Home

Lincoln Electric IM716 User's Manual

1. e AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes Na0 opere com os paineis abertos ou guardas removidas e e 20 Sel Sepe Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O Chinese Qai oe dul ade f cs jua jl sq Sarin e gad os uui ARI ge cal sd ue Ao pha J dust e cuts Fi gall l Jai y e Ll gt LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR
2. NOTE Turn main input power to the machine OFF before performing connection procedure Failur do so will result in damage to the machine 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 INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move this con nection to a different input voltage see the diagram located on the inside of the input access door If the main reconnect switch or link position is placed in the wrong position the welder will not produce output power If the Auxiliary A lead is placed in the wrong position there are two possible results If the lead is placed in a position higher than the applied line voltage the welder may not come on at all If the Auxiliary A lead is placed in a position lower than the applied line volt age the welder wi
3. OL a HOlIMS dOD Oil 90h 5 9 gt sor 5 gt eor E 9 92 n gt IS 1331 d WHOHSNVd1 Tirer oL oooi 08 7008 sso 39009 HgBnNS LIS 462 WH3HL 1038 zez 118298 ANY HOLIOVdVO SALON I CNVd103NNOO3801 10019313 mi YYYYYYY 1OV1d O d ul T i Y Hi YYY as HU ut i PEM EISE 1109819 VOL go AGLL 75 HITOlO VOL La POWER WAVE 455 STT ee J HO LO3NNOO 55554 55 vrvvvvY i D 119V1d3934 35V HOA eS leg ums E AV734 LV1S ANOS OL IN3HH O 3 3191 anos OL daHL ear V d SHNHOVW YAAA NO BUH GALONNOD XD OL VIH 7HNVd 103NNOO3H veo ae xn oL 1934 OL X FERMEN s3MOd OL n po i EDS ae Ven ex oH Sy WESSWHOJSNVHL 1 NIVW MDVOL OL Pdl HI 3Od331NI Ll 30334 JAIM IS IOV1d 9 ELLE 34292
4. 0 FAIS HHR ele BEHE TT Saal La aui J al gll Gail guet ag ls LINCOLN amp World s Leader in Welding and Cutting P roducts 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
5. m o a 2 D i L Y Y Sx NN NNN NNNNNN NN 7 POWER WAVE 455 STT LINCOLN 11 14 97 M18241 F 4 NOTES POWER WAVE 455 STT LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e 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 pega e terra E GUB MU DERNIERE see Oa CRM EER SHBg Xe sd s Bp e 2x9 Weal AMI d ous uil el jay oa Y O ay gl uit ae slt All usu DA daas ule Y Jio moe e Keep flam
6. 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 m MAGNETIC FIELDS i may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel
7. Left side facing machine Excess voltage on the main capacitors May be caused by improp er input configuration excessive line voltage or improper capacitor 35 Capacitor B over voltage balance see Error 43 Right side facing 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 Thermal error 37 Softstart error Capacitor precharge failed Usually accompanied by codes 32 35 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 41 Secondary overcurrent error NOTE The secondary limit is 570 amps for the standard stud and 325 amps for the STT stud and all single phase operation The maximum voltage difference between the main capacitors has 43 Capacitor delta error been exceeded May be accompanied by errors 32 35 49 Single phase error Indicates machine is running on single phase input power Usually caused by the loss ofthe 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 CAUTION If for any reason you do not unders
8. Machines above code 10500 are equipped with F A N fan as needed circuitry 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 minutes after the out put is disabled to ensure all components 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 con nect 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 LIMIT ON STACKING CAUTION FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder e Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lifting Do not stack more than three high Do not stack the CV 400 on top of any other machine 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 PROT
9. POWER WAVE 455 STT LINCOLN A 7 Group and Feed Head ID numbers are ignored in a simple System 8 INSTALLATION A 8 Multiple Group System FIGURE A 9 No Alllowed Single Group Multi Head System FIGURE A 10 No Alllowed The Dual Head option allows the abil ity to maintain 2 sets of procedures If more then 2 heads are used odd 5 use FH1 settings even 5 use FH2 settings Power Wave 455 POWER WAVE 455 STT LINCOLN 9 INSTALLATION A 9 Single Group Multi Head System Alternate Method FIGURE A 11 No FHO Alllowed 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 Im Group 0 ei FH 1 POWER WAVE 455 STT LINCOLN 318 INSTALLATION A 10 CAUTION CAUTION FIGURE A 2 TWO POWER WAVES 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 455 STT LINCOLN 11 INSTALLATION A 11 MULTIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Power Source Current flow from Arc 1 affects sense lead 2 Current flow from Arc 2 affects sense lead Z1 Source 2 Neither sense lead picks up the correct work voltage causing starting and welding arc instability Power S Source Sense 1 is only affected
