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Lincoln Electric IM690-A User's Manual

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1. VOLTAGE 440 460V 200 208V 220 230V e 440 460V 550 575V VOLTAGE 550 575V 01 200 208 220 230 e 440 460 Pa 550 575V 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 Connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A 1 on the following page INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes Fuse the input circuit with the recommend ed super lag fuse or delay type breakers also called inverse time or thermal magnetic circuit breakers Choose an input and grounding wire size according to local or national electrical codes Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move this con nection to a different input voltage see the diagram lo
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3. 2 23322 2 23333232 gt L gt 1 gt N 5 x 8 mus Zu i p 1 8 8 1 Y 21 1 E Y Y iun NX NNN NWANNNNNNNNNNN UT POWER WAVE 455 R LINCOLN M18241 F 6 NOTES POWER WAVE 455 R LINCOLN 8 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese BIR Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra ELE EE LATE MLMPT APSSAPRBS NTUSHIELTFSU e SR ER ER 945 e RACHANIE ecran SSE RE Jy AXE ole AMI W o e Qi Quali Ye eani
4. Aie l i ghil Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas EX E Ro e 20 Sel dos Asal L t Cols Vil lu Qai ye Al WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ie BR LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR 2 018 8 60 SUCR RH ND FEE EL ORE IDE Ss FAS EH ETS BEHE Aal d aul 24 AAL Gail guet L LINCOLN amp 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 lincolnelect
5. 1 5 rent Gig 3009 33d QNnOMO W31SAS VOL 9 NS OL 1 est er SLLVM SNHO SHOLSISSY SLIONGAN SHOLIOVAVO San VA LNINOdNO 15813 STOSWAS 13 161 066 SI NMOHS NOLLO3NNOD BOVLIOA 3804 30 74 O N S SIUL ALON ANYA 115 30191534 LLS 52 AGIS 0v SI NMOHS NOLLO3NNOO NOLLISOd NI HOLIMS 39V Td 13008 03120 1 SN3103140 3903 1 143 1 LSHUVAN e ES 109 9 207 wor xO 2 ls 1311934 sod lfldNl l OINOWHVH 2 I lt D uj c HOLMS 108NNOO3H OL t vee lt 8 6 DIAGRAMS TOL UD EEREN LOANNOOSY HOLIMS OL ol yani OL 1 as HoLIMS HOLIMS LOANNOOSY ANIHOVW 30 Q3M3lA SIHL
6. y 319v1d3934 SAIHQ3HIM 19110904 95 168 ze pvo arzal we pc we 1 HOLINNOD 95 TET AYOM ARE VD LAN 3913A TlOHINO2 ANIHOVW 40 3GIS 1331 NVOIHANY HLHON INVHOVIO ONISIM 967 3AVM H3MOd POWER WAVE 455 R LINCOLN E CONNECTOR PIN DEFINITIONS F 3 TABLE 1 INTERFACE CONNECTOR S6 TABLE 4 RS232 CONNECTOR S3 Function Lead Function 15vdc Tach voltage RS232 Receive Tach common RS232 Transmit Tach 1A differential signal 53 Pin5 Tach 1B differential signal 53 Pin4 Tach 2A differential signal 53 Pin20 Tach 2B differential signal 53 Single Tach Input RS232 Common Reserved for future use Voltage sense lead Motor Motor TABLE 5 DEVICENET CONNECTOR S5 Reserved for future use Reserved for future use n Function 40vdc for solenoid 24vdc Devicenet Solenoid input Commom Devicenet Devicenet H Devicenet L Reserved for future use Reserved for future use Shield ground to case Reserved for future use Reserved for future use Reserved for future use for f E Tor future uge 15vdc for Trigger group Trigger input TABLE 2 WIRE FEEDER RECEPTACLE S1 GE Function Dual procedure input 4 Step input Arclink L Arclink H 15vdc for cold inch group cold inch forward Electrode Voltage Sense Ground Ov cold inch revers
7. Section F 6 Parts BT CEET P377Series vi INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 455 K1761 1 K1761 2 INPUT AT RATED OUTPUT THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY CONDITIONS a POWER RATED OUPUT RATED OUPUT K1761 1 450A 38V 100 70 65 35 208 230 460V 60HZ 5A 43V 60 87 82 48 200 220 440V 50 7 400A 36V 100 72 67 36 89 MIN 500 40 60 79 74 41 K1761 2 400 Watts 208 230 460 575 60 7 450 38V 100 58 53 25 22 Max 570 43V 60 82 78 37 31 208 230 460 575V 50HZ 4009 36V 1009e 49 45 23 1 500A 40V 60 6249293 OUTPUT OPEN CURRENT PULSE AND 5 PARAMETERS AUXILIARY POWER CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND CIRCUIT BREAKER VOLTAGE TIME RANGE PROTECTED 75VDC 5 570 0 15 1000 2 5 55 100 MICRO SEC 40 325 AMPS 40 VDC 10 AMPS 3 3 SEC 115VAC 10 AMPS PROCESS CURRENT RANGES DC CURRENT MIG MAG 50 570 Average Amps FCAW 40 570 Average Amps SMAW 30 570 Average Amps Pulse 5 750 Peak Amps STT 40 325 Average Amps RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT TYPE 75 C TYPE 75 C TYPE 75 C VOLTAGE COPPER WIRE IN CON GROUND WIRE IN CON SUPER LAG FREQUENCY DUIT AWG IEC SIZES DUIT AWG IEC SIZES OR BREAKER HZ MM2 SIZE AMPS K1761 1 208 50 60 230 50 60 460 50 60 K1761 2 208 50 60 230 50 60 460 50 60 575
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9. gh la uae DUA dan Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos THEW EA ein IEEE IIS eis ALD al gl e AI Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und perschutz Use prote o para a vista ouvido e corpo RRR ez 12 59 didi due de putes Ci sf A d READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFT
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11. POWER WAVE 455 R LINCOLN B 7 OPERATION B 7 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 Trim in the STT mode adjusts the tailout and background portion of the waveform Trim values greater than 1 0 add more energy to the weld and make the weld puddle hotter trim values less than 1 0 reduce energy to weld A nominal value of 1 0 will work for most applications See Figure A 7 FIGURE A 7 Current Time For most programs peak current is adjusted by wave control values A value of 10 0 maximizes the peak current while a wave control of 10 0 minimizes peak current In general the peak current is proportional torch arc length See Figure A 8 Trim 1 50 Trim 1 00 Trim 0 50 NOTE The ranges on Wave Control and Trim are dependent on the weld programs The values shown are typical ranges FIGURE A 8 Current Wave Control 10 0 Wave Control 0 0 Wave Control 10 0 POWER WAVE 455 R LINCOLN C1 ACCESSORIES 1 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 Install the 5 8 18 male outlet on the regulator to the proper 5 8
12. voltage sense leads as follows TABLE 2 Process Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required 67 lead required Work Voltage Sensing 21 lead 21 lead optional 21 lead optional 21 lead optional 21 lead required Voltage sense at studs Voltage sense at studs 67 lead required 21 lead optional The electrode voltage 67 sense lead is part of to the control cable to the wire feeder For consitent weld quality work voltage sensing is recommended Work Voltage Sensing The Power Waves are shipped from the factory with the work sense lead enabled For processes requiring work voltage sensing con nect the 21 work voltage sense lead from the Power Wave to the work Attach the sense lead to the work as close to the weld as practical Enable the work volt age sensing in the Power Wave as follows A WARNING ELECTRIC SHOCK can kill 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 1 Turn off power to the power source at the discon nect switch 2 Remove the front cover from the power source 3 The control board is on the left side of the power source Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using a pencil or other small object slide the switch right to
13. 49 Single phase error Indicates machine is running on single phase input power Usually caused by the loss of the middle leg L2 Other Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the PS Control Board If cycling the input power on the machine does not clear the error try reloading the operating system If this fails replace the control board A 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 LINCOLN Jequunu y e 10 eu 2 au j sjeued y jo euo uo y LL peised s epoo e eut Aq je 104 eq jou 10 51 5 41 310 c6LED VODOZ LL Jo 3018 IN3NOdWOO ALIAVO HOLIANNOO on r tests ot ve d amen RT E 9999939 4 555855 5905 2999 E 8 3 E B 8 SLIVMSNHO SHOLSIS3H NMOME N WOLOVINOD OL 89 OL el
14. 504 802 EEEE VOL 280 ar a 11112 3001 0313 OL f WC Mas HIT O1F ugs YY HOLIMS zao 193NNO23H OL ASNSS or Y iu Y TM YYYYYYYY Y REAR OF MACHINE 1 Y 1 9 310v1d1034 75 HOLOANNOO Zs ANIHOVW 30 LNOYS Y 1 950 4 223 801 390819318 OL 431009 sagi 85 2 m 1938 I 2 a 12 HOLIMS OL 1934 OL one aoz gt OL DIAGRAMS aassna p 08 a LO VOL 180 L 1 ul moouuor oxazz gt ach E 1 0 5 66258 sur oi Ka BO E 3IOV1ddO3H LI HOTT TED m OL Mt Q8 HOLIMS 061 T Hos L93NNO934 4015 1391 m NIV ANIHOVW 30 SIHL x oL e 182 2131 ONOS OL 3 WERL H een
15. 8 20000 SLTONGAN SHOLIOVAVI be 19 SINIYA LNSNOdNOO 115 40102 ear E 15913 STOBWAS Oe ANIHOVW ACIS LHOIX vel o on 4 MOLDVINOOOL 901 3009 WORM19313 TYNOLLYN 401 Y Had NALSAS V OL 115 emer Soi 099099 SI NMOHS NOLLO3NNOO 116 90 OVT ON Wo SANIT 14408 OL SI NMOHS Amen NOLLISOd 1 NI HOLIMS 32V 1d r zo 13905 Q3 40 SNO IV 3103140 3903 1474 1S24V3N S310N BEEN 2 e 1 69 be oro of 59 1 115 TOI LLS 1701 A as mmm VN 037 8 1 18 VN SERT YYYY zs If OL _ 1934 ovr OL 504
16. General iieri deii eed HORE LC B 3 Recommended Processes and Equipment B 3 Required 10116 4 11 B 3 Bn ce TE B 3 Duty Cycle and Time Period B 3 Case Front Controls 4 Constant Voltage Welding 5 Pulse Welding 6 STT WeldiNg 7 5 5 Section C Optional Equipment iii C 1 Factory EE EE C 1 Field Installed C 1 nem Section D Safety Precautions uet re D 1 Routine Maintenance Periodic Calibration Specification D 1 Troubleshooting Section E How to use Troubleshooting Guide E 1 Using the Status LED to Troubleshoot System E 2 Troubleshooting Guide E 3 thru E 6 Error Codes for the Power Wave E 7 E 8 Wiring el Tel Section F 1 2 Connector Pin Definitions nent Section F 3 Connection Diagrams sens Section F 4 F 5 Dimension
17. beneath the spring loaded output cover at the bottom of the case front A work lead must be run from the negative power source output connection to the work piece The work piece connection must be firm and secure especially if pulse welding is planned CAUTION Excessive voltage drops at the work piece con nection often result in unsatisfactory pulse weld ing performance 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 non standard cables especially in lengths greater than 25 feet can lead to communi cation problems system shutdowns poor motor acceleration poor arc starting and low wire dri ving force wire feeding problems Lincoln control cables are copper 22 conductor cable in a SO type rubber jacket INSTALLATION A 8 EXTERNAL I O CONNECTOR The Power Wave is equipped with a port for making simple input signal connections The port is divided into three groups Trigger group Cold Inch Group and Shutdown Group Because the Power Wave is a slave on the DeviceNet network the Trigger and Cold Inch Groups are disabled when the DeviceNet Gateway is active The shutdown group is always enabled Shutdown 2 is used for signaling low flow in the water cooler Unused shutdowns must be jumpered Machines
18. ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of
19. que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recou
