the output capabili-
ty of the machine. Make cer-
tain the input voltage is correct
for the machine and the recon-
nect switch and jumper lead
configuration are correct.
2. The output current or voltage
may not be calibrated correctly.
Check the values displayed on
the Power Feed 10/11 versus
readings on an external voltage
and ammeter.
3. The welding current may be too
high . The machine will fold
back to 100 amps if the weld-
ing current exceeds 450 amps.
1. Perform the Output Rectifier
Test.
2. Perform the Main Switch
Board Test.
3. Perform the Power Board
Test.
4. Perform the Current
Transducer Test.
5. The control board may be
faulty.