10. 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and 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 skin and that of your helpers from the arc rays Pr
11. 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 metallique 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 defonctionnement 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 zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d
12. 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 soudage par les chaines de lev age 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 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 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie en LE
13. 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 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page LL LE VIE ferae Section A Technical Specifications POWER WAVE 455 A 1 Safety Precautions oett ner ee ere as baa a a was A 2 Select Suitable LOCATION uuu a rte se dirt o ri teaser tete A 2 EMIN EET 2 icr A 2 Machine Gouin x Esai t UR etes A 2 High Frequency Protection densit s detre A 2 iyu gere A 2 Input Fuse and Supply Wire Considerations A 3 Input Voltage Change Over Procedure A 3 Elctrode and Work Cable Connection A 3 Cable Inductance and its Effects on Pulse Welding A 4 Negative Electrode Polarity gt d rectc inne A 4 Voltage Sensing aut 4 thru
14. of misadjustments have been the Rating Plate located on the checked and the problem persists rear of the machine contact your local Lincoln the Thermal LED is also lit Authorized Field Service Facility see Yellow Thermal LED is Lit section Primary current limit has been exceeded Possible short in out put circuit Turn machine off Remove all loads from the out put of the machine Turn back on If condition persists turn power off and contact an autho rized Lincoln Electric Field Service facility This problem will normally be 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 CAUTION Iffor any reason you do 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 STT LINCOLN 8 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine often noodle welds 1 Secondary current limit has been put is limited to approximately 100 exceeded and the machine
15. 5 E 6 COMTI M E 6 Constant Voltage Welding esses eene nnne nnns B 7 Pulse Welding o Dente A tut Lt B 8 IAC COSSOMIOS i Section C C 1 Factory Bom uuu uuu u or x viso aired usss s C 1 Field Installed uiuere trees ite C 1 Maintenance ic Section D Safety Precaltions iskuna D 1 Routine MAIMTOM ANC Civics C D 1 Periodic Maintenance iii D 1 Calibration Specification trt err tte e tete t e tn dit ata D 1 vii TABLE OF CONTENTS Page Troubleshooting Section E How to use Troubleshooting Guide uuu E 1 Using the Status LED to Troubleshoot System Problems E 2 Troubleshooting onte E 3 thru E 7 Wiring Diagram Section F 1 Connection Dig GRAM iat LIL LI I III as sen Section F 2 F 3 Dimension Print U LLULLU Section F 4 Parts LIStS ll l M P394 Series vii 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS POWER WAVE 455 STT K1518 4 INPUT AT RATED OUTPUT THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT IDLE POWERFACTOR
16. 5 Power Wave to Semi automatic Power Feed Wire Feeder Interconnections A 5 System DESPON miai a A 6 eversa A 7 thru A 9 Welding with Multiple Power Waves A 10 Control Cable Specifications A 10 Multiple Arc Sense Lead and Work Lead Placement Guidelines A 11 Q Receptacle Specifications A 12 Dip Switch Settings and Locations A 12 Control Board Dip SWIECH sanu A 12 Power Wave Watercooler Field Installed A 12 lucus EIE A 12 Section B Safety Precautions uc mind gta a esie x dE XP eerie B 1 Graphic Symbols that appear on this machine or in this manual B 2 General DeseriptiOn uiuit umasa ax B 3 Recommended Processes and Equipment uu B 3 Required Egue Nisser RR x ERE rein re DES B 3 qu B 3 Duty Cycle and Time Period B 3 Case Front COMMONS ae RE B 4 Constant Voltage Welding 5 cx a oan a xu d d as 5 Finge Proc dures ette oce u B 5 Making A Weld 5 Welding rere lioe Eee pace eiu ite eden eni gs B
17. EFFICIENCY CONDITIONS CURRENT power RATEDOUPUT RATED AMPS OUPUT 208 230 460 575V 60HZ 450A 9 38V 100 6 58 53 25 22 570A Q 43V 60 82 78 37 31 400 Watts 95 MIN 8876 200 220 440 575V 50HZ 400A 9 36V 100 6 49 45 23 18 Max 500A Q 40V 60 67 61 31 25 OUTPUT OPEN PULSE AND AUXILIARY POWER CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND CIRCUIT BREAKER PROTECTED VOLTAGE TIME RANGE 75 VDC 5 570 10 15 1000 Hz 5 55 VDC 100 MICRO SEC 40 VDC AT 5 325 10 AMPS 115VAC AT 10 AMPS PROCESS CURRENT RANGES DC CURRENT MIG MAG 50 570 Average Amps FCAW 40 570 Average Amps SMAW 30 570 Average Amps Pulse 5 750 Peak Amps 40 325 Average Amps RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT TYPE 75 TYPE 75 VOLTAGE SUPER LAG FREQUENCY CONDUIT AWG IEC DUIT AWG IEC SIZES OR BREAKER SIZES 2 SIZE AMPS 208 50 60HZ 230 50 60HZ 460 50 60HZ 575 50 60HZ PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 26 10 in 19 86 in 32 88 in 293 lbs 663 mm 505 mm 835 mm 133 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 40 C to 40 POWER WAVE 455 STT LINCOLN 8 2 SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn the input power OFF at the disconnect swit
