Lincoln Power Wave 455 Operator'S Manual Download Page 40 | Manualshive

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F-5

CONNECTION DIAGRAM

F-5

POWER WAVE 455/R

K1796 COAXIAL WELD CABLE

User supplied
work lead

User supplied
electrode lead

-

+

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE OR
K1804-2 AND ANY K1795 CONTROL CABLE

Robotic Set Up, Electrode Positive, CV/Pulse
Configuration

User supplied
work lead

User supplied
electrode lead

CONTROL CABLE K1805-1

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Summary of Contents for Power Wave 455

Page 1: ...d most importantly think before you act and be careful For use with machines having Code Numbers 10675 10676 Date of Purchase Serial Number Code Number Model Where Purchased IEC 60974 1 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 World s Leader in Welding and Cutting Products Co...

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 in Welding 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 ...

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 h 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 3 i When ...

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 Have a fire extinguisher readily available 6 b 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 Cut...

Page 5: ...inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigner les ma...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Page 7: ...ption B 3 Recommended Processes and Equipment B 3 Required Equipment B 3 Limitations B 3 Duty Cycle and Time Period B 3 Case Front Controls B 4 Constant Voltage Welding B 5 Pulse Welding B 6 STT Welding B 7 ________________________________________________________________________ Accessories Section C Optional Equipment C 1 Factory Installed C 1 Field Installed C 1 _________________________________...

Page 8: ...10 10 6 10 6 TYPE 75 C COPPER WIRE IN CON DUIT AWG IEC SIZES MM2 4 25 4 25 8 10 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 Amps 30 570 Average Amps 5 750 Peak Amps 40 325 Average Amps PULSE VOLTAGE RANGE 5 55 VDC AUXILIARY POWER CIRCUIT BREAKER PROTECTED 40 VDC 10 AMPS 115VAC 10 AMPS PULSE AND BACKGROUND TIME RANGE 100 MICRO...

Page 9: ... PHYSICAL DIMENSIONS TEMPERATURE RANGES HEIGHT 26 10 in 663 mm WIDTH 19 86 in 505 mm DEPTH 32 88 in 835 mm WEIGHT K1761 1 247 lbs 112 kg K1761 2 295lbs 133 kg OPERATING TEMPERATURE RANGE 20 C to 40 C STORAGE TEMPERATURE RANGE 40 C to 40 C ...

Page 10: ...CK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before work ing on the equipment Do not touch electrically hot parts Always connect the Power Wave grounding lug locat...

Page 11: ...the applied line volt age the welder will 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 NOTE Turn main input power to the machine OFF before performing connection procedure Failure to do so will result in damage to the machine K1761 1 FIGURE A 1 CONNECTION DIAGRAM ON CO...

Page 12: ...ork piece at the end of the weld 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 TWO POWER WAVES CAUTION For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves When these parameters are identical the pulsing fre quency will be the same helpi...

Page 13: ...he electrode cable should be sized according to the specifications given in the work cable connections 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 welding is planned Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance When w...

Page 14: ...t the wire feeder A 7 INSTALLATION POWER WAVE 455 R A 7 5 Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately 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 ...

Page 15: ... unsatisfactory pulse weld ing performance CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables be used at all times Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed system The use of non standard cables especially in lengths greater than 25 feet can lead to communi cation problems system shutdowns poor motor ...

Page 16: ... dry insulating gloves 1 Set the High Low switch code on Wire Drive PC board as follows Turn off power to the power source at the discon nect switch Remove the front cover from the power source The wire feed head board is on the right side of the power source Locate the 8 position DIP switch and look for position 8 of the DIP switch Using a pencil or other small object slide the switch right to th...

Page 17: ...e use switch 8 work sense lead 1 LEASE SIGNIFICANT BIT 2 MOST SIGNIFICANT BIT switch 8 work sense lead off work sense lead not connected on work sense lead connected Feed Head Board DIP Switch switch 1 Object Instance LSB see table 1 switch 2 Object Instance MSB see table 1 switch 3 Equipment Group 1 Select switch 4 Equipment Group 2 Select switch 5 Equipment Group 3 Select switch 6 Equipment Grou...

