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I ON
O OFF
POWERWAVE 455/R
RETURN TO MAIN MENU
SVM156-A
October, 2001
TM
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 in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT
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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 kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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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 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les Pour votre propre protection lire et observer toutes les instructions zones où l’on pique le laitier. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de antes: prévenir tout risque d’incendie dû aux éti
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v v - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety .................................................................................................................................................i-iv Installation.............................................................................................................................Section A Operation................................................................................................................
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Section A Section A TABLE OF CONTENTS - INSTALLATION SECTION - Installation.............................................................................................................................Section A Technical Specifications..............................................................................................................A-2 Safety Precautions......................................................................................................................A-4 Select Suita
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY VOLTS CONDITIONS CURRENT POWER @ RATED OUTPUT @ RATED OUTPUT AMPS (K1761-1) 70/65/35 450A@38V 100% 87/82/48 208/230/460V - 60HZ 570A@43V 60% 0.89 MIN 400A@36V 100% 64/58/32 200/220/440V - 50HZ 500A@40V 60% 79/74/41 400 Watts 88% (K1761-2) MAX 450@38V 100% 58/53/25/22 570@43V 60% 208/230/460/575V-60HZ 82/78/37/31 0.95 MIN
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A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2) (continued) 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) 254 lbs. 115 kg. TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE -20°C to +40°C -40°C to +40°C POWER WAVE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC R
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A-4 A-4 INSTALLATION SAFETY PRECAUTIONS CAUTION Read this entire installation section before you DO NOT MOUNT OVER COMBUSTIBLE SURFACES. start installation. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface WARNING shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) ELECTRIC SHOCK can kill. beyond the equipment on all sides. • Only qualified personnel should per- form this installat
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A-5 A-5 INSTALLATION FIGURE A.1 (K1761-1) 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=220-230V VOLTAGE=380-415V VOLTAGE=440-
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SENSE LEAD A-6 A-6 INSTALLATION INPUT VOLTAGE CHANGE OVER WELDING WITH MULTIPLE POWER (FOR MULTIPLE INPUT VOLTAGE WAVES MACHINES ONLY) CAUTION Welders are shipped connected for the highest input Special care must be taken when more than one Power voltage listed on the rating plate. To move this con- Wave is welding simultaneously on a single part. Arc nection to a different input voltage, see the diagram blow and arc interference may occur or be magnified. located on the inside of the input ac
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A-7 A-7 INSTALLATION When these parameters are identical, the pulsing fre- Most welding applications run with the electrode being quency will be the same, helping to stabilize the arcs. positive (+). For those applications, connect one end of the electrode cable to the positive (+) output terminal Every welding gun requires a separate shielding gas on the power source (located beneath the spring regulator for proper flow rate and shielding gas cover- loaded output cover near the bottom of the ca
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I ON O OFF POWERWAVE 455/R A-8 A-8 INSTALLATION The sense leads connect to the Power Wave at the VOLTAGE SENSING four-pin connector located underneath the output ter- The best arc performance occurs when the Power minal cover. Lead 67 senses electrode voltage. Lead Wave has accurate data about the arc conditions. 21 senses work voltage. Depending upon the process, inductance within the Enable the voltage sense leads as follows: electrode and work lead cables can influence the volt- age appare
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A-9 A-9 INSTALLATION WORK VOLTAGE SENSING CONTROL CABLE SPECIFICATIONS The Power Wave is shipped from the factory with the It is recommended that genuine Lincoln control cables work sense lead enabled. be used at all times. Lincoln cables are specifically designed for the communication and power needs of For processes requiring work voltage sensing, connect the Power Wave / Power Feed system. the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as
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A-10 A-10 INSTALLATION DIP SWITCH SETTINGS AND LOCATIONS CONTROL BOARD DIP SWITCH: DIP switches on the PC boards allow for custom con- switch 1 = reserved for future use figuration of the Power Wave. Access the DIP switch- switch 2 = reserved for future use es as follows: switch 3 = reserved for future use switch 4 = reserved for future use switch 5 = reserved for future use WARNING switch 6 = reserved for future use switch 7 = reserved for future use ELECTRIC SHOCK CAN KILL. switch 8 = work se
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A-11 A-11 INSTALLATION DEVICENET/GATEWAY BOARD DIP SWITCH, BANK (S2): switch 1,2 = configure the baud rate for DeviceNET Prior to S24958-6 software switch 1 switch 2 baud rate off off ------- on off 125K off on 250K on on 500 S24958-6 and later software switch 1 switch 2 baud rate off off 125K off on 250K on off 500K on on 500K Programmable value. Consult local Lincoln Technical representative. switch 5 = reserved for future use switch 6 = reserved for future use switch 7 = reserved for future
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A-12 A-12 NOTES POWER WAVE 455/R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Precautions......................................................................................................................B-2 Graphic Symbols.........................................................................................................................B-3 General De
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B-2 B-2 OPERATION SAFETY PRECAUTIONS 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 electrically 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 dr
