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RETURN TO MAIN MENU
IM716
POWER WAVE
455/STT
October, 2003
™
10835
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.
R
IEC 60974-1
OPERATOR'S MANUAL
Copyright © 2003 Lincoln Global Inc.
• 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
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric POWER WAVE IM716
Summary of Contents for Lincoln Electric POWER WAVE IM716
- Page 1 RETURN TO MAIN MENU IM716 POWER WAVE 455/STT October, 2003 ™ 10835 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 ...
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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 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.
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Page 7: Table Of Contents
Installation ...Section A Technical Specifications - POWER WAVE 455 ...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 Input Voltage Change Over Procedure...A-3 Elctrode and Work Cable Connection...A-3 Cable Inductance, and its Effects on Pulse Welding ...A-4 Negative Electrode Polarity ...A-4... -
Page 8: Table Of Contents
Troubleshooting ...Section E How to use Troubleshooting Guide ...E-1 Using the Status LED to Troubleshoot System Problems ...E-2 Troubleshooting Guide...E-3 thru E-7 ________________________________________________________________________ Wiring Diagram ...Section F-1 Connection Diagram...Section F-2, F-3 Dimension Print...Section F-4 ________________________________________________________________________ Parts Lists ...P394 Series ________________________________________________________________________ TABLE OF CONTENTS Page... -
Page 9: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT (K1518-4) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS CONDITIONS 208/230/460/575V - 60HZ. 450A@38V.100% 570A@43V. 60% 200/220/440/575V - 50HZ. 400A@36V.100% 500A@40V. 60% OPEN CURRENT PULSE CIRCUIT RANGE / FREQUENCY VOLTAGE 75 VDC 5 - 570 0.15 - 1000 Hz 5 - 325... -
Page 10: Safety Precautions
Dirt, dust, or any foreign material 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. Failure to observe these precautions can result in excessive operating tem- peratures and nuisance shutdowns. -
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: Cable Inductance, And Its Effects On Pulse Welding
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 13: 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 14: System Description
SYSTEM DESCRIPTION The Power Wave 455/STT and Power Feed 10/11 family of products utilize a digital communication sys- tem called Linc-Net. Simply put, Linc-Net allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communica- tion, and because of its bus-like structure, the compo- nents may be connected to the network in any order,... -
Page 15: System Set-Up
Basic Rules • Each group is required to have one user interface. No group may have more than one user interface. • Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads. - Page 16 INSTALLATION Multiple Group System FIGURE A.9 No “FH0 Alllowed! Single Group Multi-Head System FIGURE A.10 No “FH0 Alllowed! Dual Head option allows the abil- ity to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings.
- Page 17 INSTALLATION Single Group Multi-Head System (Alternate Method) FIGURE A.11 No “FH0 Alllowed! When a standard User Iterface is used in a group with multi- ple Feed Heads, all of the Feed Heads use a single set of procedures. POWER WAVE 455/STT...
- Page 18 A-10 CAUTION POWER WAVE POWERWAVE INSTALLATION FIGURE A.2 TWO POWER WAVES Travel Direction Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 455/STT A-10 CAUTION POWER WAVE POWERWAVE Connect All Work Sense Leads at the End of the Joint...
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Page 19: Multiple Arc Sense Lead And Work Lead Placement Guidelines
A-11 MULTIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Arc #1 Current Flow Arc #2 Arc #1 Power Source Current Flow Work #1 Sense #1 Arc #1 Current Flow Arc #2 Sense #1 Sense # 2 INSTALLATION Power Source Ø... -
Page 20: I / O Receptacle Specifications
A-12 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 nyour 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 455/STT SMAW GMAW FCAW GTAW OPEN CIRCUIT... -
Page 23: General Description
GENERAL DESCRIPTION The Power Wave semi-automatic 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, and pulse welding modes. The surface tension transfer mode is supported only by the 455/STT. -
Page 24: 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 25: 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 26: Welding Mode
OPERATION • VOLTS / TRIM: In constant voltage modes (synergic CV, standard CV) the control adjusts the welding voltage. In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting to adjust the arc length. It is adjustable from 0.500 to 1.500. A Trim set- ting of 1.000 is a good starting point for most condi- tions. -
Page 27: Constant Voltage Welding
CONSTANT VOLTAGE WELDING Synergic CV: For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The nominal preprogrammed volt- age is the best average voltage for a given wire feed speed, but may be adjusted to preference. -
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: Wave Control
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 vari- ables effect the waveform. Trim in the STT mode adjusts the tailout 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 PowerWave WaterCooler, K1767-1 * Water Flow Sensor, K1536-1 *The Dual Cylinder Undercarriage, K1570-1 is not compatible in combination with the Power Wave WaterCooler K1767-1. -
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 problem, contact the Lincoln Electric Company for the calibration 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 feedhead) 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 455/STT 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 per- formance Excessively long and erratic arc 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.
- Page 39 DIAGRAMS REAR OF MACHINE POWER WAVE 455/STT...
- Page 40 Connection Diagram Semi-automatic "Simple System" (Electrode Positive,CV/Pulse Configuration shown) POWER WAVE / STT WORK WORK SENSE CONNECTION DIAGRAM CONTROL CABLE K1543 POWER WAVE 455/STT CV/PULSE STUD WIRE FEEDER...
- Page 41 DIAGRAMS 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...
- Page 42 DIAGRAMS POWER WAVE 455/STT...
- Page 43 NOTES POWER WAVE 455/STT...
- Page 44 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 45 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- 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...