18. 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 455 STT 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 extension The out put receptacle on the Power Wave 455 STT is located beneath the spring loaded output cover at the bottom of the case front The input receptacle 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 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 sys tem For specific configuration information consult the semi automatic Power Feed instruction manual POWER WAVE 455 STT LINCOLN 8 6 INSTALLATION A 6 SYSTEM DESCRIPTION The Power Wave 455 STT and Power Feed 10 11 family of products utilize a digital communication sys tem called Linc Net Simply put Linc Net allows large amounts of information t
19. STT stud and not the OWERWAVE stud Check that the POWERWAVE 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 455 STT LINCOLN 8 97009 SDISUI paysed si epoo sejnomed oyioeds 40 3dIS IN3NOdWOO OH G3M3IA ON nO S ALAYO HOLO3NNOO 2 10 E 50500000 5000000 3009 1991319378 TVNOLLVN Yad QNnOdS W31SAS V OL Soi Sant Teens Or n vel fus oL pus z L PUT SAZFOLT no 3LHM M 3me n d CE SLIVIWSIHO SNOLSIS NMOMB N SLIONGAN SHOLIOVEWO N33H9 9 iS3mvA 1N NOdWOO ovis 8 09 40102 VAI 16513 H3d S1O WAS 1214199719 ANIHOVW dO 3GIS LHOIX Jequunu epoo 1ueuudinbe eu SAID 104 3ueuniedeg 9OIAJSGS eu SI eui sjeued y euo uo y 14 Aq paJeAoo SSUIUOBUU 104 eje1nooe eq jou Aew 1 Aluo SI 141 ION LMS HOLOVINOO OL JNN avo iBTdVd NO I
20. WAVE 455 LINCOLN for selecting a QUALITY product by Lincoln Electric We want you Thank 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 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
21. 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 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 STT 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 INS
22. consists of one power source one user interface and one feeder Under these circum stances the group and feed head ID DIP switches are ignored and the system will function regardless of their position The same is true for the minimum sys tem consisting of a power source and one UI Example a stick welding system FIGURE A 7 POWER WAVE 455 STT LINCOLN 7 Simple System 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 e 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 its user interface No two feed heads can have identical Group and Feed Head numbers Group and Feed Head ID numbers must be set on the appropriate dipswitches at each node Consult the PF 10 11 Instruction Manual for specific details regarding dipswitch settings Feed head 0 not allowed Exception Simple sys tem ignores all ID numbers therefore FHO will function Each node must be connected to the Linc Net com munication network The order of connection is not important as each node is identified by 5 unique Group and Feed Head ID number as defined on it s dipswitches See Figures A 8 thru A 12 FIGURE A 8
23. for technical assistance POWER WAVE 455 STT LINCOLN 8 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 per 1 Check for feeding problems bad Excessively long and erratic arc In the STT mode the arc is exces sively long and erratic In the STT mode the spatter is high er than normal and the arc is incon sistent connections excessive loops in cabling etc Verify weld mode is correct for processes The power source may require calibration Check the actual current dis played on the Power Feed 10 vs actual current measured via exter nal 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 Check for proper configuration and implementation of voltage sensing circuits Check that the 21 work sensellf all recommended possible areas of lead is connected and configured misadjustments have been checked and the problem persists contact your local Lincoln Authorized properly Check that the 21 work senselField Service Facility lead is connected and configured properly Dip S witch Set Verify that the electrode lead is connected to the
24. 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 12 switch 8 off work sense lead not connected on work sense lead connected FIGURE A 3 CONTROL BOARD DIP Switch Location POWER WAVE WATERCOOLER FIELD INSTALLED OPTION The K1767 1 is the recommended water cooler for the Power Waves Incorporated into the cooler is an auto matic flow sensor to detect low coolant flow If proper ly configured a low flow condition will cause a fault signal to be sent to the PF 10 11 feed head and weld ing output will automatically stop to protect the torch The water coolers are designed to cool only one weld ing gun and should be not used to cool multiple guns or other devices Water cooler manufacturers often specify additives to the coolant such as fungicides or alkalides Follow manufacturers recommendations to achieve proper operation and long lifetimes without clogging 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 those water coolers that do not have an integral flow sensor Recommended practice is to install a water flow sen sor such as K1536 1 on the water return line of the torch When fully