20. the Power Wave Water Cooler K1767 1 POWER WAVE 455 R LINCOLN 0 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e Only Qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment not touch electrically hot parts ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a low pressure airstream to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine PERIODIC MAINTENANCE Calibration of the Power Wave 455 R is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield sat isfactory weld performance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the factory 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 The accuracy of the calibration will be directly affected by t
21. your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and und
22. 11 INTERFACE CONNECTOR S6 12 STT STUD 13 POSITIVE STUD 14 AUXILIARY OUTPUT FIGURE A 4 Case Front Layout Power Wave 455 R Domestic Canadian Version POWER WAVE 455 R LINCOLN B 5 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 Wave control adjusts the inductance of the wave shape This adjustment is often referred to as pinch Inductance is inversely proportional pinch Increasing wave control greater than 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 10 109 3 Current va POWER WAVE 455 R LINCOLN 6 6 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 Using a preset
23. 18 female gas inlet on the back panel of the wire drive Secure fitting with flow adjuster key at top Voltage Sense Leads K940 10 25 or 50 The voltage sense leads connect at the front of the machine See Section A 6 Power Wave Water Cooler K1767 1 See Section F 4 Connection Diagram The K1767 1 is the recommended water cooler for the Power Waves Incorporated into the cooler is an automatic flow sensor to detect low coolant flow In the event of a low flow condition a fault signal is sent to the Power Wave and welding output auto matically stops to protect the torch The water coolers are designed to cool only one welding gun and should be not used to cool multiple guns or other devices Water cooler manufacturers often specify additives to the coolant such as fungicides or alkalides Follow manufacturers recommendations to achieve proper operation and long lifetimes without clogging Water Flow Sensor K1536 1 Water cooled guns can be damaged very quickly if they are used even momentarily without water flow ing Recommend practice is to install a water flow sensor such as on the water return line of the torch When fully integrated into the welding system the sensor will prevent welding if no water flow is pre sent Dual Cylinder Undercarriage K1570 1 Coaxial welding Cable K1796 See Section F 5 Connection Diagram The Dual Cylinder Undercarriage K1570 1 is not compatible in combination with
24. 50 60 POWER WAVE 455 LINCOLN 8 2 INSTALLATION 2 PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT K1761 1 247 lbs 26 10 in 19 86 in 32 88 in 112 kg 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 LINCOLN 3 SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before work ing on the equipment Do not touch electrically hot parts Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Do not use Power Waves in outdoor environments The Power Wave power source should not be subject ed to falling water nor should any parts of it be sub merged in water Doing so may cause improper opera tion as well as pose a safety hazard The best practice is to keep the machine in a dry sheltered area Place the welder where clean cooling air can freely cir culate in through the rear louvers and out through the case sid
25. EN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 6 e SH7IAE 2 4 205 717471 AHBSMAS aaa oe lue bacs d e Maul ge gaal us e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e X7TTL2A 9 U ACWRUPD PRE gt RK AGS
26. RETURN TO MAIN MENU Ld IM690 A POWER WAVE 455 R For use with machines having Code Numbers 10675 10676 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 150 9001 6 lesigned Inder o 6 60974 1 OPERATOR S MANUAL LINCOLN Copyright 2001 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines T
27. Surface Tension transfer process STT is supported at currents up to 325 amps at 10096 duty cycle If the duty cycle is exceeded a thermostat will shut off the output until the machine cools to a reasonable operating temperature RECOMMENDED PROCESSES AND 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 including GMAW GMAW P FCAW GTAW and STT for a variety of materials including mild steel stain less steel cored wires and aluminum The STT process supports mild steel and stainless steel weld ing The Power Wave 455 R is recommended only for automatic or mechanized applications such as robotic welding RECOMMENDED EQUIPMENT Automatic Operation All welding programs and procedures are set through software for the robotic Power Waves FANUC robots equipped with RJ 3 controllers may communi cate directly to the Power Wave Other pieces of equipment such PLC s or computers can commu nicate to the Power Wave using DeviceNET All wire welding processes require a robotic Power Feed wire feeder REQUIRED EQUIPMENT PF 10 R Wire Feeder K1780 1 Control Cables 22 pin to 22 pin K1795 10 25 50 100 Control Cables for use on FANUC robot arm 22 pin to 14 pin 10 ft K1804 1 Control Cables for use on FANUC robo
