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Lincoln Electric IM808-A User's Manual

1. a gll e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo A HEROS SCRHREUCF eA HRARGHRBAR ez 119 Sal Soares s ESSAI du due le aga s cil gal amp 2 A d READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES BE 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 UNFALLVERHUTUNGSVORSCHRIFTEN 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 ter les fum es des zo
2. Section 2 F 3 Dimension Print issue Section F 4 Parts P450 Series A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS POWER WAVE 455M STT CE K2203 2 INPUT AT RATED OUTPUT THREE PHASE ONLY OUTPUT CONDITIONS OUTPUT CONDITIONS AMPS VOLTS DUTY CYCLE AMPS VOLTS DUTY CYCLE EXCEPT STT PROCESS EXCEPT STT PROCESS 380V 60Hz 380V 50Hz 415V 60Hz 415V 2 STT PROCESS ALL VOLTAGES 400A Q 36V 100 400A Q 36V 100 400A Q 36V 100 400A Q 36V 100 325A Q 33V 100 500A Q 40V 60 500A Q 40V 60 500A Q 40V 60 500A Q 40V 60 STT PROCESS ALL VOLTAGES 325A Q 33V 100 OUTPUT PULSE AND FREQUENCY VOLTAGE BACKGROUND TIME RANGE AUXILIARY POWER STT PARAMETERS PEAK amp BACK GROUND CURRENT OPEN CIRCUIT VOLTAGE 40 VDC AT 10 AMPS 15 450 AMPS 220 VAC AT 5 AMPS CURRENT AMPS 50 500 A 40 500 A 30 500 A 5 750 40 325 A 75 VDC 5 570 0 15 1000 Hz 5 55 VDC 100 MICRO SEC PROCESS CURRENT RANGE DC TYPE 75 C SUPER LAG OR BREAKER INPUT VOLTAGE FREQUENCY INPUT AMPERE RATING ON NAMEPLATE 380V Hz 415V Hz PHYSICAL DIMENSIONS WEIGHT 121 kg 267 lbs HEIGHT 663 mm 26 10 in 505 mm 835 mm 19 86 in 32 88 in TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 to 40 40 C to 40 C POWER WAVE 455M STT CE
3. WA ms so e EU GE EMA ANANI ni oc i SOVMALNI 3A 5 ui 9N SNIHOVW 30 LNOYS 310V1d3O3M p eui pd Von E HALVM Ae ae E r Wee m EI Je LON gon GATE ANO reene nen NES A ANS SIMON pacs es he Sed DEE LC E Bag So e our EP od 1 41 193NNOO3N sus uuu HN ON ON E MOLO3NNOO ANIHOV JO urd SEE souz KENE SHL Mer T E E a i E At zx mi RE exor Wei E ind LZ SCH OL Tor ww nf TOH1NOO amo Aleng wee Quivog Aiddns YSE n g a AVIS IMON Pay LAS YO 13N30 30 au 30 3GIS 1431 INVIO VIO 39 LLS WSSY POWER WAVE 455M STT LINCOLN E 2 CONNECTION DIAGRAM 2 Connection Diagram Semi automatic Sim
4. 808 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 be careful IEC 60974 1 NRTL C E OPERATOR S MANUAL 1809001 ad 6 lt gt IN ONS Designed and Manufactured Under Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 NCOLN Copyright 2004 Lincoln Global Inc e World s Leader in Welding and Cutting Products e 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 reproductiv
5. ELECTROMAGNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 50 199 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with t
6. 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Major physical or electrical dam age 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 breaker 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 una
7. Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d 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 so
8. See Figure A 7 OPERATION B 9 For most programs peak current is adjusted by arc control also referred to as wave control A wave con trol value of 10 0 maximizes the peak current while a wave control of 10 0 minimizes peak current In gen eral the peak current is proportional to the arc length See Figure A 8 NOTE The ranges on Wave Control and Trim are dependent on the weld programs The values shown are typical ranges FIGURE A 7 Trim 1 50 Current Trim 1 00 Trim 0 50 Time FIGURE A 8 Wave Control 10 0 Wave Control 0 0 Wave Control 10 0 Current Time POWER WAVE 455 CE LINCOLN C 1 ACCESSORIES C1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available FIELD INSTALLED Work Voltage Sense Lead Kit K940 Dual Cylinder Undercarriage K 1570 1 Gas Guard Regulator K659 1 Coaxial welding Cable K1796 Cool Arc 40 Water Flow Sensor K1536 1 Wire Drive Interface Module K2205 1 DeviceNet interface Module K2206 1 Ethernet Interface Module K2207 1 COMPATIBLE LINCOLN EQUIPMENT Any ArcLink compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed M family If the wire drive interface module is installed the machine is compatible with the Power Feed 10R wire feeder POWER WAVE 455M STT CE LINCOLN 8 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill o Only Qualified personnel should perform this mainten
9. and along the channels formed into the base of the Power Wave out the back of the channels and then to the wire feeder Due to the flexibility of the platform the configuration may vary The following is a general description of the system For specific configuration information consult the semi automatic Power Feed instruction manual SYSTEM DESCRIPTION The Power Wave 455M STT CE and Power Feed M family of products utilize a digital communication system called ArcLink Simply put ArcLink allows large amounts of information to be passed at very high speeds between components nodes in the system The system requires only two wires for communication and because of its bus like structure the components may be connected to the network in any order thus simplifying the system set up Each system must contain only one power source The number of wire feeders is determined by the type of wire feeder Refer to the wire feeder instruction man ual for details POWER WAVE 455M STT LINCOLN 6 INSTALLATION A 6 CONFIGURING THE SYSTEM For codes below 11100 consult the semi automatic Power Feed instruction manual for configuration infor mation about DIP switch settings For codes above 11100 the power source will Auto Map the system eliminating most of the need to set DIP switches to configure the system SINGLE HEAD FEEDER UP TO 4 FEEDERS ALLOWED POWER WAVE 455M STT If a system can n
10. 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 and wire feeder Avoid excessive lengths and do not coil excess cable Minimum work and electrode cables sizes are as follows TABLE A 1 Current 60 Duty Cycle MINIMUM COPPER Po WORK CABLE SIZE AWG Up To 30 m Length 100 Ft 400 Amps 67 mm 2 0 500 Amps 85 mm 3 0 600 Amps 85 mm 3 0 NOTE K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths This is especially important in Pulse and STT applications CAUTION When using inverter type power sources like the Power Waves use the largest welding electrode and ground cables that are practical At least 67 mm 2 0 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used POWER WAVE 455M STT LINCOLN 4 CABLE INDUCTANCE AND 5 EFFECTS ON PULSE WELDING For Pulse Welding processes cable inductance will cause the welding performance to degrade For the total welding loop length less than 15 24m 50 ft traditio