25. integrated into the welding system the sensor will prevent welding if no water flow is pre sent POWER WAVE 455 STT LINCOLN OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill 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 nyour cloth ing gloves or work area is damp or 9 if working on under or inside work piece Use the following equipment DC manual stick welder AC welder with reduced voltage control sDo not operate with panels removed Diconnect input power before ser vicing ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTUCTIONS EMPLOYER S SAFTEY PRACTICES AND MATERI AL SAFTEY DATA SHEETS MSDS FOR CONSUM ABLES READ THIS WARNIMG PROTECT YOURSELF amp OTHERS 23 FUMES AND GASES can be dangerous M AR Keep your head out of fumes 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 J DM fire or explosion Do not weld near flammable material Do not weld on containers which have held flammable material ARC RAYS can burn 2 Wear eye ear and body pro
26. 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 automatically 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 con tact tip to the work piece The Power Wave wave forms are optimized for a 0 75 19mm 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 reaching physical limitations of the welding process Arc Control often referred to as wave control in pulse programs usually adjusts the focus or shape of the 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 Wave Control 10 0 Wave Co
27. they may be struck or subjected to physical damage 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 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a 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 POWER WAVE 455 LINCOLN i 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
28. 2222 929292206923324 3 YYYYYY YYYY YYYYYYYYYYYY 0 HHH H lddns H3MOd TVIIDIQ C yYYTYYTYYTYYTYYY YYYY YYYY YYYYYYYYY al ANIHOVW 3GIS 1331 INVHOVIC ONIHIM 115 667 w H3MOd LINCOLN E F 2 CONNECTION DIAGRAM F 2 Connection Diagram Semi automatic Simple System Electrode Positive CV Pulse Configuration shown POWER WAVE STT CV PULSE POWER WAVE 455 STT LINCOLN F 3 DIAGRAMS F 3 Connection Diagram Semi automatic Simple System Electrode Positive STT Configuration shown POWER WAVE STT POWER WAVE 455 LINCOLN 4 DIMENSION PRINT POWER WAVE 455 DIAGRAMS D 1 o f co B YYYYYYY m YNYYYYYYYYYYYYYYYYY 7 97777777777777777 Q bs Es Y o m i1 Z 1 o a
29. ECTION Locate the Power Wave away from radio controlled machinery CAUTION The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTION WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electrical codes and the connection 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 1 75 inch 45 mm 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 on the following page POWER WAVE 455 STT LINCOLN INSTALLATION FIGURE A 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR Disconnect input power before inspecting or servicing machine Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install use or service this equipment VOLTAGE 220 230V 200 208V 220 230V A 440 460V 550 575V
30. N3S3 Hd 38 LON AW D nj ng ieonvot ad 109 dar OL Tor OL z lt gt W x lt x HOIINS 19RNNOOSH 01 H 2925736293 YYYYYYYYYY HHul YYYYYYY Y qadvOd 1 amp OINOWHVH CE HJWHOJSNVHL VITIXTIV 5 Y 088 O4 SI NMOHS 1ndNI 3404 NOLLO3NNOO 3 VItidOMddV NO QV311 V 30V 1d ON ASLS O SI NMOHS NOLLO3NNOO 9VI1OA ANANI HO TVIHdOHddV NI HOLIMS 39V ld BN 139008 93130 SNOV aa0H1v9 SN313130 3903 1v14 3H1 1S3NV3N Nid o dais LHOW osr a WE ee LD Hon 61108 Tid 31OV1d3938 lt aooo 5 CP uw t 298 95 1 lt ose OL lt O lt a LO3NNO934 MALT IINONYVH OL 02 OL N 31411938 1ndNI OL OINOWINH HOLMS 1 OL zh Was aedOdSNySL NN or LU ox o vega 1431 HOLMS WOLLO8 d Ol ad o k 30095 fi IddvOd HOLIMS 9 zeaa 1491 6 MEOS HOLIMS SOd amp HOLIMS 12 NNO2 ANIHOVW JO WO33 Q3M3IA SIHT OL
31. OURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 455 STT LINCOLN 8 2 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user inter face and feedhead 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 inter face in most cases indicate only that a 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
32. RETURN TO MAIN MENU Lud IM716 POWER WAVE 455 STT mE 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 careful IEC 60974 1 OPERATOR S MANUAL 180 9001 E ANSI RAB IS PY wN Desig ra Q Inc LINCOLN Copyright 2003 Lincoln Global Inc 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 ABS Quality Eval to ISO 9001 Re s CERTIFICATE NUMBER 30273 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 reproductive harm The Above For Diesel Engines The Above For Gasoline Engines
33. S MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement 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 TRANSFORMATEUR ET 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 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place POWER
34. TALLATION 4 For additional Safety information regarding the electrode and 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 connections often result in unsatisfactory welding per formance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connec tions 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 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 impro