28. are Selectable Line 0 Default Setting Line 62 POWER WAVE 455 R LINCOLN 1 SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill Unless using cold feed feature when feeding with gun trigger the electrode and drive mechanism are always elec trically energized and could remain energized several seconds after the welding ceases 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 FUMES AND GASES can be dan erous 9 AR Keep your head out of fumes 77 Use ventilation or exhaust to remove fumes from breathing zone ant WELDING SPARKS can cause fire or explosion y 7 Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection De Observe additional guidelines detailed in the begin ning of this manual POWER WAVE 455 R LINCOLN 2 O 0 SYMBOLS THAT APPEAR THIS MACHINE OR IN THIS MANUAL INPUT POWER ON OFF HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER p
29. cated on the inside of the input access door If the main reconnect switch or link position is placed in the wrong position the welder will not produce output power If the Auxiliary A lead is placed in the wrong position there are two possible results 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 If this occurs turn off the input voltage properly connect the A lead reset the breakers and try again POWER WAVE 455 R LINCOLN 5 INSTALLATION A 5 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 Do not combine all of the work leads into one lead The welding travel direc tions should be in the direction moving away from the work lead as shown below Connect all of the work sense leads from each power source to the work piece at the end of the weld For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves When these parameters are identical the pulsing fre quency will be the same hel
30. cover from the power source 3 The wire feed head board is on the right side of the power source Locate the 8 position DIP switch and look for switch 7 of the DIP switch 4 Using pencil other small object slide the switch right to the OFF position for positive electrode polarity Conversely slide the switch left to the ON position for negative electrode polarity 1 2 3 4 5 6 7 8 POWER WAVE 455 R LINCOLN 7 INSTALLATION A 7 5 Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately VOLTAGE SENSING The best arc performance occurs when the Power Waves have accurate data about the arc conditions 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 CAUTION If the voltage sensing is enabled but the sense leads are missing or improperly connected extremely high welding outputs may occur Do not tightly bundle the work sense lead to the work lead The ELECTRODE sense lead 67 is built into the K1795 control cable The WORK sense lead 21 con nects to the Power Wave at the four pin connector located underneath the output stud cover Enable the
31. e switch 8 2 work sense lead 1 LEASE SIGNIFICANT 2 MOST SIGNIFICANT BIT switch 8 work sense lead work sense lead not connected work sense lead connected INSTALLATION A 10 Feed Head Board DIP Switch switch 1 Object Instance LSB see table 1 switch 2 Object Instance MSB see table 1 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 Equipment Group 3 Select switch 6 Equipment Group 4 Select switch 7 negative polarity switch switch 7 electrode polarity positive default switch 8 high speed gear switch 8 low speed gear default high speed gear DeviceNET Gateway Board DIP Switch Bank S1 switch 1 Object Instance LSB see table1 switch 2 Object Instance MSB see table 1 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 Equipment Group 3 Select switch 6 Equipment Group 4 Select switch 7 Reserved for future use switch 8 Reserved for future use TABLE 1 Object Instance POWER WAVE 455 R LINCOLN 11 INSTALLATION A 11 Bank S2 switch Description 1 Devicenet Baud Rate see table 2 TABLE 2 Prior to S24958 6 software switch 1 off on off on 24958 6 and later software SWItC baud rate off 125K off 250K 500K Programmable value switch Description 3 Devicenet Mac ID thru see table 3 8 TABLE 3 SWITCH SECH 7ISWITCH 6 SWITCH S SWITCH Een Softw
32. e gas purge input 15vdc for shutdown group 40vdc shutdown1 input shutdown2 input input B Jo O1 PS TABLE 3 VOLTAGE SENSE RECEPTACLE S2 Lead Function Work Voltage Sense POWER WAVE 455 R LINCOLN F 4 CONNECTION DIAGRAM Hard Automation Electrode Positive STT Configuration DEVICENET CABLE TO SHIELDING GAS TO PLC CONTROLLER ELECTRODE LEAD CONTROL CABLE K1795 co o Jo C2 954 SHIELDING GAS WATER COOLER POWER CONNECTION WORK WATERCOOLED SENS et LEAD POWER WAVE 455 R LINCOLN F 4 5 CONNECTION DIAGRAM F 5 Robotic Set Up Electrode Positive CV Pulse Configuration CONTROL CABLE K1805 1 K1804 1 CONTROL CABLE OR K1804 2 AND ANY K1795 CONTROL CABLE User supplied electrode lead DEVICENET CABLE User supplied work lead K1796 COAXIAL WELD CABLE WORK SENSE LEAD POWER WAVE 455 R LINCOLN F 6 DIMENSION PRINT POWER WAVE 455 DIAGRAMS s 2 5 N yyy N 5 2 23322 2 SIDS yyy
33. e Facility 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 LINCOLN 2 USING THE STATUS LED 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 Alternating Green and Red Steady Red Blinking Red TROUBLESHOOTING E 2 always check the color of the Status LED and refer to the following chart to help you determine which system component power source wire feeder wire drive etc may be faulty Replace the components identified as potentially faulty with known good components and the system should operate normally System OK Power source communicating normally with wire feeder and its components Occurs during a reset and indicates the Power Wave is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during opera tion Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the Power Wave Read the
