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POWER WAVE
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
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
RETURN TO MAIN MENU
™
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 Electric POWER WAVE IM690-A
Summary of Contents for Lincoln Electric POWER WAVE IM690-A
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Page 1: Power Wave
POWER WAVE 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
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
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 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
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 Electrode and Work Cable Connections...A-6 Negative Electrode Polarity ...A-6... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS (K1761-1) 450A@38V.100% 208/230/460V - 60HZ. 570A@43V. 60% 400A@36V.100% 200/220/440V - 50HZ. 500A@40V. 60% (K1761-2) 450@38V.100% 208/230/460/575V-60HZ. 570@43V.60% 400@36V.100% 208/230/460/575V-50HZ. 500A@40V. 60% OPEN CURRENT PULSE... - Page 9 HEIGHT 26.10 in 663 mm OPERATING TEMPERATURE RANGE -20°C to +40°C INSTALLATION PHYSICAL DIMENSIONS WIDTH DEPTH 19.86 in 32.88 in 505 mm 835 mm TEMPERATURE RANGES STORAGE TEMPERATURE RANGE POWER WAVE 455/R WEIGHT (K1761-1) 247 lbs. 112 kg. (K1761-2) 295lbs. 133 kg.
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Page 10: Safety Precautions
Dirt, dust, or any foreign mater- ial 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 11: Input Fuse And Supply Wire Considerations
If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary (A) lead is placed in a position lower than the applied line volt- age, the welder will not come on, and the two circuit breakers in the reconnect area will open. -
Page 12: 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 13: Electrode And Work Cable Connections
ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. -
Page 14: Voltage Sensing
Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc condi- tions and can have a dramatic effect on performance. -
Page 15: Power Wave / Power Feed Wire Feeder Interconnections
POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Waves is located under the spring loaded output cover, near the bottom of the case front. The control cable is keyed and polarized to prevent improper connection. -
Page 16: High Speed Gear Box
HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. -
Page 17: Dip Switch Settings And Locations
A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches: WARNING • Turn off power at the disconnect switch. ------------------------------------------------------------------------ • Remove the top four screws securing the front access panel. -
Page 18: Bank (S2
A-11 Bank (S2): switch Description Devicenet Baud Rate (see table 2) TABLE 2 Prior to S24958-6 software switch 1 switch 2 baud rate Programmable value 125K 250K 500K S24958-6 and later software switch 1 switch 2 baud rate 125K 250K 500K Programmable value Bank (S2):... -
Page 19: Operation
SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Observe additional guidelines detailed in the begin- ning of this manual. -
Page 20: 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 455/R SMAW GMAW FCAW GTAW OPEN CIRCUIT... -
Page 21: General Description
GENERAL DESCRIPTION The Power Wave power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, Surface Tension Transfer and pulse welding modes. The Power Wave power source is designed to be used with the family of Power Feed wire feeders, operating as a system. -
Page 22: Case Front Controls
CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure A.4) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. -
Page 23: Constant Voltage Welding
OPERATION CONSTANT VOLTAGE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes the Power Wave will automatically adjust the voltage correspondingly. -
Page 24: 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 25: Stt Welding
STT WELDING The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the variables effect the waveform. Current Time For most programs, peak current is adjusted by wave control values. -
Page 26: Accessories
OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for the Power Wave 455R. FIELD INSTALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive unit. -
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 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
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case front can help diagnose problems down to the system component (power source, wire feeder, wire drive, etc.) level. If, for any reason, the system does not appear to be working properly, Steady Green Blinking Green... -
Page 30: Troubleshooting Guide
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 detailed in the beginning of this manual. - Page 31 (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 detailed in the beginning of this manual.
- Page 32 . 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 detailed in the beginning of this manual.
- Page 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The PowerWave is triggered to weld, but there is no output. In the STT mode, the arc is exces- sively long and erratic. In the STT mode, the spatter is high- er than normal and the arc is incon- sistent.
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Page 34: Error Codes For The Powerwave
Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the PW-455 can output via the status light (see "Troubleshooting the PowerWave / Power Feed System Using the Status LED"). Error Code # CAN communication bus off. - Page 35 Observe all Safety Guidelines detailed throughout this manual Error Code # Secondary overcurrent error Capacitor delta error Single phase error Other 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.
- Page 36 DIAGRAMS REAR OF MACHINE MACHINE FRONT POWER WAVE 455/R...
- Page 37 DIAGRAMS REAR OF MACHINE MACHINE FRONT POWER WAVE 455/R...
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Page 38: Connector Pin Definitions
CONNECTOR PIN DEFINITIONS TABLE 1 INTERFACE CONNECTOR S6 Lead # Function +15vdc Tach voltage Tach common Tach 1A differential signal Tach 1B differential signal Tach 2A differential signal Tach 2B differential signal Single Tach Input Reserved for future use Voltage sense lead Motor "+"... -
Page 39: Connection Diagram
Hard Automation, Electrode Positive, STT Configuration SHIELDING GAS WATERCOOLED TORCH CONNECTION DIAGRAM DEVICENET CABLE TO SHIELDING GAS DEVICENET CABLE TO PLC/CONTROLLER TO PLC/CONTROLLER CONTROL CABLE K1795 CONTROL CABLE K1795 WATER COOLER WATER COOLER POWER POWER CONNECTION CONNECT ION WATER LINES WORK SENSE LEAD... - Page 40 Robotic Set Up, Electrode Positive, CV/Pulse Configuration CONTROL CABLE K1805-1 CONTROL CABLE K1805-1 User supplied User supplied electrode lead electrode lead User supplied User supplied work lead work lead WORK SENSE LEAD K940 CONNECTION DIAGRAM K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE DEVICENET CABLE K1796 COAXIAL WELD CABLE POWER WAVE 455/R...
- Page 41 DIAGRAMS POWER WAVE 455/R...
- Page 42 NOTES POWER WAVE 455/R...
- Page 43 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 44 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- 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...