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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
Section F-1 Section F-1
POWER WAVE 450