34. eaker CB4 in recon nect area may have opened Reset Also check input volt age selection below Input voltage selection made improperly Power down check input voltage reconnect according to diagram on reconnect cover RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln 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 LINCOLN 8 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Thermal LED is lit Fan thermostat has opened Check for proper fan opera tion Fan should run whenev er main power is on Check for material blocking intake or exhaust louvers or for exces sive dirt clogging cooling channels in machine Secondary rectifier thermostat has opened After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers Machine won t weld can t get any Input voltage is too low or too output CR1
35. ended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode 12222853 s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylind
36. engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nib minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to overr
37. error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be sepa rated by a green light To clear the error turn power source off and back on to reset Not applicable Not applicable POWER WAVE 455 R LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal covers are removed Input fuses keep blowing or input breaker keeps tripping Machine will not power up no lights no fan etc POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service facility for technical assis tance Make certain that fuses or breakers are properly sized See Installation section of this manual for recommended fuse and breaker sizes Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle or both There is internal damage to the power source Contact an authorized Lincoln Electric Service facility Make certain that the Power Switch SW1 is in the position Circuit br
38. ers should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 POWER WAVE 455 R LINCOLN 8 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien
39. erstand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 POWER WAVE 455 R LINCOLN SAFETY WELDING SPARKS can gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecomm
40. es and bottom 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 Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns Machines above code 10500 are equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under loaded or open circuit conditions The fan also runs for a period of time approximately 5 minutes after the output is disabled to ensure all components are properly cooled If desired the F A N feature can be disabled causing the fan to run whenever the power source is on To disable F A N connect leads 444 and X3A together at the output of the solid state fan control relay located on the back of the Control PC board enclosure See Wiring Diagram CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES INSTALLATION A 3 Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides LIFTING Lift the machine by the lift bail only The lift bail is designed to lift the power source only Do not attempt to lift the Power Wave with accessories attached to it STACKING Power Wave machines can be stacked
41. es 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 EEE _______ 11 CAN communication bus off Probably due to excessive number of communication errors 12 User Interface time out error User Interface is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or control cable 21 Unprogrammed Weld Mode Contact the Service Department for instructions on reloading the Welding Software 22 Empty Weld Table Contact the Service Department for instructions on reloading the Welding Software 23 Weld Table checksum error Contact the Service Department for instructions on reloading the Welding Software Primary overcurrent error Excessive Primary current present May be related to a switch board or output rectifier failure Capacitor A under voltage Low voltage on the main capacitors May be caused by improper input Left side facing machine configuration When accompanied by an overvoltage error on the same side it indi Capacitor B under voltage cates no capacitor voltage present on that side and is usually the result Right side facing machine of an open or short in the primary side of the machine A over voltage Excess voltage on the main capacitors Ma
42. from the factory come with the shutdowns already jumpered See Figure A 3 FIGURE A 3 Shutdown2 input Water Fault Dual Procedure Input 4 Step Input Cold Inch Forward Cold Inch Reverse Gas Purge Input 15 for shutdown group Shutdown1 input Reserved for future use Trigger Input 15 VDC for Cold Inch Group 2 o e O 2 O gt te T POWER WAVE 455 R LINCOLN 9 INSTALLATION 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 To change Gear ratio see Power Feed 10 R Instruction Manual A WARNING ELECTRIC SHOCK can kill 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 1 Set the High Low switch code on Wire Drive PC board as follows Turn off power to the power source at the discon nect switch Remove the front cover from the power source The wire feed head board is on the right side of the power source Locate the 8 position DIP switch and look for position 8 of the DIP switch Using a pencil or other small object slide the switch right to the OFF position when the low speed