35. TZ 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 e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 9 e zzv 24758 else SUAS MAS 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 Na0 opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e
36. ain similar arc characteristics throughout the WFS range 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 OPERATION B 7 All CV Modes Arc Control often referred to as wave control adjusts the inductance of the waveshape 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 than 0 0 provides a softer hotter arc See Figure A 5 FIGURE A 5 CURRENT WAVE FORM CV Wave Control 10 0 77 wm PES 4 Wave Control 0 00 Current Time _ 7 Wave Control 10 0 lt POWER WAVE 455 STT LINCOLN 8 PULSE WELDING Pulse welding procedures are set by controlling an 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
37. and green Status LED is solid red no blinking Status LED is blinking red 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 455 STT 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 MEANING 1 System OK Power source communicating normally with wire feeder and its components Occurs during a reset and indicates the Power Wave 455 STT is mapping identifying each compo nent in the system Normal for first 1 10 seconds after power is turned on or if the system configura tion 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 455 STT 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 separated 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 c
38. 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 Power Source 1 i Both Sense leads are out of the current paths Both Sense leads detect arc voltage accurately No voltage drop between Arc and Sense lead Best starts best arcs most reliable results POWER WAVE 455 LINCOLN A 12 I O RECEPTACLE SPECIFICATIONS TABLE 3 Communication Bus L Communication Bus H Electrode Voltage Sense Ovdc 40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE 52 LEAD FUNCTION PIN Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 RS 232 Transmit S3 Pin5 S3 Pin4 S3 Pin20 S3 Pin6 RS232 Commom DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P C Boards allow for custom configuration of the Power Wave To access the DIP switches off power at the disconnect switch 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 Adjustthe DIP switches as necessary Replace the panel and screws and restore power CONTROL BOARD DIP SWITCH switch 1 2 reserved for
39. ch 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 work ing on the equipment 0 Do not touch electrically hot parts Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Do not use Power Waves in outdoor environments The Power Wave 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 safety hazard The best practice is to keep the machine in a dry sheltered area Do not mount the Power Wave 455 STT over combustible sur faces Where there is a combustible surface directly under sta tionary or fixed electrical equipment that surface shall be cov ered with a steel plate atleast 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bot tom Dirt dust or any foreign material 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 operating tem peratures and nuisance shutdowns
40. e in long cable lengths This is especially important in Pulse and STT applica tions CAUTION When using inverter type power sources like the Power Waves use the largest welding electrode and ground cables that are practical At least 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 455 STT LINCOLN 4 CABLE INDUCTANCE AND ITS 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 50 feet traditional welding cables may be used without any effects on welding performance For the total welding loop length greater than 50 feet the K1796 Coaxial Welding Cables are recommended The welding 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 A 4 FIGURE A 4 e A ic WORK Et 4 SLIDING WORK CONNECTION K1796 COAXIAL CABLE 2 MEASURE FROM END OF OUTER JACKET OF CABLE Output connections on some Power
41. e 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 X 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 POWER WAVE 455 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 ground use the following equipment
42. eck reveals a problem contact the Lincoln Electric Company for the calibration 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 455 STT LINCOLN 8 D 1 1 TROUBLESHOOTING E 1 HOW TO USE 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 C