11. explosion C Do not weld near flammable material Do not weld on containers which have held flammable material ARC RAYS can burn 4 Wear eye ear and body protection L POWER WAVE 455 LINCOLN 2 O O OPERATION B 2 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER D HIGH TEMPERATURE D 5 5 90 WES CIRCUIT BREAKER U4 olo WIRE FEEDER 02 POSITIVE OUTPUT ly NEGATIVE OUTPUT lo S DAC pip 3 PHASE INVERTER QD pi INPUT POWER 3 THREE PHASE N DIRECT CURRENT POWER WAVE 455M STT LINCOLN SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION 3 DEFINITION WELDING TERMS NON SYNERGIC WELDING MODES A Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES A Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator 455M 455 WFS Wire Feed Speed Constant Current CV Constant Voltage GMAW Gas Metal Arc welding GMAW P e Gas Metal Arc welding P ulse Arc GMAW S Gas Metal Arc welding S hort Circuiting Arc GTAW Gas Tungst
12. power source output stud to the work piece The work piece connection must be firm and secure especially if pulse weld ing is planned When welding with the STT process use the positive output connection labeled STT for welding If desired other welding modes can be used on this stud however the aver age output current will be limited 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 avail able Do Not connect the STT and Power Wave stud together Paralleling the connection will bypass the STT circuitry and severely deteriorate STT welding performance INSTALLATION 4 For additional Safety information regarding the electrode work cable set up See the standard SAFETY INFORMA TION located in the front of the Instruction Manuals CAUTION Excessive voltage drops caused by poor work piece con nections often result in unsatisfactory welding perform ance 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 Electrode Sense Polarity DIP switch must be set to the Negative position on the Wire Drive Feed Head PC Board The default setting of the switch
13. DE PRECAUCION French ATTENTION German WARNUNG Japanese BIR Do not touch electrically live parts electrode with skin or wet clothing e Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da 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 K rper 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 pe a e terra eod EmBOBaumm ELE het EE LATE NTUWSHIELTFSu MOTO Ok e Sea SUBS Xe uc su M x ng e sj AXE HAR nia JU qoas uil el ol oa gh la Aal zial P Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material inflamaveis bem guarda dos COREE CIE REA 5 YA IEEE LS Aal uie
14. Equipment B 4 care nee nsc B 4 Dut Cycl and Time Period oi eet deni B 4 Case Front Controle ss B 5 Nominal Proc dures 6 Fringe Proc dures PET B 6 Making a 6 Welding 6 Constant Voltage Welding et re th tid dte ania B 7 ami HH B 8 uw 9 550 5 Section C Optional Equipment sise C 1 Factory Mtae daanin ernea a C 1 Field nstalled diti EET C 1 Compatible Lincoln Eouipment ss C 1 Maintenance ss dico Section D Safety Precautions D 1 Routine 4 54 D 1 Periodic Maintenance ie D 1 Calibration Specification viene Elite thin D 1 viii TABLE OF CONTENTS Page Troubleshooting 2 1uccc crecen cc renuit 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 deisel iecit oerte eei be cae rn E 4 thru E 7 Wiring Diagram Section F 1 Connection
15. German WARNUNG ATEN O it ie BIR Chinese Qai dul jua oi Jaial e os Qui al z ue Aie 4 ale cuts UI ai UA Jai y e Aale Cut Al all LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETISRIUCESU CL TRHORERME HS ET REL BE EE RU Rr de OE D EL FEE fS AXIS SAAD FAIS zeit ele BEHE ET alal al d illai aul y AAL oig 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 lincolnelectric com
16. S103NNOO SENS Can SOd HOLIMS 193NNOO3H V 3AVH LON OQ STIGON 35 HN amupa STAGON 32 NO 1N3S3Md ATNO 7 f 3d0u10313 ee STAGON NO INSS3Hd ANO EE psi INOWd 3690 NO 31OVLd3034 HLIM SHOW NI AINO SI VZSE QV31 3SVO NO m us 101430 STAGOW NI 1 365344 SI 66 QV31 AN 1390S 31 40 QV371311HM 5 SN31 3130 3903 1V4 153 3 Nid ON m m NOLLVH3dO ES 4 645 056 SI NMOHS Ze On LNdNI IPPON 39 E 303 NOLLO3NNOO 1VdOHdAY NO 32 74 MN Cie voe on m 289 NOLLVH3dO unosio vs AGIS Ovy SI NMOHS NOLIO3NNOO 39V 0A 292 HO NOLLISOd 3L ViidOHddV NI HOLMS 39V d 1 139905 99130 SEN 399 3QOHLY9 SN31031 3903 LYH LS3HV3N Nid VN vs rms 9d Sse 3009 voua ou EISE a SE Leslie x mE 9 fvi ANGOL 1 THOT rb a CES 193138 x a 85 39V L10 SUNT RIS mi n M zr m deen E in pn ah YN em 44 on ax eris ES m von Ae 8 88 m 3ovissogi is mies seen m lt dE aus EN EC D 1 Loon 2 a 5 Guvos sw 3 2 lt xw
17. 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 met allique 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 defonc tionnement 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 contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps
18. needs If a special welding program is desired contact the local Lincoln Electric sales repre sentative To make a weld the Power Wave needs to know the desired welding parameters The Power Feed PF family of feeders communicate settings to the Power Wave through control cable connection Arc length wire feed speed arc control etc are all communicated digitally via the control cable WELDING ADJUSTMENTS All adjustments are made on the system component known as the User Interface Control Box which con tains the switches knobs and digital displays neces sary to control both the Power Wave and a Power Feed wire feeder Typically the Control Box is supplied as part of the wire feeder It can be mounted directly on the wire feeder itself the front of the power source or mounted separately as might be done in a welding boom installation Because the Control Box can be configured with many different options your system may not have all of the following adjustments Regardless of availability all controls are described below For further information consult the Power Feed wire feeder instruction manu al WFS AMPS In synergic welding modes synergic CV pulse GMAW STT WFS wire feed speed is the dominant control parameter controlling all other variables The user adjusts WFS according to factors such as weld size penetration requirements heat input etc The Power Wave then uses the WFS setting to adjust it