43. gear is installed Conversely slide the switch left to the ON position when the high speed gear is 22 lt installed 12 3 4 5 6 7 8 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 LINCOLN 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 A WARNING Turn off power at the disconnect switch Remove the top four screws securing the front access panel Loosen but not completely remove the bottom two screws holding the access panel Open the access panel allowing the weight of the panel to be carried by the bottom two screws Make sure to prevent the weight of the access panel from hanging on the harness Adjust the DIP switches as necessary Replace the panel and screws and restore power Control Board Feed Head Board Left Right i DeviceNET Gateway Board Control Board DIP Switch switch 1 Object Instance LSB see table 1 switch 2 Object Instance MSB see table 1 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 Equipment Group 3 Select switch 6 Equipment Group 4 Select switch 7 reserved for future us
44. he Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 1 To avoid scalding do remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 Sem MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot
45. he accuracy of the mea suring equipment you use Detailed instructions are available with the utility POWER WAVE 455 R LINCOLN D 1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE A 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Servic
46. ide the governor idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 POWER WAVE 455 R LINCOLN 8 SAFETY 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or
47. ing or servicing machine Do not operate with covers removed ELECTRIC not touch electrically live parts SHOCK CAN KILL Only qualified persons should install use or service this equipment VOLTAGE 220 230V 200 208V 220 230V E 380 415 440 460 VOLTAGE 200 208V 200 208V 220 230V 380 415V 440 460V VOLTAGE 440 460V 200 208V 220 230V 380 415V 440 460V 380 415 440 460 Lol 200 208 o T e D N 4 Disconnect power before inspecting or servicing machine Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install a gt 5 gt d o 2 2 220 230 VOLTAGE z 200 208V 200 208V 220 230 ON 440 460 pe 550 575V use or service this equipment VOLTAGE 220 230V 200 208V 220 230 IN 440 460V 550 575
48. lectrode autour de n importe quelle partie NS LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et di
49. minor personal injury or damage to this equipment TABLE OF CONTENTS Page INSTANT ON ip Een Section A Technical Specifications Power Wave 455 R _ 1 2 Safety Wed 3 Select Suitable Location A 3 RER A 3 Stacking EE A 3 Machin Grounding eee A 3 High Frequency Protection A 3 Input Connection EE A 3 Input Fuse and Supply Wire Considerations 2 4 Input Voltage Change Over Procedure 4 Welding with Multiple Power Waves A 5 Electrode and Work Cable Connections A 6 Negative Electrode Polarity AAA A 6 Voltage Sensing at the Work A 7 Power Wave Power Feed Wire Feeder A 8 Control Cable Specifications A 8 External Connector sise A 8 High Speed Gear BOX ite ne Ce e A 9 Dip Switch Settings and Locations A 10 Control Board Dip Switch A 10 Feed Head Board Dip Switch ss A 10 Devicenet Gateway Board Dip Switch Bank 51 A 10 Bank 82 11 22 22 25 Hi ee AR eee Section B Safety TEE B 1 Graphic Symbols that appear on this machine or in this manual B 2
50. o INPUT POWER THREE PHASE DIRECT CURRENT POWER WAVE 455 R B 2 SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION B 3 OPERATION 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 Each component in the system has special circuitry to talk with the other system components so each component power source wire feeder electrical accessories knows what the other is doing at all times The components communicate using Arc Link protocol Robotic systems can communicate with other industri al machines via DeviceNET protocol The result is a highly intrigated and flexible welding cell GENERAL DESCRIPTION POWER WAVE 455 R The Power Wave 455 R is a high performance digital ly controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW GTAW and STT processes It carries an out put rating of either 450 amps 38 volts or 400 amps 36 volts both at 10096 duty cycle depending on input voltage and frequency The
51. oaxial welding cable is recommended to reduce the cable inductance in long distance Pulse and STT applications up to 300 amps When using an inverter type power source like the Power Waves use the largest welding electrode and ground cables that are practical At least 2 0 copper wire even if the average output current would not normally require it CAUTION When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if under sized welding cables are used Most welding applications run with the electrode being positive For those applications connect one end of the electrode cable to the positive output stud on the power source located beneath the spring loaded output cover near the bottom of the case front Connect the other end of the electrode cable to the wire drive feed plate using the stud lockwasher and nut provided on the wire drive feed plate The electrode cable lug must be against the feed plate Be sure the connection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in the work cable connections section Connect a work lead from the negative power source output stud to the work piece The work piece connection must be firm and secure especially if pulse welding is planned Excessive voltage drops caused by poor work piece connections of
