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POWER WAVE 455M/STT
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR
THIS
EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS
CONTAINED
THROUGHOUT.
And,
most
importantly, think before you act
and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
™
11008, 11204
IEC 60974-1
NRTL/C
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2004 Lincoln Global Inc.
IM808-A
June, 2004
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric POWER WAVE IM808-A
Summary of Contents for Lincoln Electric POWER WAVE IM808-A
- Page 1 POWER WAVE 455M/STT For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
-
Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 SAFETY...
- Page 7 SAFETY...
- Page 8 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
-
Page 9: Table Of Contents
viii Installation ...Section A Technical Specifications - POWER WAVE 455M/STT ...A-1 Safety Precautions ...A-2 Select Suitable Location ...A-2 Lifting...A-2 Stacking ...A-2 Machine Grounding ...A-2 High Frequency Protection ...A-2 Input Connection ...A-2 Input Fuse and Supply Wire Considerations...A-3 Electrode and Work Cable Connections ...A-3 Cable Inductance, and its Effects on Pulse Welding ...A-4 Negative Electrode Polarity ...A-4 Voltage Sensing ... -
Page 10: Table Of Contents
Troubleshooting ...Section E How to use Troubleshooting Guide ...E-1 Using the Status LED to Troubleshoot System Problems...E-2 Error Codes For Power Waves ...E-3 Troubleshooting Guide ...E-4 thru E-7 ________________________________________________________________________ Wiring Diagram ...Section F-1 Connection Diagrams...Section F-2, F-3 Dimension Print...Section F-4 ________________________________________________________________________ Parts Lists ...P450 Series ________________________________________________________________________... -
Page 11: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT OUTPUT CONDITIONS VOLTS AMPS / VOLTS / DUTY CYCLE EXCEPT STT PROCESS 380V - 60Hz. 400A@36V. 100% 380V - 50Hz. 400A@36V. 100% 415V - 60Hz. 400A@36V. -
Page 12: Safety Precautions
Dirt, dust, or any foreign mate- rial that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. -
Page 13: Input Connection
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do so will result in damage to the machine. -
Page 14: Cable Inductance, And Its Effects On Pulse Welding
WORK work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance. Sense Lead Kits (K940-10, -25 or -50) are available for this purpose. -
Page 15: Power Wave To Semi-Automatic Power Feed Wire Feeder Interconnections
Enable the voltage sense leads as follows: TABLE A.2 Process Electrode Voltage Work Voltage Sensing 67 lead * Sensing 21 lead GMAW 67 lead required 21 lead optional GMAW-P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional 67 lead required 21 lead required GTAW... -
Page 16: Configuring The System
If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the welder output will be disabled. If a system is not “Auto- mappable”, then consult the instruction manual for the... -
Page 17: Alternate Hard Automatic Application
ALTERNATE HARD AUTOMATIC APPLICATION (using a UI, WD Module, and PF-10R) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto, WD Module, and PF-10R) DUAL HEAD System that is NOT "Auto Mappable" DUAL HEAD BOOM FEEDER (using two single heads) POWER WAVE 455M/STT (CE) In this case the individual feed heads need to be assigned to the dual head control and the PW455M/STT (CE) auto mapping disabled and the Equipment Groups set. -
Page 18: Welding With Multiple Power Waves
WELDING WITH MULTIPLE POWER WAVES CAUTION Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. -
Page 19: Multiple Arc Unsynchronized
INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 455M/STT (CE) -
Page 20: I / O Receptacle Specifications
A-10 I / O RECEPTACLE SPECIFICATIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 0vdc +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 LEAD# FUNCTION Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 LEAD# FUNCTION RS232 Receive... -
Page 21: Operation
• Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not use AC welder if your cloth- ing, gloves or work area is damp or if working on, under or inside work- piece. -
Page 22: Graphic Symbols That Appear On This Machine Or In This Manual
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPERATION POWER WAVE 455M/STT (CE) SMAW GMAW FCAW GTAW... -
Page 23: Definition Of Welding Terms
DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage based on the wire feed speed (WFS) set by the operator. -
Page 24: General Description
GENERAL DESCRIPTION The Power Wave 455M/STT (CE) semi-automatic power source is designed to be a part of a modular, multi-process welding system. Depending on configura- tion, it can support constant current, constant voltage, STT and pulse welding modes. The Power Wave 455M/STT (CE) power source is designed to be used with the semi automatic family of Power Feed wire feeders, operating as a system. -
Page 25: Case Front Controls
CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates sys- tem errors. -
Page 26: Nominal Procedures
Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative. To make a weld, the Power Wave needs to know the desired welding parameters. -
Page 27: Constant Voltage Welding
• WELDING MODE May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characteristics of the Power Wave power source. For a more complete description of the welding modes available in the Power Wave, see the explanation below. -
Page 28: Pulse Welding
PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. -
Page 29: Stt Welding
STT WELDING The pictures illustrate the wave shape of current for the process. They are not drawn to scale, and are intend- ed only for the purpose of showing how the variables effect the waveform. Trim in the STT mode adjusts the tail out and back- ground portion of the waveform. -
Page 30: Accessories
ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED Work Voltage Sense Lead Kit, K940 Dual Cylinder Undercarriage, K1570-1. Gas Guard Regulator, K659-1 Coaxial welding Cable, K1796 Cool Arc 40 Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-1 Ethernet Interface Module, K2207-1 COMPATIBLE LINCOLN EQUIPMENT Any ArcLink compatible semi-automatic wire feeding... -
Page 31: Maintenance
Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a prob- lem, contact the Lincoln Electric Company for the cali- bration software utility. The calibration procedure itself requires the use of a resistive load bank, and certified actual meters for volt- age and current. -
Page 32: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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. -
Page 33: Using The Status Led To Troubleshoot System Problems
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. -
Page 34: Error Codes For Power Wave
Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the POWER WAVE 455M/STT (CE) can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF- 10/11 these error codes will generally be accompanied by an "Err 006"... -
Page 35: Troubleshooting
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF... - Page 36 (CR1 will not pull in.) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 37 Auxiliary receptacle is “dead” no auxiliary voltage . If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 38 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) General degradation of the weld performance Excessively long and erratic arc. In the STT mode, the arc is exces- sively long and erratic. In the STT mode, the spatter is higher than normal and the arc is inconsistent.
- Page 39 MACHINE DIAGRAMS REAR OF MACHINE FRONT POWER WAVE 455M/STT (CE)
- Page 40 CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455M/STT (CE)
- Page 41 CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, STT Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455/STT...
- Page 42 DIAGRAMS POWER WAVE 455M/STT (CE)
- Page 43 NOTES...
- Page 44 ● Do not touch electrically live parts or WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● No toque las partes o los electrodos AVISO DE bajo carga con la piel o ropa moja- PRECAUCION ●...
- Page 45 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
- Page 46 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...