19. not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 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 Connect the work cable to the workpiece as close as possible to the area being welded 1 0 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 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
20. the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration 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 A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page Installati n ee Section A Technical Specifications POWER WAVE 455 A 1 Safety Precautions iin ack eta ian e cine dae viel e Pedo dies A 2 Select Suitable Location sis A 2 Ming A 2 crede 2 Machine Groundlirg BE 2 High Frequency Protection 2 Input Connect M EE A 2 Input Fuse and Supply Wire Consid
21. the switch to the ON position if the work sense lead is present 5 Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately A 5 Electrode Voltage Sensing Enabling or disabling electrode voltage sensing is automatically configured through software The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present CAUTION Important The electrode polarity must be config ured at the feed head for all semi automatic processes Failure to do so may result in extreme ly high welding outputs POWER WAVE TO SEMI AUTOMAT IC POWER FEED WIRE FEEDER INTERCONNECTIONS The Power Wave 455M STT CE and semi automatic POWER FEED family communicate via a 5 conductor control cable K1543 The control cable consists of two power leads one twisted pair for digital communication and one lead for voltage sensing The cables are designed to be connected end to end for ease of exten sion The output receptacle on the Power Wave 455 is located beneath the spring loaded out put cover at the bottom of the case front The input recep tacle on the Power Feed is typically located at the back of the feeder or on the bottom of the user interface For convenience sake the electrode and control cables can be routed behind the left or right strain reliefs under the spring loaded output cover
22. 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 represents 6 minutes of welding and 4 minutes of idling in a ten minute period POWER WAVE 455M STT LINCOLN 5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 1 POWER SWITCH Controls input power to the Power Wave STATUS LIGHT A two color light that indicates sys tem errors Normal operation is a steady green light Error conditions are indicated per table 3 NOTE The POWER WAVE 455M STT CE 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 3 Light Condition Steady Green System OK Power source communicating normal ly with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 455 5 CE 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 operation Non recoverable system fault If the PS Status light is flashing any combination red and green errors are present in the POWER WAVE 455M STT CE Read the error code before the machine is turned
23. 10 29S eu si eui sjeued y jo euo uo y episur poised si e 4 out siy je jou 10 S SIUL 310 00 79 1 LL 08 MOT38 S3009 350 40 NI GASN 51 dV OL TN Y3HLYY Od NO BOL22NNOO 30 16613 H3d SIOSNAS TVOld13 3 ANdNI 3HL OL Q3 103NNOO 2 8 SOV31 ONY 8 V SQV31A8 EL ANY 21711 SAYI STSGOW 39 NO No ess OLEO LMS OL S1O3NNOO ONS ANIHOVN 3GIS LH IY SINTA IN3NOdAOO QV3 LSNI T3NVd LOSNNOO3Y V 3AVH LON OQ STSGOW 35 IHL TN 80 30 9 OL S103NNO2 Qv31 9 OL 0 40 0 ELS CIL uL d SIO3NNOO 9 ava1 30 OL A1193MQ
24. ES The Power Wave is designed to operate with 3 4 elec trode stick out for CV and Pulse processes FRINGE PROCEDURES Excessively short or long electrode stick outs may function only on a limited basis if at all MAKING A WELD A WARNING The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selection The steps for operating the Power Wave will vary depending upon the options installed in the user inter face control box of the welding system The flexibility of the Power Wave system lets the user customize operation for the best performance First consider the desired welding process and the part to be welded Choose an electrode material diameter shielding gas and process GMAW GMAW P etc Second find the program in the welding software that best matches the desired welding process The stan dard software shipped with the Power Waves encom passes a wide range of common processes and will meet most
25. LINCOLN 2 SAFETY PRECAUTIONS Read this entire installation section before you start installa tion WARNING ELECTRIC SHOCK can kill Sc 0 Only qualified personnel should per form 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 working on the equipment Do not touch electrically hot parts Always connect the Power Wave 455M STT CE grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Do not use Power Wave 455M STT CE in outdoor environments The Power Wave 455M STT CE power source should not be subjected to falling water nor should any parts of it be submerged in water Doing so may cause improper operation as well as pose a safe ty hazard The best practice is to keep the machine in a dry sheltered area Do not mount the Power Wave 455M STT CE over combustible surfaces Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 1 6mm 060 thick which shall extend not less than 150mm 5 90 beyond the equipment on all sides Place the welder where clean cooling air can freely cir culate in through the rear louvers and out through t
26. S AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE 455 5 CE can be setup in a number of configurations some requiring optional equipment or welding programs Each machine is fac tory preprogrammed with multiple welding procedures typically including GMAW GMAW P FCAW SMAW GTAW STT and for a variety of materials including mild steel stainless steel cored wires and aluminum The POWER WAVE 455M STT CE is recommended for semi automatic welding with ArcLink compatible equipment like the Power Feed M STT series of feed ers The POWER WAVE 455M STT CE can have a number of modules installed that allow the machine to be used in Robotic and hard automation applications Wire Drive Interface Module For Robotic platforms the Wire Drive Control Module is required to drive the Power Feed 10R wire drive This module can be factory installed through our automation division or field installed for robotic applications The Wire Drive Control Module is also be equipped with a terminal strip for making simple input signal connec tions It can be used to externally control the basic wire drive function It is divided into three groups Trigger group Cold Inch group and Shutdown group OPERATION B 4 DeviceNet Interface Module This module can be used for DeviceNet capability It will be a 5 pin sealed mini connector per ANSI B93 55M 1981 EtherNet DeviceNet Module This module includes the DeviceNet and Eth