52. ping to stabilize the arcs Every welding gun requires a seperate shielding gas regulator for proper flow rate and shielding gas cover age Do not attempt to supply shielding gas for two or more guns from only one regulator If an anti spatter system is in use then each gun must have its own anti spatter system See Figure A 2 FIGURE A 2 TWO POWER WAVES Travel Connect All Welding Work Leads at the Beginning of the Joint irection Connect All Work Sense Leads at the End of the Joint POWER WAVE 455 R LINCOLN 6 INSTALLATION A 6 ELECTRODE AND WORK CABLE CAUTION 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 Avoid excessive lengths and do not coil excess cable Do not tightly bundle the electrode and work cables together Use K1796 Coaxial welding cables wherever possible See Section F 5 Connection Diagram Minimum work and electrode cables sizes are as follows TABLE 1 Current 6096 Duty Cycle MINIMUM COPPER WORK CABLE SIZE AWG Up To 100 Ft Length 30 m 2 0 67 mm2 3 0 85 mm2 3 0 85 mm2 400 Amps 500 Amps 600 Amps NOTE K1796 c
53. ric com
54. rned off In the STT mode the arc is exces 1 Check that the 21 work sense sively long and erratic lead is connected In the STT mode the spatter is high 1 Check that the 21 work sense er than normal and the arc is incon lead is connected sistent 2 Verify that the electrode lead is connected to the STT stud and not the POWERWAVE stud 3 Check that the POWERWAVE stud is not electrically connected to the STT stud The feeder will not cold inch wire 1 Check for fault signals from the connector Possible faults are lack of water flow water cooler turned off Arc loss fault on robot 1 Possibly caused by wire feeding f all recommended possible areas problem of misadjustments have been checked and the problem persists 2 Problem Conduit leading to the contact your local Lincoln wire feeder has bends or twists Authorized Field Service Facility which can reduce the wire feed speed Solution Remove bends and twists from conduit 3 Problem Conduit leading up to the wire feeder from the wire reel is too long Solution Use a shorter length of conduit 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 LINCOLN 7 TROUBLESHOOTING 7 Observe all Safety Guidelin
55. spositifs de s ret leur place POWER WAVE 455 R LINCOLN for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid
56. t arm 22 pin to 14 pin 18 in K1805 1 Control Cables for use on FANUC robot arm 22 pin to 14 pin 18 in K1804 2 LIMITATIONS The Power Wave 455 R is not suitable for SMAW CAC A or other processes not listed Power Waves are not to be used in outdoor environ ments Only Arc Link Power Feed wire feeders and user interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used DUTY CYCLE AND TIME PERIOD The Power Feed wire feeders are capable of welding at a 10096 duty cycle continuous welding The power source will be the limiting factor in determining system duty cycle capability Note that the duty cycle is based upon a ten minute period A 6096 duty cycle repre sents 6 minutes of welding and 4 minutes of idling in a ten minute period POWER WAVE 455 R LINCOLN B 4 OPERATION B 4 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 Normal operation is a steady green light Error conditions are indicated per table 4 NOTE The robotic Power Waves status light will flash green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up TABLE 4 condition Condition S
57. teady Green System OK Power source communicating normal poem ly with wire feeder and its components Occurs during a reset and indicates the PW 455 R is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system con figuration is changed during operation Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the PW 455 R Read the error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be sepa rated by a green light To clear the error turn power source off and back on to reset See Troubleshooting Section Not applicable Blinking Red Not applicable 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled until the machine cools down When cool the light goes out and output is enabled 4 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply 5 10 AMP AUXILIARY POWER CIRCUIT BREAKER Protects 115 volt AC case front receptacle auxiliary supply 6 LEAD CONNECTOR S2 SENSE LEAD 7 5 PIN ARC LINK S1 8 5 PIN DEVICENET CONNECTOR S5 9 1 CONNECTOR 10 NEGATIVE STUD
58. ten result in unsatisfactory welding performance When welding with the STT process use the positive output connection labeled STT for STT welding If desired other welding modes can be used on this stud however their average output current will be lim ited to 325 amps For non STT processes use the positive output connection labeled Power Wave so that the full output range of the machine is available CAUTION Do not connect the STT and Power Wave stud together Paralleling the studs will bypass STT cir cuitry and severely deteriorate STT welding perfor mance See Section F 3 Connection Diagram NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud When operating with electrode polarity negative the switch 7 must be set to ON on the Wire Feed Head PC Board The default setting of the switch is OFF to rep resent positive electrode polarity Set the Negative Polarity switch on Wire Feed Head PC board as follows WARNING ELECTRIC SHOCK can kill e 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 1 Turn off power to the power source at the disconnect Switch 2 Remove the front
