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IM716
October, 2003
™
POWER WAVE 455/STT
For use with machines having Code Numbers: 10835
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 ca
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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 ....................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Lifting....
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vii vii TABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems .....................................E-2 Troubleshooting Guide.............................................................................E-3 thru E-7 ____________________________________
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT (K1518-4) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT EFFICIENCY IDLE POWER FACTOR CONDITIONS CURRENT @ RATED POWER @ RATED OUPUT OUPUT AMPS 208/230/460/575V - 60HZ. 450A@38V.100% 58/53/25/22 570A@43V. 60% 82/78/37/31 88% 400 Watts .95 MIN. 200/220/440/575V - 50HZ. 400A@36V.100% 49/45/23/18 Max. 500A@40V. 60% 67/61/31/25 OUTPUT OPEN CURRENT PULSE PULSE PULSE AND AUXILIARY POWER CIRCUIT RANGE / FREQUEN
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A-2 A-2 INSTALLATION LIFTING SAFETY PRECAUTIONS Lift the machine by the lift bail only. The lift bail is Read this entire installation section before you designed to lift the power source only. Do not attempt start installation. to lift the Power Wave with accessories attached to it. LIMIT ON STACKING WARNING CAUTION ELECTRIC SHOCK can kill. FALLING EQUIPMENT can cause injury. • Only qualified personnel should per- � Do not lift this machine using lift form this installation. bale if it is e
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A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM = 200-208V VOLTAGE W / L3 WARNING 200-208V V / L2 CR1 . Disconnect input power before 220-230V inspecting or servicing machine. U / L1 'A' . 440-460V Do not operate with covers removed. 550-575V . ELECTRIC Do not touch electrically live parts. SHOCK Only qualified persons should install, CAN KILL use or service this equipment. = VOLTAGE = 440-460V VOLTAGE= 550-575V VOL
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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 CAUTION loop length less than 50 feet, traditional welding cables may be used without any effects on welding performance. For the Excessive
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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 GMAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder GMAW-P 67 lead required 21 lead optional is present. FCAW 67 lead required 21
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A-6 A-6 INSTALLATION From a network perspective, each component in the SYSTEM DESCRIPTION system is considered a separate node, regardless of its physical location. For example, even though a UI The Power Wave 455/STT and Power Feed 10/11 and FH may be physically mounted together, they are family of products utilize a digital communication sys- still viewed as separate pieces (nodes) by the net- tem called Linc-Net. Simply put, Linc-Net allows large work, and can only communicate via Linc-Net
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A-7 A-7 INSTALLATION SYSTEM SET-UP Basic Rules � Each group is required to have one user interface. No group may have more than one user interface. � Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads. � Each system has only one power source. For net- work purposes, the PS belongs to Group 3, which is why group 3 is only allowed 6 feed heads in addition it’s user interface. � No two feed heads can have identical Group and Feed Head numbers
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A-8 A-8 INSTALLATION Multiple Group System FIGURE A.9 No “FH0 Alllowed! Single Group Multi-Head System FIGURE A.10 No “FH0 Alllowed! The Dual Head option allows the abil- ity to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings. POWER WAVE 455/STT
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A-9 A-9 INSTALLATION Single Group Multi-Head System (Alternate Method) No “FH0 Alllowed! FIGURE A.11 When a standard User Iterface is used in a group with multi- ple Feed Heads, all of the Feed Heads use a single set of procedures. POWER WAVE 455/STT
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A-10 A-10 INSTALLATION CAUTION CAUTION FIGURE A.2 TWO POWER WAVES POWER WAVE POWER WAVE POWERWAVE POWERWAVE - + + - - + - + Travel Direction Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 455/STT
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A-11 A-11 INSTALLATION MULTIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Power Source BAD #1 Ø Current flow from Arc #1 Work #1 affects sense lead #2 Sense #1 Arc #1 Ø Current flow from Arc #2 Current Flow Power Work #2 affects sense lead #1 Source Sense #2 #2 Ø Neither sense lead picks up Arc #2 the correct work voltage, causing starting and welding arc instability. Power BETTER Arc #1 Power Source Source Ø Sense #1 is only affected by weld #2 #1 current from Arc #1 Ø Sense #2 is on
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A-12 A-12 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