27. TAGE SENSE RECEPTACLE S2 LEAD FUNCTION FUNCTION 21 Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 RS232 Receive RS232 Transmit S3 Pin5 53 Pin4 53 20 S3 Pin6 RS232 Common DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P C Boards allow for custom con figuration of the Power Wave To access the DIP switches Turn off power at the disconnect switch e Remove the top four screws securing the front access panel Loosen but do 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 DIP SWITCH switch 1 reserved for future use switch 2 reserved for future use switch 3 reserved for future use switch 4 reserved for future use switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future use switch 8 2 work sense lead INSTALLATION A 10 switch 8 work sense lead off work sense lead not connected work sense lead connected FIGURE A 3 CONTROL BOARD DIP Switch Location WATER FLOW SENSOR Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing A water flow sensor is recommended for tho
28. TROUBLESHOOTING GUIDE 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 F acility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service F acility CAUTION any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorize
29. an 0 0 provides a softer hotter arc See Figure A 5 FIGURE A 5 CURRENT WAVE FORM CV Wave Control 10 OT 444 pt Wave Control 0 00 Current Time 57 Wave Control 10 0 s POWER WAVE 455M STT LINCOLN 8 PULSE WELDING Pulse welding procedures are set by controlling 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 voltage becomes impracti cal 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 synergic As the wire feed speed is adjusted the Power Wave will automati cally recalculate the waveform parameters to maintain similar arc properties OPERATION B 8 The Power Wave utilizes adaptive control to com pensate for changes in electrical stick out while weld ing 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
30. ance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment e Do 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 455M STT CE is criti cal to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfac tory 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 facto ry Generally speaking the machine calibration will not need adjustment However if the weld performance changes orthe yearly calibration check reveals a prob lem contact the Lincoln Electric Company for the cali bration software utility The calibration procedure itself requires the use of a resistive load bank and certified actual meters for volt age and current The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use Detailed instructions are available with the utility POWER WAVE 455M STT LINCOLN 8 1 TROUBLESHOOTING E 1 HOW TO USE
31. ble to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455M STT CE LINCOLN 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Thermal LED is lit Machine won t weld can t get any output CR 1 will not pull in POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Fan thermostat has opened Check for proper fan operation Fan should run whenever output power is on Check for material blocking intake or exhaust lou vers or for excessive dirt clog ging cooling channels in machine Secondary rectifier or Choke thermostat has opened After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers DC Bus PC board thermostat has opened check for excessive load on 40VDC supply Input voltage is too low or too high Make certain that input volt age is proper according to the Rating Plate located on the rear of the machine Ifthe Thermal LED is also lit see Yellow Thermal LED is Lit sec tion Primary current limit has been exceeded Possible short in out put circuit Turn machine off Remove all loads from the output of the machine Turn back on If condition persists turn power off and contact an authorized Lincoln Electric Field Service facility This problem will normally b
32. cated Away from areas where they may be struck or subjected to physical damage e A 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 Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 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 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 que les pr cautions de s ret g n rales suiv
33. ces 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode re sr 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 Cylinders should be lo
34. d Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 455 CE LINCOLN 8 2 USING THE STATUS LED TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user inter face and feed head has a status light and when a problem occurs it is important to note the condition of each In addition errors displayed on the user interface in most cases indicate only thata problem exists in the power source not what the problem may be Therefore prior to cycling power to the system check the power source status light for error sequences as noted below This is especially important if the user interface displays Err 006 or Err 100 Included in this section is information about the power source Status LED and some basic troubleshooting LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LED is blinking red and green Status LED is solid red no blinking TROUBLESHOOTING E 2 charts for both machine and weld performance The STATUS LIGHT is a two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated in the following chart NOTE The POWER WAVE 455M STT CE 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 situati
35. d fuel from vaporizing on contact with hot 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 a 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 posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts 3 f Exposure to EMF fields in welding have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 e some cases it may be necessary to remove safety dd px 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 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan ww Do
