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IM690-A
May, 2001
™
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
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455/R ..............................................A-1,A-2 Safety Precautions.................................................................................................A-3 Select Suitable Location ........................................................................................A-3 Lifting....
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY CONDITIONS CURRENT POWER @ RATED OUPUT @ RATED OUPUT AMPS (K1761-1) 70/65/35 450A@38V.100% 208/230/460V - 60HZ. 570A@43V. 60% 87/82/48 .89 MIN. 400A@36V.100% 200/220/440V - 50HZ. 72/67/36 500A@40V. 60% 79/74/41 400 Watts 88% (K1761-2) Max. 450@38V.100% 58/53/25/22 208/230/460/575V-60HZ. 570@43V.60% 82/78/37/31 .95
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A-2 A-2 INSTALLATION PHYSICAL DIMENSIONS WEIGHT HEIGHT WIDTH DEPTH (K1761-1) 247 lbs. 112 kg. 26.10 in 19.86 in 32.88 in 663 mm 505 mm 835 mm (K1761-2) 295lbs. 133 kg. TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE -20°C to +40°C -40°C to +40°C POWER WAVE 455/R
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A-3 A-3 INSTALLATION Where there is a combustible surface directly under SAFETY PRECAUTIONS stationary or fixed electrical equipment, that surface Read this entire installation section before you shall be covered with a steel plate at least start installation. .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides. WARNING LIFTING ELECTRIC SHOCK can kill. Lift the machine by the lift bail only. The lift bail is • Only qualified personnel should desi
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A-4 A-4 INSTALLATION (K1761-1) FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE=200-208V W / L3 WARNING 200-208V V / L2 CR1 . Disconnect input power before 220-230V inspecting or servicing machine. U / L1 ’A’ . Do not operate with covers 380-415V removed. 440-460V . ELECTRIC Do not touch electrically live parts. SHOCK Only qualified persons should install, CAN KILL use or service this equipment. VOLTAGE=220-
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A-5 A-5 INSTALLATION For the best results when pulse welding, set the wire WELDING WITH MULTIPLE POWER size and wire feed speed the same for all the Power WAVES Waves. When these parameters are identical, the pulsing fre- CAUTION quency will be the same, helping to stabilize the arcs. Special care must be taken when more than one Power Wave is welding simultaneously on a single Every welding gun requires a seperate shielding gas part. Arc blow and arc interference may occur or regulator for p
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A-6 A-6 INSTALLATION ELECTRODE AND WORK CABLE CAUTION CONNECTIONS Excessive voltage drops caused by poor work Connect a work lead of sufficient size and length (Per piece connections often result in unsatisfactory Table 1) between the proper output terminal on the welding performance. power source and the work. Be sure the connection to ------------------------------------------------------------------------- the work makes tight metal-to-metal electrical contact. When welding with the STT pr
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A-7 A-7 INSTALLATION 5. Replace the cover and screws. The PC board will Work Voltage Sensing “read” the switch at power up, and configure the The Power Waves are shipped from the factory with work voltage sense lead appropriately. the work sense lead enabled. For processes requiring work voltage sensing, con- VOLTAGE SENSING nect the (21) work voltage sense lead from the Power The best arc performance occurs when the Power Wave to the work. Attach the sense lead to the work Waves have accurat
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A-8 A-8 INSTALLATION EXTERNAL I/O CONNECTOR POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS The Power Wave is equipped with a port for making Connect the control cable between the power source simple input signal connections. The port is divided and wire feeder. The wire feeder connection on the into three groups: Trigger group, Cold Inch Group and robotic Power Waves is located under the spring Shutdown Group. Because the Power Wave is a loaded output cover, near the bottom of the case
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A-9 A-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. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the
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A-10 A-10 INSTALLATION DIP Switch Settings and Locations Feed Head Board DIP Switch: DIP switches on the P.C. Boards allow for custom switch 1 = Object Instance LSB (see table 1) configuration of the Power Wave. To access the DIP switch 2 = Object Instance MSB (see table 1) switches: switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select WARNING switch 6 = Equipment Group 4 Select � Turn off power at the disconnect switch. switch 7 = negat
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A-11 A-11 INSTALLATION SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3 Bank (S2): SWITCH 8 SWITCH 7 switch Description 18 010010 1 Devicenet Baud Rate 19 010011 2(see table 2) 20 010100 21 010101 TABLE 2 22 010110 Prior to S24958-6 software 23 010111 switch 1 switch 2 baud rate 24 011000 off off Programmable value 25 011001 on off 125K 26 011010 off on 250K 27 011011 on on 500K 28 011100 29 011101 S24958-6 and later software 30 011110 switch 1 switch 2 baud rate 31 011111 off off 125K 32 100000 off o
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B-1 B-1 OPERATION 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 wea
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B-2 B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SMAW INPUT POWER ON GMAW OFF FCAW HIGH TEMPERATURE GTAW OPEN CIRCUIT MACHINE STATUS U 0 VOLTAGE CIRCUIT BREAKER U INPUT VOLTAGE 1 WIRE FEEDER U OUTPUT VOLTAGE 2 POSITIVE OUTPUT I INPUT CURRENT 1 NEGATIVE OUTPUT I OUTPUT CURRENT 2 PROTECTIVE 3 PHASE INVERTER GROUND INPUT POWER WARNING OR THREE PHASE CAUTION DIRECT CURRENT POWER WAVE 455/R