43. has amps when running a particular phased back to protect itself procedure especially a procedure Adjust procedure or reduce load with high WFS to lower current draw from the machine single phase input loss of L2 or applications running from the STT stud will reduce the sec ondary current limit from 570 Amps to 325 Amps Machine won t produce full output Input voltage may be too low limiting output capability 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 If all recommended possible areas proper on all three Input lines of misadjustments have been STT machines only May be checked and the problem persists exceeding the 325 amp limit on Contact your local Lincoln the STT output terminal Authorized Field Service Facility Secondary current or voltage not be properly calibrated Check values displayed on the Power Feed 10 11 verses readings on an external meter Auxiliary receptacle is dead 1 Circuit breaker 2 on case auxiliary voltage front may have opened Reset Circuit breaker CB4 in recon nect area may have opened Reset CAUTION Iffor any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility
44. ll not come on and the two circuit breakers in the reconnect area will open If this occurs turn off the input voltage properly connect the A lead reset the breakers and try again VOLTAGE 200 2081 IL 200 208V 220 230V N VOLTAGE 440 460V 200 208V 220 230V gt N 440 460V 550 575V 440 460V 550 575V VOLTAGE 550 575V 1 I 200 208V 220 230V N 440 460V B 7 550 575V THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A to ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length 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 WORK CABLE SIZE AWG Up To 100 Ft Length 30 m 2 0 67 mm2 3 0 85 mm2 3 0 85 mm2 400 Amps 500 Amps 600 Amps NOTE K1796 coaxial welding cable is recommended to reduce the cable inductanc
45. m 0 500 to 1 500 A Trim set ting of 1 000 is a good starting point for most condi tions Power Wave 455 STT Only In STT modes the user can adjust the Trim setting to change the overall heat input to the weld 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 to 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 POWER WAVE 455 STT LINCOLN 7 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 maint
46. mable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e eis A Jo ALD al gll Ac AI 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 prote o para a vista ouvido corpo e HRSESOREME ez 119 mol Soares s ESSAI de vues al ad ne t daag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO 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 ELEKTRODENEINSA
47. ntrol 0 0 Current Wave Control 10 0 Time POWER WAVE 455 STT LINCOLN 9 STT WELDING The pictures illustrate the waveshape of current for the process They are not drawn to scale and are intended only for the purpose of showing how the vari ables effect the waveform Trim in the STT mode adjusts the tailout and back ground portion of the waveform For open root processes the tailout is 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 pud dle hotter trim values less than 1 0 reduce energy to weld A nominal value of 1 0 will work for most applica tions 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 general the peak current is proportional to the arc length See Figure A 8 FIGURE A 7 Trim 1 50 curteni Trim 1 00 Trim 0 50 Time FIGURE 8 Wave Control 10 0 Wave Control 0 0 Wave Control 10 0 Current POWER WAVE 455 LINCOLN 1 ACCESSORIES E OPTIONAL EQUIPMENT FACTORY INSTALLED None Available FIELD INSTALLED Work Voltage Sense Lead Kit K940 Dual Cylinder Undercarriage K1570 1 Gas Guard Regulator K659 1 Coaxial welding Cable K1796 PowerWave WaterCooler K1767 1 Water Fl
48. nues to run until the machine cools down When cool the light goes out and output is enabled 4 10 AMP AUXILIARY POWER CIRCUIT BREAKER Protects 115 volt AC case front receptacle auxiliary supply CASE FRONT LAYOUT POWER WAVE 455 STT NORTH AMERICAN CANADIAN 5 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply 6 LEAD CONNECTOR 52 SENSE LEAD 7 DIAGNOSTIC CONNECTOR RS 232 8 WIRE FEEDER RECEPTACLE S1 5 PIN 9 NEGATIVE STUD 10 POSITIVE STUD 11 AUXILIARY OUTPUT 12 STT STUD POWER WAVE 455 STT LINCOLN 5 OPERATION NOMINAL PROCEDURES The Power Wave is designed to operate with 3 4 electrode stick out for CV and Pulse processes and a 1 2 stick out for STT processes FRINGE PROCEDURES Excessively short or long electrode stick outs may function only on a limited basis if at all MAKING A WELD WARNING The serviceability of a product or structure utiliz ing 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 respon
49. o be passed at very high speeds between components nodes in the system The system requires only two wires for communica tion and because of its bus like structure the compo nents may be connected to the network in any order thus simplifying the system set up Each system must contain only one power source The power source may be connected to a maximum of four feeder groups Each group containing one user interface UI and up to seven Feed Heads FH SEE FIGURE A 7 The UI controls all of the FH s of that group The Ul s and FH s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards For example all of the FH s to be controlled by a given UI must have their Group ID switches set to the same group number as the UI In addition each FH must be assigned a separate FH number within that group See the system set up sec tion for further details System Model From a network perspective each component in the system is considered a separate node regardless of its physical location For example even though a UI and FH may be physically mounted together they are stil viewed as separate pieces nodes by the net work and can only communicate via Linc Net The Linc Net connection is generally made external through the Linc Net Control Cable but can also be made internally as with the PF 10 bench model feed er The most common Linc Net configuration called a simple system