36. e accompanied by an error code Error codes are displayed as a series of red and green flashes by the status light See Troubleshooting the Power Wave Power Feed System Using the Status LED section of this text 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 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 CE LINCOLN 8 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Machine often noodle welds out put is limited to approximately 100 amps when running a particular procedure especially a procedure with high WFS Machine won t produce full output Auxiliary receptacle is dead no auxiliary voltage POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 5 current limit has been exceeded and the machine has phased back to protect itself 2 Adjust procedure or reduce load to lower current draw from the machine A single phase input loss of L2 will reduce the secondary current limit from 570 Amps to 325 Amps Input voltage may be too low limiting output capability
37. e harm The Above For Diesel Engines The 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 Z49 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 D 8 h To avoid scalding do not remove the powered equipment 9 0 radiator pressure cap when the engine is hot 1 the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spille
38. ead and understand 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 SAFETY WELDING SPARKS 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 Recommended Safe Practi
39. ed Do not operate machine while suspended from lift bail Do not stack the Power Wave 455M STT CE on top of any other machine FALLING EQUIPMENT can cause injury 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 adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE 455M STT LINCOLN 8 3 INSTALLATION A 3 FIGURE A 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM 9 removed SHOCK Only quali WARNING or servicing machine Disconnect input power before inspecting Do not operate with covers ELECTRIC Do not touch electrically live parts ied persons should install CAN KILL use or service this equipment THE LINCOLN ELECTRIC CLEVELAND OHIO U S A Po tig NOTE Turn main input power to the machine OFF before perf
40. en Arc welding GTAW P Gas Tungsten Arc welding P ulse Arc PAW Plasma Arc welding OPERATION B 3 SMAW Shielded Metal Arc welding SW Stud Arc Welding SAW Submerged Arc Welding SAW S Submerged Arc Welding Series STT e Surface Tension Transfer FCAW Flux Core Arc Welding CAC Carbon Arc Cutting POWER WAVE 455M STT LINCOLN 4 GENERAL DESCRIPTION The Power Wave 455M STT CE semi automatic power source is designed to be a part of a modular multi process welding system Depending on configura tion it can support constant current constant voltage STT and pulse welding modes The Power Wave 455M STT CE power source is designed to be used with the semi automatic 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 compo nent power source wire feeder user interface knows what the other is doing at all times These components communicate with ArcLink The POWER WAVE 455M STT CE is a high perform ance digitally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW STT and CAC processes It car ries an output rating of 400 amps 36 volts at 10096 duty cycle The STT process is supported at currents up to 325 amps at 100 duty cycle RECOMMENDED PROCESSE
41. erNet capability The DeviceNet uses a 5 pin sealed mini connector per ANSI B93 55M 1981 The EtherNet uses a RJ 5 connector RECOMMENDED EQUIPMENT Power Wave 455M STT CE Semi Automatic Operation Semi Automatic Power Waves 455M STT CE can only be used with ArcLink compatible Power Feed semi automatic wire feeders and modules In addition the Power Feed semi automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave Other mod els of Lincoln feeders or any models of non Lincoln wire feeders cannot be used All welding programs and procedures are selected through the Power Feed M semi automatic user inter face REQUIRED EQUIPMENT Any ArcLink compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed M family A WARNING LIMITATIONS The Power Waves not to be used in outdoor environments Only ArcLink compatible Power Feed semi automatic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used e POWER WAVE 455 5 CE Output Limitations The POWER WAVE 455M STT CE will support maximum average output current of 500 Amps 60 duty cycle on the standard Power Wave stud and a maximum average output current of 325 amps 100 duty cycle on the STT stud DUTY CYCLE AND TIME PERIOD The Power Feed wire feeders are capable of welding at 10096 duty cycle continuous
42. eratons A 3 Electrode and Work Cable Connections A 3 Cable Inductance and its Effects on Pulse Welding 4 Negative Electrode Polarity ss 500 4 Voltage Sensing iii 4 Power Wave to Semi automatic Power Feed Wire Feeder Interconnections A 5 System Description si 5 Configuring the System uice ud ode tice ha cree it A 6 Alternate Hard Automatic Application A 7 Combinaation Hard Automtion A 7 Dual Head Boom Feeder ss A 7 Welding with Multiple Power Waves A 8 Control Cable Specifications 8 Multiple Arc Unsyrichronlzed iecit A 9 O Receptacle Specifications A 10 Dip Switch Settings and Locations A 10 Control Board Dip Switch ss A 10 Water FlOW Sensor iiie icons die donne Dee A 10 6 8 Section Safety 1 Graphic Symbols that appear on this machine in this manual B 2 Definition of Welding Terms B 3 General Description ES 4 Recommended Processes and 4 Required
43. g used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093 SAFETY ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instruc
44. 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 LINCOLN 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 ski
45. he case sides and bottom Dirt dust or any foreign mate rial 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 oper ating temperatures and nuisance shutdowns Machines are equipped with F A N fan as needed cir cuitry 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 min utes after the output is disabled to ensure all compo nents 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 INSTALLATION A 2 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 to a maximum of 3 high WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is damag
46. he technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transmitters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment bein
47. ial 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 directions 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 puls ing frequency will be the same helping to stabilize the arcs Every welding gun requires a separate 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 INSTALLATION A 8 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 of non standard cables especially in lengths greater than 7 6m 25 ft can lead to com munication problems system shutdowns poor motor acceleration poor arc sta
48. is positive electrode polarity Consult the Power Feed instruction manual for further details 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 voltage apparent at the studs of the welder Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance Sense Lead Kits K940 10 25 or 50 are available for this purpose CAUTION If the voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polar ity switch is improperly configured extremely high weld ing outputs may occur The ELECTRODE sense lead 67 is built into the control cable and is automatically enabled for all semi automatic processes The WORK sense lead 21 connects to the Power Wave 455M STT CE at the four pin connector locat ed underneath the output stud cover By default the WORK voltage is monitored at the output stud in the Power Wave 455M STT CE For more information on the WORK sense lead 21 see Work Voltage Sensing in the following para graph All constant current processes sense the voltage at the out put studs of the POWER WAVE 455 by default POWER WAVE 455M STT LINCOLN 5 INSTALLATION Enable the voltage sense leads as follows TABLE A 2 Electrode V
49. n and that of 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 2 FUMES AND GASES can be dangerous 5 a 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 R
50. nal welding cables may be used without any effects on welding performance For the total welding loop length greater than 15 24m 50 ft the K1796 Coaxial Welding Cables are recommended The weld ing loop length is defined as the total of electrode cable length A work cable length B work length C See Figure FIGURE A 3 J For long work piece lengths a sliding work connection should be considered to keep the total welding loop length less than 50 feet See Figure 4 FIGURE A 4 SLIDING WORK CONNECTION K1796 COAXIAL CABLE 7 MEASURE FROM OF OUTER JACKET OF CABLE 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 Most welding applications run with the electrode being posi tive For those applications connect the electrode cable between the wire feeder and 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 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 con nections section Connect a work lead from the negative
51. nes de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir 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 eti ADP5oUtRc5cuc Ss e za 24758 else SUAS sis PARAH 7 Turn power off before servicing 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 N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas 9 PRE ET BRAY FE q ocCt v e HE BIS SHA AGS XA Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s 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 NRIVOAN ERUALEEE CHkBEELZVCNEUS e EIE E Ro e 20 Sel dos Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION
52. o vary the arc characteristics from soft to harsh in all weld modes It is adjustable from 10 0 to 10 0 with a nominal setting of 00 0 The nominal set ting of 00 0 may be displayed as OFF on some Power Feed wire feeder control panels See the Welding Mode descriptions below for detailed explanations of how the Arc Control affects each mode CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The nominal preprogrammed volt age is the best average voltage for a given wire feed speed but may be adjusted to preference When the wire feed speed changes the Power Wave automati cally adjusts the voltage level correspondingly to main tain similar arc characteristics throughout the WFS range OPERATION B 7 Non Synergic CV This type of CV mode behaves more like a conven tional CV power source Voltage and WFS are inde pendent adjustments Therefore to maintain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS All CV Modes Arc Control often referred to as wave control adjusts the inductance of the wave shape The wave control adjustment is similar to the pinch function in that it is inversely proportional to inductance Therefore increasing wave control greater than 0 0 results in a harsher colder arc while decreasing the wave control to less th
53. of the power source Make certain that the input voltage is proper 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 STT machines only May be exceeding the 325 amp limit on the STT output terminal Secondary current or voltage not be properly calibrated Check values displayed on the Power Feed 10 11 verses readings on an external meter Circuit breaker CB2 on case front may have opened Reset Circuit breaker 4 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 not understand the test procedures or are unable to perform the tests repairs safely tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455M STT CE LINCOLN 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION General degradation of the weld l Check for feeding problems bad performance connections excessive loops in cabling etc Verify weld mode is correct for processes The power source may require cal ibrati
54. 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 Non recoverable hardware fault Generally indicates nothing is connected to the Power Wave 455M 455M STT CE wire feeder receptacle See Trouble Shooting Section HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled and the fan continues to run until the machine cools down When cool the light goes out and output is enabled 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply OPERATION 5 14 I5 16 FIGURE B 1 CASE FRONT LAYOUT POWER WAVE 455M STT CE 5 AMP AUXILIARY POWER CIRCUIT BREAKER Protects 220 volt AC case front receptacle auxiliary supply LEAD CONNECTOR 5S2 SENSE LEAD DIAGNOSTIC CONNECTOR RS 232 WIRE FEEDER RECEPTACLE S1 5 PIN NEGATIVE STUD POSITIVE STUD AUXILIARY OUTPUT 5 PIN DEVICENET CONNECTOR OPTIONAL ROBOTIC WIRE FEEDER RECEPTACLE OPTIONAL CONNECTOR OPTIONAL STT STUD ETHERNET CONNECTOR OPTIONAL POWER WAVE 455M STT LINCOLN B 6 OPERATION B 6 NOMINAL PROCEDUR
