Lincoln Electric POWER WAVE 455/STT Operator'S Manual Download Page 18 | Manualshive

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A-10

INSTALLATION

POWER WAVE 455/STT

A-10

FIGURE A.2

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+

POWERWAVE

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+

POWERWAVE

Connect All Work
Sense Leads at the End
of the Joint

Connect All Welding
Work Leads at the
Beginning of the Joint

Travel

Direction

-

+

POWER WAVE

-

+

POWER WAVE

TWO POWER WAVES

CAUTION

CAUTION

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Summary of Contents for POWER WAVE 455/STT

Page 1: ...TALL 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 For use with machines having...

Page 2: ...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 i...

Page 3: ...th ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3...

Page 4: ...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 Ha...

Page 5: ...on inflammables 4 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 sa...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...tch A 12 Power Wave Watercooler Field Installed A 12 Water Flow Sensor A 12 ________________________________________________________________________ Operation Section B Safety Precautions B 1 Graphic...

Page 8: ...hooting Guide E 3 thru E 7 ________________________________________________________________________ Wiring Diagram Section F 1 Connection Diagram Section F 2 F 3 Dimension Print Section F 4 __________...

Page 9: ...EC SIZES MM2 6 16 6 16 10 6 10 6 TYPE 75 C COPPER WIRE IN CONDUIT AWG IEC SIZES MM2 4 25 4 25 8 10 10 6 PROCESS CURRENT RANGES DC MIG MAG FCAW SMAW Pulse STT CURRENT 50 570 Average Amps 40 570 Average...

Page 10: ...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 work ing on...

Page 11: ...CTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR 200 208V 220 230V 440 460V 550 575V 200 208V 220 230V 220 230V 220 230V 200 208V 220 230V 440 460V 550 575V 200 208V U L1 550 575V 440 460V A A 440 460V A...

Page 12: ...he connection will bypass the STT circuitry and severely deteriorate STT welding performance For additional Safety information regarding the electrode and work cable set up See the standard SAFETY INF...

Page 13: ...able the voltage sense leads as follows TABLE A 2 Process Electrode Voltage Work Voltage Sensing 67 lead Sensing 21 lead GMAW 67 lead required 21 lead optional GMAW P 67 lead required 21 lead optional...

Page 14: ...he 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 syst...

Page 15: ...nterface 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...

Page 16: ...9 Multiple Group System No FH0 Alllowed FIGURE A 10 Single Group Multi Head System No FH0 Alllowed The Dual Head option allows the abil ity to maintain 2 sets of procedures If more then 2 heads are us...

Page 17: ...WAVE 455 STT A 9 FIGURE A 11 Single Group Multi Head System Alternate Method No FH0 Alllowed When a standard User Iterface is used in a group with multi ple Feed Heads all of the Feed Heads use a sin...

Page 18: ...455 STT A 10 FIGURE A 2 POWERWAVE POWERWAVE Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint Travel Direction POWER WAVE POWER WAVE TWO...

Page 19: ...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 BAD Sense 1 is only affected by weld current from...

Page 20: ...se switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future use switch 8 work sense lead switch 8 work sense lead off work sense lead not connected on work sense...

Page 21: ...voltage control Do 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 INSTU...

Page 22: ...FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE...

Page 23: ...utomatic 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...

Page 24: ...f 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 I...

Page 25: ...ke 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 s...

Page 26: ...sp 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 des...

Page 27: ...re 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 ma...

Page 28: ...ilar arc properties POWER WAVE 455 STT Wave Control 0 0 Wave Control 10 0 Wave Control 10 0 FIGURE A 6 Current Time CURRENT WAVE FORM PULSE The Power Wave utilizes adaptive control to com pensate for...

Page 29: ...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 For most progra...

Page 30: ...9 1 Coaxial welding Cable K1796 PowerWave WaterCooler K1767 1 Water Flow Sensor K1536 1 The Dual Cylinder Undercarriage K1570 1 is not compatible in combination with the Power Wave WaterCooler K1767 1...

Page 31: ...ot 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 b...

Page 32: ...IBLE 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 genera...

Page 33: ...e machine is first turned on This is a normal situation as the machine goes through a self test at power up LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LE...

Page 34: ...artment for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloadin...

Page 35: ...tact your local authorized Lincoln Electric Field Service facility for technical assis tance 1 Make certain that fuses or breakers are properly sized See Installation section of this manual for recomm...

Page 36: ...r machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers 3 DC Bus PC board thermostat has opened check for excessive load on 40VDC supply 1 Input volta...

Page 37: ...rotect itself 2 Adjust procedure or reduce load to lower current draw from the machine 3 A single phase input loss of L2 or applications running from the STT stud will reduce the sec ondary current li...

Page 38: ...correct for processes 3 The power source may require calibration 4 Check the actual current dis played on the Power Feed 10 vs actual current measured via exter nal meter 5 Check the actual voltage d...

Page 39: ...11 12 20D TO SWITCH BD 2 TO RECONNECT SWITCH H5 H6 CAPACITORS MFD VOLTS RESISTORS OHMS WATTS H1 200 208 H2 220 230 PRI TOP LEFT R 115V N 24V X4 COLLECTOR 2 6 TO J61 H1D TOP LOAD LINE TO CB3 612B TO C...

Page 40: ...ION DIAGRAM F 2 POWER WAVE 455 STT Connection Diagram Semi automatic Simple System Electrode Positive CV Pulse Configuration shown POWER WAVE STT CV PULSE STUD WIRE FEEDER CONTROL CABLE K1543 TO WORK...

Page 41: ...F 3 DIAGRAMS F 3 POWER WAVE 455 Connection Diagram Semi automatic Simple System Electrode Positive STT Configuration shown POWER WAVE STT STT STUD WIRE FEEDER CONTROL CABLE K1543 TO WORK WORK SENSE...

Page 42: ...F 4 DIAGRAMS F 4 POWER WAVE 455 STT 3 2 8 8 2 6 1 0 2 2 6 3 1 2 3 5 1 9 0 0 1 9 9 0 1 9 1 6 9 4 8 1 4 6 2 2 3 1 2 2 3 5 1 11 14 97 M18241 DIMENSION PRINT POWER WAVE 455...

Page 43: ...NOTES POWER WAVE 455 STT...

Page 44: ...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 da Aislese del trabajo y...

Page 45: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 46: ...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 World s Leader in Welding and Cutting Pr...

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