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IM808-A
June, 2004
™
POWER WAVE 455M/STT
For use with machines having Code Numbers:
11008, 11204
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 MAN-
UAL AND THE SAFETY PRE-
CAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and b
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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 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque d’inc
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v v SAFETY
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vi vi SAFETY
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vii vii 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 shipm
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viii viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455M/STT .........................................A-1 Safety Precautions ................................................................................................A-2 Select Suitable Location........................................................................................A-2 Lifting.......
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ix ix TABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems.....................................E-2 Error Codes For Power Waves .............................................................................E-3 Troubleshooting Guide ...................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT OUTPUT CONDITIONS INPUT OUTPUT CONDITIONS INPUT VOLTS AMPS / VOLTS / DUTY CYCLE CURRENT AMPS / VOLTS / DUTY CYCLE CURRENT EXCEPT STT PROCESS AMPS EXCEPT STT PROCESS AMPS 380V - 60Hz. 400A@36V. 100% 36 A 500A@40V. 60% 48 A 380V - 50Hz. 400A@36V. 100% 36 A 500A@40V. 60% 48 A 415V - 60Hz. 400A@36V. 100% 33 A 500A@40V. 60% 44 A 415V - 50Hz. 400A@36V. 100% 33 A 500A@40V
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A-2 A-2 INSTALLATION LIFTING SAFETY PRECAUTIONS Read this entire installation section before you start installa- Lift the machine by the lift bail only. The lift bail is tion. designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it. WARNING ELECTRIC SHOCK can kill. STACKING • Only qualified personnel should per- Power Wave machines can be stacked to a maximum form this installation. of 3 high. • Turn the input power OFF at the WARNING dis
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A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM . Disconnect input power before inspecting or servicing machine. . Do not operate with covers removed. . Do not touch electrically live parts. Only qualified persons should install, use or service this equipment. W / L3 V / L2 CR1 U / L1 THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. XA S24190 NOTE: Turn main input power to the machine OFF before performing connection proc
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A-4 A-4 INSTALLATION CABLE INDUCTANCE, AND ITS EFFECTS For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMA- ON PULSE WELDING TION" located in the front of the Instruction Manuals. For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop CAUTION length less than 15.24m (50 ft.), traditional welding cables may be used without any effects on welding performance. For Excess
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A-5 A-5 INSTALLATION Enable the voltage sense leads as follows: Electrode Voltage Sensing TABLE A.2 Enabling or disabling electrode voltage sensing is Process Electrode Voltage Work Voltage automatically configured through software. The 67 Sensing 67 lead * Sensing 21 lead electrode sense lead is internal to the cable to the wire GMAW 67 lead required 21 lead optional feeder and always connected when a wire feeder is GMAW-P 67 lead required 21 lead optional present. FCAW 67 lead required 21
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A-6 A-6 INSTALLATION If a system can not be “Auto Mapped” then the status CONFIGURING THE SYSTEM light on the power source will blink green fast and the welder output will be disabled. If a system is not “Auto- For codes below 11100, consult the semi-automatic mappable”, then consult the instruction manual for the Power Feed instruction manual for configuration infor- accessory being used for configuration information mation about DIP switch settings. about DIP switch settings, or consult yo
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A-7 A-7 INSTALLATION ALTERNATE HARD AUTOMATIC APPLICATION (using a UI, WD Module, and PF-10R) POWER WAVE 455M/STT (CE) PF-10R WIRE DRIVE MODULE (FH1) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto, WD Module, and PF-10R) POWER WAVE 455M/STT (CE) PF-10R WIRE DRIVE MODULE DUAL HEAD (FH1) System that is NOT "Auto Mappable" DUAL HEAD BOOM FEEDER (using two single heads) POWER WAVE 455M/STT (CE) DUAL HEAD FH-1 FH-2 In this case the individual feed heads need to be assigned to the dual head
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A-8 A-8 INSTALLATION WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables WAVES be used at all times. Lincoln cables are specifically designed for the communication and power needs of CAUTION the Power Wave / Power Feed system. Special care must be taken when more than one Power Wave is welding simultaneously on a single CAUTION part. Arc blow and arc interference may occur or be The use of non-standard cables, especially in magnified
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A-9 A-9 INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 455M/STT (CE)
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A-10 A-10 INSTALLATION switch 8 work sense lead I / O RECEPTACLE SPECIFICATIONS off work sense lead not connected TABLE 3 WIRE FEEDER RECEPTACLE S1 on work sense lead connected PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc FIGURE A.3 E 51 +40vdc CONTROL BOARD (DIP Switch Location) TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 PIN LEAD# FUNCTION