55. oltage Sensing 67 lead GMAW 67 lead required GMAW P 67 lead required 67 lead required FCAW STT GTAW GMAW SAW CAC 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs 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 21 lead optional Voltage sense at studs The electrode voltage 67 sense lead is integral to the control cable to the wire feeder Work Voltage Sensing The standard Power Wave 455M STT CE is shipped with the work voltage sense lead enabled For processes requiring work voltage sensing connect the 21 work voltage sense lead K940 from the Power Wave work sense lead receptacle to the work piece Attach the sense lead to the work piece as close to the weld as practical but not in the return current path Enable the work voltage sensing in the Power Wave as follows 1 Turn off power to the power source at the disconnect 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 e switch M 4 Using a pencil or other small object slide i the switch right to the OFF position if the work sense lead is NOT connected 2 2 Conversely slide
56. on Check the actual current displayed on the Power Feed 10 vs actual current measured via external meter Check the actual voltage dis played on the Power Feed 10 vs actual voltage measured via exter nal meter Check the actual WFS displayed on the Power Feed 10 vs actual WFS measured via external meter If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility Excessively long and erratic arc Check for proper configuration and implementation of voltage sensing circuits In the STT mode the arc is exces 1 Check that the 21 work sense sively long and erratic lead is connected and configured properly In the STT mode the spatter is Check that the 21 work sense higher than normal and the arc is lead is connected and configured inconsistent properly Dip Switch Set Verify that the electrode lead is connected to the STT stud and not the POWER WAVE stud Check that the POWER WAVE stud is not electrically connected to the STT stud 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 455M STT CE LINCOLN 8 epoo y e
57. on as the machine goes through a self test at power up MEANING 1 System OK Power source communicating normally with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 455M STT CE is mapping identifying each component in the system Normal for first 1 10 sec onds 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 POWER WAVE 455M STT CE 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 sep arated by a green light To clear the error turn power source off and back on to reset Non recoverable hardware fault Generally indicates nothing is connected to the POWER WAVE 455M STT CE wire feeder receptacle See Trouble Shooting Section Status LED is blinking red Not applicable POWER WAVE 455 LINCOLN 8 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the POWER WAVE 455 5 can output via the status light see Troubleshooting the Power Wave Power Feed S
58. orming connection procedure Failure to do so will result in damage to the machine INPUT CONNECTION A WARNING Only a qualified electrician should connect the input leads to the Power Wave 455M STT CE Connections should be made in accordance with all local and national electrical codes and the con nection diagram 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 45 mm 1 75 inch diameter access hole for the input supply is located on the upper left case back next to the input access door 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 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 ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length
59. ot be Auto Mapped then the status light on the power source will blink green fast and the welder output will be disabled If a system is not Auto mappable then consult the instruction manual for the accessory being used for configuration information about DIP switch settings or consult your local Lincoln sales representative DUAL HEAD FEEDER POWER WAVE 455M STT CE SINGLE HEAD BOOM FEEDER POWER WAVE 455M STT CE UP TO 4 FEED HEADS ALLOWED Typical Robotic Hard Automation using Wire Drive Module and PF 10R ROBOT PLC CONTROLLER ANALOG INTERFACE etc POWER WAVE 455MISTT CE WIRE DRIVE MODULE POWER WAVE 455MSTT CE LINCOLN 8 7 INSTALLATION A 7 ALTERNATE HARD AUTOMATIC APPLICATION using a Ul WD Module and PF 10R POWER WAVE 455M STT CE WIRE DRIVE MODULE COMBINATION HARD AUTOMATION APPLICATION w Semi Auto WD Module and PF 10R POWER WAVE 455M STT CE System that is NOT Auto Mappable DUAL HEAD BOOM FEEDER using two single heads 455M STT CE DUAL HEAD POWER WAVE zi In this case the individual feed heads need to be assigned to the dual head control and the PW455M STT CE auto mapping disabled and the Equipment Groups set See the Feeder documentation for information on setting the feeder DIP switches POWER WAVE 455M STT CE LINCOLN P 8 WELDING WITH MULTIPLE POWER WAVES CAUTION Spec
60. other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained 50199 Electromagnetic Compatibility product standard for arc welding equipment 3 1 96H L10093 vii vii for selecting QUALITY product by Lincoln Electric We want you ank 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 Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over
61. ple System Electrode Positive CV Pulse Configuration shown POWER WAVE STT WIRE FEEDER WORK SENSE CONTROL CABLE K1543 POWER WAVE 455M STT LINCOLN E CONNECTION DIAGRAM F 3 Connection Diagram Semi automatic Simple System Electrode Positive STT Configuration shown POWER WAVE STT WIRE FEEDER WORK SENSE CONTROL CABLE K1543 POWER WAVE 455 STT LINCOLN DIAGRAMS 14 62 ol o o 11 14 97 M18241 32 88 26 10 DIMENSION PRINT POWER WAVE 455M 19 90 La n N N La m N N Loch LLLL LLLLLLLLLL q 9 4 SS o N o m 1 m mU NM NNNN NNNNNNN NC PE POWER WAVE 455 CE LINCOLN NOTES LINCOLN 8 WARNING Spanish AVISO