50. 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 unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455 STT LINCOLN 8 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Thermal LED is lit l Fan thermostat has opened Check for proper fan operation Fan should run whenever out put power is on Check for material blocking intake or exhaust louvers or for excessive dirt clogging 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 Machine won t weld can t get any Input voltage is too low or too output CR1 will not pull in high Make certain that input If all recommended possible areas voltage is proper according to
51. onnected to the Power Wave 455 STT wire feeder receptacle See Trouble Shooting Section Not applicable POWER WAVE 455 STT LINCOLN 8 E 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 STT can output via the status light see Troubleshooting the Power Wave Power Feed System 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 Indication 11 CAN communication bus off Probably due to excessive number of communication errors 12 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 21 Unprogrammed Weld Mode Contact the Service Department for instructions on reloading the Welding Software 22 Empty Weld Table 23 Weld Table checksum error 31 Primary overcurrent error Excessive Primary current present May be related to a short in the main transformer or output rectifier 32 Capacitor A under voltage Left side facing machine Low voltage on the main capacitors May be caused by improper 33 Capacitor B under voltage input configuration or an open short circuit in the primary side of Right side facing machine the machine 34 Capacitor A over voltage
52. or 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 POWER WAVE 455 LINCOLN SAFETY 7 WELDING SPARKS can lt gt 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 Practices for the Preparation fo
53. otect 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 23 FUMES AND GASES can be dangerous 5 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 Read and understand the manufacturer s instructions f
54. ow Sensor K1536 1 The Dual Cylinder Undercarriage K1570 1 is not compatible in combination with the Power Wave WaterCooler K 1767 1 COMPATIBLE LINCOLN EQUIPMENT Any Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF 10 PF 10X2 PF 11 POWER WAVE 455 STT LINCOLN 8 D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only Qualified personnel should perform this maintenance 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 455 STT is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the cali bration 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 or the yearly calibration ch
55. perly configured extremely high welding 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 at the four pin connector located underneath the output stud cover By default the WORK voltage is moni tored at the output stud in the Power Wave 455M STT For more information on the WORK sense lead 21 see Work Voltage Sensing in the following paragraph All constant current processes sense the voltage at the out put studs of the POWER WAVE 455M STT by default POWER WAVE 455 STT LINCOLN 5 Enable the voltage sense leads as follows TABLE A2 Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Work Voltage Sensing 21 lead p 21 lead optional 21 lead optional 21 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required 21 lead optional Voltage sense atstuds 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 455 STT 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
56. r 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 e 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 its output characteristics output voltage output current according to pre programmed settings contained in the Power Wave In non synergic modes the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc character istics the operator must adjust the voltage to compen sate for any changes made to the WFS In constant current modes stick TIG this control adjusts the output current in amps POWER WAVE 455 STT LINCOLN 6 OPERATION 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 fro
57. r 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode LEM 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 Oylinders should be located Away from areas where
58. sible for welding program selec tion 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 GMAW STT 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 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 communicat ed 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 sup plied as part of the wire feeder It can be mounted directly on the wire feeder itself the front of the powe