59. the OFF position if the work sense lead is NOT connect ed Conversely slide the switch left to the ON position if the work sense lead is 02 e present 12 3 4 5 6 7 8 5 Replace the cover screws The PC board will read the switch at power up and configure the 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 LINCOLN 8 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 For convenience sake the electrode and control cables can be routed behind the left or right strain reliefs under the spring loaded output cover and along the channels formed into the base of the Power Wave out the back of the channels and then to the wire feeder Output connections on some Power Waves are made via 1 2 13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front On machines which carry the CE mark output connections are made via Twist Mate receptacles that are also located
60. the input voltage is prop er according to the Rating Plate located on the rear of the machine Input may be single phased Make certain the input voltage is proper on all three input lines Check for proper Wire Feed Speed setting In CV MIG and FCAW modes check for proper Voltage setting In the MIG MAG pulse modes check the Trim setting These controls are on the wire feed er Check for proper shielding gas mix and flow Check for loose or faulty weld cables and cable connections Circuit breaker CB2 on case front may have opened Reset Circuit breaker 4 in recon nect area may have opened Reset RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you 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 LINCOLN 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION WELDING PROBLEMS PowerWave is triggered to weld 1 Check for fault signals from the but there is no output connector Possible faults are lack of water flow water flow tu
61. to a maximum of 3 high CAUTION The bottom machine must always be placed on a firm secure level surface There is a danger of machines toppling over if this precaution is not taken MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PROTECTION Locate the Power Wave away from radio controlled machinery CAUTION The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTION WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electrical codes and the connection dia gram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line A 1 75 inch 45 mm diameter access hole for the input supply is located on the upper left case back next to the input access door POWER WAVE 455 R LINCOLN 4 INSTALLATION K1761 1 FIGURE A 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM TAN WARNING Disconnect input power before inspect
62. voltage becomes impractical and instead the arc length is set by adjusting trim Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length Most pulse welding programs are syngeric As the wire feed speed is adjusted the Power Wave will automatically recalculate the waveform parameters to maintain similar arc properties The Power Wave utilizes adaptive control to compensate for changes in electrical stick out while welding Electrical stick out is the distance from the contact tip to the work piece The Power Wave waveforms are optimized for a 0 75 19mm stick out The adaptive behavior supports a range of stickouts from 0 50 13mm to 1 25 32mm At very low or high wire feed speeds the adaptive range may be less due to reaching physical limitations of the welding process Wave control in pulse programs usually adjusts the focus or shape of the arc Wave control values greater than 0 increase the pulse frequency while decreasing the background current resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of position welding See Figure A 6 FIGURE A 6 Wave Control 10 0 Wave Control 0 0 Current Wave Control 10 0 Time
63. vrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble
64. will not pull in high Make certain that input voltage is proper according to the Rating Plate located on the rear of the machine If all recommended possible areas If the Thermal LED is also lit Of misadjustments have been see Yellow Thermal LED is checked and the problem persists Lit section contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you 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 LINCOLN 8 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine often noodle welds out put is limited to approximately 100 amps when running a particular procedure Machine won t produce full output For no apparent reason the weld ing characteristics have changed Auxiliary receptacle is dead no auxiliary voltage Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Secondary current limit has been exceeded and the machine has phased back to protect itself Adjust proce dure or reduce load to lower current draw from the machine Input voltage may be too low limiting output capability of the power source Make certain that
65. y be caused by improper Left side facing machine input configuration When accompanied by an undervoltage error on the same side it indi Capacitor B over voltage cates no capacitor voltage present on that side and is usually the result Right side facing machine of an open or short in the primary side of the machine Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 37 Softstart error Capacitor precharge failed Usually accompanied by codes 32 35 A 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 LINCOLN 8 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual Error Code Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 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 43 Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35

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