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POWER WAVE
For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
™
10675; 10676
R
IEC 60974-1
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
455/R
Copyright © 2001 Lincoln Global Inc.
IM690-A
May, 2001
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Power Wave 455
Summary of Contents for Lincoln Power Wave 455
- Page 1 ™ 10675; 10676 For use with machines having Code Numbers: This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.
-
Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
MSDS forms are available from your welding distributor or from the manufacturer. 3.j. Also see Items 6.c. and 8. 5.e. Also see item 1.b. Mar ‘95 POWER WAVE 455/R... - Page 4 Electrical Code, all local codes and the manufacturer’s or 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 POWER WAVE 455/R...
- Page 5 4. Garder tous les couvercles et dispositifs de sûreté à leur talons sans revers, et chaussures montantes. place. 5. Toujours porter des lunettes de sécurité dans la zone de Mar. ‘93 soudage. Utiliser des lunettes avec écrans lateraux dans les POWER WAVE 455/R...
- Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications - Power Wave 455/R ..........A-1,A-2 Safety Precautions....................A-3 Select Suitable Location ..................A-3 Lifting.......................A-3 Stacking ......................A-3 Machine Grounding ....................A-3 High Frequency Protection ..................A-3 Input Connection....................A-3 Input Fuse and Supply Wire Considerations ............A-4 Input Voltage Change Over Procedure..............A-4 Welding with Multiple Power Waves..............A-5... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY CONDITIONS CURRENT POWER @ RATED OUPUT @ RATED OUPUT AMPS (K1761-1) 70/65/35 450A@38V.100% 208/230/460V - 60HZ. - Page 9 WIDTH DEPTH (K1761-1) 247 lbs. 112 kg. 26.10 in 19.86 in 32.88 in 663 mm 505 mm 835 mm (K1761-2) 295lbs. 133 kg. TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE -20°C to +40°C -40°C to +40°C POWER WAVE 455/R...
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Page 10: Safety Precautions
Use a three-phase supply line. A 1.75 inch (45 mm) CAUTION diameter access hole for the input supply is located on the upper left case back next to the input access door. DO NOT MOUNT OVER COMBUSTIBLE SURFACES. POWER WAVE 455/R... -
Page 11: Input Fuse And Supply Wire Considerations
If this occurs, turn off the input voltage, properly connect the (A) lead, reset the breakers, and try again. POWER WAVE 455/R... -
Page 12: Welding With Multiple Power Waves
FIGURE A.2 TWO POWER WAVES POWERWAVE POWERWAVE Travel Direction Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 455/R... -
Page 13: Electrode And Work Cable Connections
The work piece connection must be switch right to the OFF position for positive firm and secure, especially if pulse welding is planned. electrode polarity. Conversely, slide the switch left to the ON position for negative electrode polarity. POWER WAVE 455/R... - Page 14 “read” the switch at power up, and configure the recommended. work voltage sense lead appropriately. Electrode Voltage Sensing Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead must be connected at the wire feeder. POWER WAVE 455/R...
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Page 15: Power Wave / Power Feed Wire Feeder Interconnections
------------------------------------------------------------------------ CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system. CAUTION The use of non-standard cables, especially in... -
Page 16: High Speed Gear Box
Conversely, slide the switch left to the ON position when the high speed gear is installed. • Replace the cover and screws. The PC board will “read” the switch at power up, automatically adjusting all control parameters for the speed range selected. POWER WAVE 455/R... -
Page 17: Dip Switch Settings And Locations
6 = Equipment Group 4 Select switch 7 = reserved for future use switch 8 = work sense lead 1 LEASE SIGNIFICANT BIT 2 MOST SIGNIFICANT BIT switch 8 work sense lead work sense lead not connected work sense lead connected POWER WAVE 455/R... -
Page 18: Bank (S2
250K 500K Programmable value Bank (S2): switch Description Devicenet Mac ID thru (see table 3) TABLE 3 SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3 SWITCH 8 *Software Selectable (Line 0) **Default Setting (Line 62) POWER WAVE 455/R... -
Page 19: Operation