Page 18: ... 0 0 0 0 17 0 1 0 0 0 1 18 0 1 0 0 1 0 19 0 1 0 0 1 1 20 0 1 0 1 0 0 21 0 1 0 1 0 1 22 0 1 0 1 1 0 23 0 1 0 1 1 1 24 0 1 1 0 0 0 25 0 1 1 0 0 1 26 0 1 1 0 1 0 27 0 1 1 0 1 1 28 0 1 1 1 0 0 29 0 1 1 1 0 1 30 0 1 1 1 1 0 31 0 1 1 1 1 1 32 1 0 0 0 0 0 33 1 0 0 0 0 1 34 1 0 0 0 1 0 35 1 0 0 0 1 1 36 1 0 0 1 0 0 37 1 0 0 1 0 1 38 1 0 0 1 1 0 39 1 0 0 1 1 1 40 1 0 1 0 0 0 41 1 0 1 0 0 1 42 1 0 1 0 1 0 4...

Page 19: ...g ceases 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 FUMES AND GASES can be dan gerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have...

Page 20: ... 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 GROUND WARNING OR CAUTION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U0 U1 U2 I1 I2 SMAW ...

Page 21: ... Surface Tension Transfer and pulse welding modes The Power Wave power source is designed to be used with the 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 electrical accessories knows what the other is doing at all times The components communicate using ...

Page 22: ... 5 PIN ARC LINK S1 8 5 PIN DEVICENET CONNECTOR S5 9 I O CONNECTOR 10 NEGATIVE STUD 11 INTERFACE CONNECTOR S6 12 STT STUD 13 POSITIVE STUD 14 AUXILIARY OUTPUT POWERWAVE Case Front Layout Power Wave 455 R Domestic Canadian Version 2 3 11 12 14 13 10 9 8 7 6 5 4 1 FIGURE A 4 Light Condition Steady Green Blinking Green Alternating Green and Red Steady Red Blinking Red Meaning System OK Power source co...

Page 23: ...eed speed changes the Power Wave will automatically adjust the voltage correspondingly Wave control adjusts the inductance of the wave shape This adjustment is often referred to as pinch Inductance is inversely proportional pinch Increasing wave control greater than 0 results in a harsher cold er arc while decreasing the wave control to less than 0 provides a softer hotter arc See Figure A 5 POWER...

Page 24: ...waveform parameters to maintain similar arc properties POWER WAVE 455 R The Power Wave utilizes adaptive control to compensate for changes in electrical stick out while welding Electrical stick out is the distance from the contact tip to the work piece The Power Wave waveforms are optimized for a 0 75 19mm stick out The adaptive behavior supports a range of stickouts from 0 50 13mm to 1 25 32mm At...

Page 25: ...nt is proportional torch arc length See Figure A 8 POWER WAVE 455 R Trim 1 00 Trim 1 50 Trim 0 50 Wave Control 0 0 Wave Control 10 0 Wave Control 10 0 Trim in the STT mode adjusts the tailout and background portion of the waveform Trim values greater than 1 0 add more energy to the weld and make the weld puddle hotter trim values less than 1 0 reduce energy to weld A nominal value of 1 0 will work...

Page 26: ...w condition a fault signal is sent to the Power Wave and welding output auto matically stops to protect the torch POWER WAVE 455 R The water coolers are designed to cool only one welding 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 p...

Page 27: ...will not need adjustment However neglected or improperly calibrated machines may not yield sat isfactory weld performance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the factory Generally speaking the machine calibration will not need adjustment However if the weld per fo...

Page 28: ...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 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 Autho...

Page 29: ...n and Red Steady Red Blinking Red System OK Power source communicating normally with wire feeder and its components Occurs during a reset and indicates the Power Wave is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during opera tion Non recoverable system fault If the PS Status light is flashing an...

Page 30: ...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 recommended fuse and breaker sizes 2 Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle or both 3 There is internal damage to the power source Co...

Page 31: ...CR1 will not pull in 1 Fan thermostat has opened Check for proper fan opera tion Fan should run whenev er main power is on Check for material blocking intake or exhaust louvers or for exces sive dirt clogging cooling channels in machine 2 Secondary rectifier thermostat has opened After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers 1 Input v...

Page 32: ...en exceeded and the machine has phased back to protect itself Adjust proce dure or reduce load to lower current draw from the machine 1 Input voltage may be too low limiting output capability of the power source Make certain that the input voltage is prop er according to the Rating Plate located on the rear of the machine 2 Input may be single phased Make certain the input voltage is proper on all...

Page 33: ...tor Possible faults are lack of water flow water flow turned off 1 Check that the 21 work sense lead is connected 1 Check that the 21 work sense lead is connected 2 Verify that the electrode lead is connected to the STT stud and not the POWERWAVE stud 3 Check that the POWERWAVE stud is not electrically connected to the STT stud 1 Check for fault signals from the I O connector Possible faults are l...

Page 34: ...erface is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or control cable Contact the Service Department 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 reloading the Welding Software Excessive P...

Page 35: ...l phase back to 100 amps typically result ing in a condition referred to as noodle welding NOTE For the Power Wave 455 R 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 been exceeded May be accompanied by errors 32 35 Indicates machine is running on single phase input p...

Page 36: ... LEAD ON APPROPRIATE CONNECTION FOR OPERATION RIGHT SIDE OF MACHINE 1 J8 J9 228 226 1 224 220 504 503 406 505 4 506 2 3 211 2 3 816 7 8 21A 418 514 1 273 274 5 6 2 1 TO J6 J10B RIGHT SIDE 13 512 4R 4 3 4W 2 1 VOLTAGE SENSE SELECT BOARD TO SWITCH BD 1 D4 J40 F4 403 F4 THERM 9 1 2 3 4 1 2 3 4 J72 J75 FEED HEAD BOARD 11 J42 TO J5 6 5 4 3 2 225 1 SEC TOP RIGHT 15 16 2 3 5 J50 C5 J60 10 10 9 8 7 6 5 4 ...

Page 37: ... J5 6 5 4 3 2 225 1 SEC TOP RIGHT 15 16 2 3 5 J50 C5 J60 10 10 9 8 7 6 5 4 273 3 228 274 226 TO J8 4 TO S3 1 2 J43 251 253 254 J1 9 13 7 DEVICE NET GATEWAY BOARD 14 8 6 5 4 1 3 2 NEG DIGITAL POWER SUPPLY BOARD 3R TO 3W J7 MAIN CHOKE L1 221 4 3 231 232 291 X3A 1 3 2 16 10 5 1 2 05 600V C1 TP1 TO C8 288A 345 287 TP7 RECTIFIER SWITCH RECONNECT TO 16 414 H4 A LEFT SIDE OF MACHINE RECONNECT SWITCH H4A ...

Page 38: ... for future use T 855A Shield ground to case U Reserved for future use V Reserved for future use W Reserved for future use X Reserved for future use TABLE 2 WIRE FEEDER RECEPTACLE S1 Pin Lead Function A 53 Arclink L B 54 Arclink H C 67A Electrode Voltage Sense D 52 Ground 0v E 51 40vdc TABLE 6 EXTERNAL I O S7 Pin Lead Function 1 851 15vdc for Trigger group 2 852 Trigger input 3 853 Dual procedure ...

Page 39: ...iguration WORK SENSE LEAD K940 WATERCOOLED TORCH ELECTRODE LEAD CONTROL CABLE K1795 WATER COOLER POWER CONNECTION SHIELDING GAS TO SHIELDING GAS DEVICENET CABLE TO PLC CONTROLLER DEVICENET CABLE TO PLC CONTROLLER ELECTRODE LEAD CONTROL CABLE K1795 WATER COOLER POWER CONNECTION WATER LINES ...

Page 40: ...d User supplied electrode lead POWERWAVE CONTROL CABLE K1805 1 WORK SENSE LEAD K940 DEVICENET CABLE K1804 1 CONTROL CABLE OR K1804 2 AND ANY K1795 CONTROL CABLE Robotic Set Up Electrode Positive CV Pulse Configuration User supplied work lead User supplied electrode lead CONTROL CABLE K1805 1 ...

Page 41: ...F 6 DIAGRAMS F 6 POWER WAVE 455 R 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 42: ...NOTES POWER WAVE 455 R ...

Page 43: ...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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 44: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 45: ...s 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 Products ...

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