62. rting and low wire driving force wire feeding problems The K1543 series of control cables can be connected end to end for ease of extension Do not exceed more than 30 5 m 100 ft total control cable length FIGURE A 2 TWO POWER WAVES p di ES Travel Direction Connect All Work Sense Leads at the End of the J oint Connect All Welding Work Leads at the Beginning of the J oint POWER WAVE 455M STT CE LINCOLN 8 9 INSTALLATION A 9 MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES P Source BAD Current flow from Arc 1 affects sense lead 2 Current flow from Arc 2 affects sense lead 1 Neither sense lead picks up the correct work voltage causing starting and welding arc instability Power BETTER Source Source Sense 1 is only affected by weld 1 gt current from Arc 1 Sense 2 is only affected by weld current from Arc 2 Due to voltage drops across work piece Arc voltage may be low causing need for deviation from standard procedures BEST Both Sense leads are out of the current Work 1 paths Both Sense leads detect arc voltage accurately No voltage drop between Arc and Sense lead Best starts best arcs most reliable results Sense 2 POWER WAVE 455 LINCOLN 5 10 O RECEPTACLE SPECIFICATIONS TABLE 3 Communication Bus L Communication Bus Electrode Voltage Sense Ovdc 40vdc TABLE 4 VOL
63. s output characteristics output voltage output current accord ing to pre programmed settings contained in the POWER WAVE 455 5 CE In non synergic modes the WFS control behaves more like a conven tional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc characteristics the operator must adjust the volt age to compensate for any changes made to the WFS In constant current modes stick TIG this control adjusts the output current in amps VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse synergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 500 to 1 500 A Trim set ting of 1 000 is a good starting point for most condi tions Power Wave 455M STT CE Only In STT modes the user can adjust the Trim setting to change the overall heat input to the weld POWER WAVE 455 CE LINCOLN 7 WELDING MODE May be selected by name CV MIG CC Stick Crisp Gouge etc or by a mode number 10 24 71 etc depending on the Control Box options Selecting a welding mode determines the output characteristics of the Power Wave power source For a more complete description of the welding modes available in the Power Wave see the explanation below ARC CONTROL Also known as Inductance or Wave Control Allows operator t
64. se water coolers that do not have an integral flow sensor Recommended practice is to install a water flow sensor such as K1536 1 on the water return line of the torch When fully integrated into the welding system the sen sor will prevent welding if no water flow is present POWER WAVE 455 CE LINCOLN 8 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING TV ELECTRIC SHOCK can 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 Do not use AC welder if your cloth ing gloves or work area is damp or if working on under or inside work piece Use the following equipment DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before serv icing ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTRUC TIONS EMPLOYER S SAFETY PRACTICES AND MATERIAL SAFETY DATA SHEETS MSDS FOR CONSUMABLES READ THIS WARNING PROTECT YOURSELF amp OTHERS FUMES AND GASES can be 9 dangerous AR Keep your head out of fumes M Use ventilation or exhaust at the arc or both to keep fumes and gases from your breathing zone and general area WELDING SPARKS can cause fire or
65. 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 reach ing physical limitations of the welding process Arc Control often referred to as wave control in pulse programs usually adjusts the focus or shape ofthe arc Wave control values greater than 0 0 increase the pulse frequency while decreasing the background cur rent resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of posi tion welding See Figure A 6 FIGURE A 6 CURRENT WAVE FORM PULSE Current Wave Control 10 0 Wave Control 0 0 Wave Control 10 0 gt Time POWER WAVE 455M STT CE LINCOLN P 9 WELDING The pictures illustrate the wave shape of current for the process They are not drawn to scale and are intend ed only for the purpose of showing how the variables effect the waveform Trim in the STT mode adjusts the tail out and back ground portion of the waveform For open root processes the tail outis fixed and the trim affects only the background level 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
66. tions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of
67. udage par les chaines de levage 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 11 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place LINCOLN SAFETY
68. ult of an open or short in the primary side of the machine Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 36 37 Capacitor precharge failed Usually accompanied by codes 32 35 4l The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding Thermal error Secondary overcurrent error NOTE The secondary limit is 570 amps for the standard stud and 325 amps for the STT stud Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35 Single phase error Indicates machine is running on single phase input power Usually caused by the loss of the middle leg L2 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 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 455M STT CE LINCOLN
69. ystem Using the Status LED If connected to a PF 10 11 these error codes will generally be accompanied by an Err 006 or Err 100 on the user interface display Error Code Description Indication CAN communication bus off Probably due to excessive number of communication errors User Interface time out error UI is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or con trol cable 21 Ven ee Dr the Service Department for instructions reloading the Welding Software 22 77 the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Excessive Primary current present May be related to a short in the in transformer or output rectifier Left side facing machine input configuration itor B under voltage When accompanied by an overvoltage error on the same side it side facing machine indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine itor A over voltage Excess voltage on the main capacitors May be caused by improp de facing machine er input configuration Capacitor B over voltage When accompanied by an under voltage error on the same side it HM indicates no capacitor voltage present on that side and is usually Right side facing machine the res

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