• Keep flammable material away. • Do not weld on containers that have held combustibles. ARC RAYS can burn. • Wear eye, ear, and body protection. Observe additional guidelines detailed in the begin- ning of this manual. POWER WAVE 455/R... -
Page 20: Graphic Symbols That Appear On This Machine Or In This Manual
HIGH TEMPERATURE GTAW OPEN CIRCUIT MACHINE STATUS VOLTAGE CIRCUIT BREAKER INPUT VOLTAGE WIRE FEEDER OUTPUT VOLTAGE POSITIVE OUTPUT INPUT CURRENT NEGATIVE OUTPUT OUTPUT CURRENT PROTECTIVE 3 PHASE INVERTER GROUND INPUT POWER WARNING OR THREE PHASE CAUTION DIRECT CURRENT POWER WAVE 455/R... -
Page 21: General Description
6 minutes of welding and 4 minutes of idling in a ten minute period. EQUIPMENT RECOMMENDED PROCESSES The Power Wave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory prepro- grammed with multiple welding procedures, typically... -
Page 22: Case Front Controls
To clear the error, turn power source off, and back on to reset. See Troubleshooting Section. Steady Red Not applicable. Blinking Red Not applicable. Case Front Layout Power Wave 455/R (Domestic/Canadian Version) POWER WAVE 455/R... -
Page 23: Constant Voltage Welding
0 results in a harsher, cold- er arc while decreasing the wave control to less than 0 provides a softer, hotter arc. (See Figure A.5) FIGURE A.5 Wave Control +10.0 Wave Control 0.00 Wave Control -10.0 Current Time POWER WAVE 455/R... -
Page 24: Pulse Welding
(See Figure A.6) maintain similar arc properties. FIGURE A.6 Wave Control -10.0 Current Wave Control 0.0 Wave Control +10.0 Time POWER WAVE 455/R... -
Page 25: Stt Welding
-10.0 minimizes peak current. In general, the peak current is proportional torch arc length. (See Figure A.8) FIGURE A.8 Wave Control +10.0 Wave Control 0.0 Wave Control -10.0 Current Time POWER WAVE 455/R... -
Page 26: Accessories
In compatible in combination with the Power Wave the event of a low flow condition, a fault signal is Water Cooler K1767-1. sent to the Power Wave and welding output auto- matically stops to protect the torch. POWER WAVE 455/R... -
Page 27: Maintenance
Generally speaking the machine calibration will not need adjustment. However, if the weld per- formance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current. -
Page 28: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 29: Using The Status Led To Troubleshoot System Problems
To clear the error, turn power source off, and back on to reset. Steady Red Not applicable. Blinking Red Not applicable. POWER WAVE 455/R... -
Page 30: Troubleshooting Guide
CAUTION 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. POWER WAVE 455/R... - Page 31 Authorized Field Service Facility. CAUTION 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. POWER WAVE 455/R...
- Page 32 Reset. CAUTION 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. POWER WAVE 455/R...
- Page 33 Solution – Use a shorter length of conduit. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. POWER WAVE 455/R...
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Page 34: Error Codes For The Powerwave
Capacitor precharge failed. Usually accompanied by codes 32-35. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. POWER WAVE 455/R... - Page 35 100 amps, typically result- ing in a condition referred to as "noodle welding" NOTE: For the Power Wave 455/R the secondary limit is 570 amps for the standard stud, and 325 amps for the STT stud and all single phase operation.
- Page 36 DIAGRAMS REAR OF MACHINE POWER WAVE 455/R...
- Page 37 DIAGRAMS REAR OF MACHINE POWER WAVE 455/R...
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Page 38: Connector Pin Definitions
Arclink H cold inch reverse Electrode Voltage Sense gas purge input Ground(0v) +15vdc for shutdown group +40vdc shutdown1 input shutdown2 input input B TABLE 3 VOLTAGE SENSE RECEPTACLE S2 Lead # Function Work Voltage Sense POWER WAVE 455/R... -
Page 39: Connection Diagram
TO SHIELDING GAS DEVICENET CABLE TO PLC/CONTROLLER TO PLC/CONTROLLER ELECTRODE LEAD ELECTRODE LEAD CONTROL CABLE K1795 CONTROL CABLE K1795 SHIELDING GAS WATER COOLER WATER COOLER POWER POWER CONNECTION CONNECT ION WATER LINES WORK WATERCOOLED SENSE TORCH LEAD K940 POWER WAVE 455/R... - Page 40 K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE User supplied User supplied electrode lead electrode lead POWERWAVE DEVICENET CABLE User supplied User supplied work lead work lead K1796 COAXIAL WELD CABLE WORK SENSE LEAD K940 POWER WAVE 455/R...
- Page 41 DIAGRAMS POWER WAVE 455/R...
- Page 42 NOTES POWER WAVE 455/R...
- Page 43 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 44 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 45 • 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...