59. 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 condition 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 STT is mapping identify ing 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 of red and green errors are present in the Power Wave 455 STT 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 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 455 STT wire feeder receptacle See Trouble Shooting Section Blinking Red Not applicable 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled and the fan conti
60. t the GMAW GMAW P FCAW SMAW GTAW CAC A and STT processes It carries an output rating of either 450 amps 38 volts 400 amps 36 volts both at 100 duty cycle depending on input voltage and frequency The Surface Tension transfer process STT is supported at currents up to 325 amps at 10096 duty cycle RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave 455 STT can be set up in a number of configurations some requiring optional equipment or welding programs Each machine is factory prepro grammed with multiple welding procedures typically including GMAW GMAW P FCAW SMAW GTAW CAC A and STT for a variety of materials including mild steel stainless steel cored wires and aluminum The STT process supports mild steel and stainless steel welding The Power Wave 455 STT is recommended for semi automatic welding and may also be suitable for basic hard automation applications OPERATION B 3 RECOMMENDED EQUIPMENT Power Wave 455 STT Semi Automatic Operation Semi Automatic Power Waves can only be used with Linc Net compatible Power Feed semi automatic wire feeders In addition the Power Feed semi automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave Other models 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 semi automatic user in
61. tand 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 455 STT LINCOLN 8 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage 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 ON 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
62. tection POWER WAVE 455 STT LINCOLN 2 O OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER ON OFF HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT U P 3 PHASE INVERTER po INPUT POWER THREE PHASE DIRECT CURRENT POWER WAVE 455 STT B 2 SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION 3 GENERAL DESCRIPTION The Power Wave semi automatic power source is designed to be a part of a modular multi process welding system Depending on configuration it can support constant current constant voltage and pulse welding modes The surface tension transfer mode is supported only by the 455 STT The Power Wave 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 component power source wire feeder user interface knows what the other is doing at all times These components commu nicate with Linc Net The Power Wave 455 STT is a high performance dig itally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can suppor
63. ter face REQUIRED EQUIPMENT Any Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF 10 PF 10X2 PF 11 LIMITATIONS WARNING e The Power Waves are not to be used in outdoor environments e The Power Wave 455 STT will support a maximum average output current of 570 Amps 60 Duty Cycle on the standard Power Wave stud and a maximum average output current of 325 Amps 10096 Duty Cycle on the STT stud e Only Linc Net compatible Power Feed semi auto matic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used DUTY CYCLE AND TIME PERIOD The Power Feed wire feeders are capable of welding ata 10096 duty cycle continuous 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 repre sents 6 minutes of welding and 4 minutes of idling in a ten minute period POWER WAVE 455 STT LINCOLN B 4 OPERATION B 4 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure 4 1 POWER SWITCH Controls input power to the Power Wave 2 STATUS LIGHT A two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated per table 3 NOTE The Power Wave 455 STT
64. 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 WARNING e Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Alwoays wear dry insulating gloves 1 Turn off power to the power source atthe disconnect switch NA Remove the front cover from the power source 199 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 Switch 4 Using a pencil or other small object slide the switch right to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 12 3 45 6 7 8 lt Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately INSTALLATION 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
65. 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 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 position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to 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 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan ND Do not attempt to override the governor or idler by pushing on th

Lincoln Electric IM716 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents