background image

F-1

DIAGRAMS

F-1

POWER WAVE 455/STT

NOTE:  This diagram is for reference only.   It may not be accurate for all machines covered by this manual.  The specific diag

ram for a particular code is pasted inside

the machine on one of the enclosure panels.  If the diagram is illegible, write to the Service Department for a replacement.  G

ive the equipment code number..

(22

0-2

30

)

H2

A

(38

0-4

15

)

H4

A

H1

A

4

6

H3

H6

A

(55

0-5

75

)

1

4

H1

A

H2

H1

H5

A

3

3

H5 (44

0-4

60

)

H6

1

H4

2

6

2

5

(20

0-2

08

)

H3

A

5

H6

A

P50 JU

MPER

(MA

Y N

O

T BE PRESEN

T

ON EARLIER 

MACH

INES)

61

2A

CB3 10A

BREAKER

TO

 CB4

TO S

W

1

TO J6

1

CB3

61

2A

61

2

H1

A

TO

 AUX 

#2

CIRCUIT

CB4 6A

BREAKER

CIRCUIT

61

2B

"H1

A TO AU

#2"

CONN

EC

TED H

ER

E

ON E

ARLI

ER MAC

HINE

S

H1

JUMP

ER

 (H1

A)

TO AUX 

#1

-

TO J9

20

2

W

ORK

20

2A

TO R1

TO T

P

6

TO

 T

P

3

TO CB1

S1

W

IRE

FEEDER

RECEPTAC

LE

J47

+

ELECTRODE

22

3

22

1

20

6A

R3

C8

TO

 D5

28

9D

R2

  2

Y

28

8C

28

8D

28

9E

288E

TO

3R3R 3W

238

15

5

J10

TO SS

R

REC

T

THERM

223

222

CH

OPPER

BD

SEC

(BOT

TO

M

LEFT)

POW

ER BD

RECTI

FI

ER

AC

EM

IT

TE

R

212 213 81

3

81

1

21

6

4

CONTRO

L B

OARD

+

TO J6

1

CR

1

X4

6

TO AUX 

#1

503

504

505

506

IN

P

U

T

20

D

17

18

S

TT SNU

B

B

ER

15

16

F1

F1

TO CB1 J41

1

4R

J4

25

1

20

C

J47

TO P9

0

P9

1

RECT

29

2

SEC (TOP LEFT)

U

TO S

W

1

L1

A

V

L3

AC 3

TO CR1

SW

1

CB4

L3

A

T2

L2

AC 2

H1D

T3

T1

T2

612

T3

NEG

1 2 3 4

+

4W

34

6

C3 AUX. #

1

TO

4

3

D3

TO

CH

O

K

E

TH

ER

M

D

CUR

RENT

TRANSDUCER

TO

 C8

19

D

SW

ITCH B

OARD

#2

289

A

-

+

28

8B

TO C1

0

SW

1

PO

W

E

R

C1

0

28

9F

A

20

2

225

J7

2

J2

20

6

S1

TO

52

J5

E

LEC

TRODE

CB2

AUX 2

TO

32

ST

T

W

ORK

TO

TP

6

1 2 3 4 5 6 7

J3

4 5 6

3

2

4

1

8

7

6

5

4

3

2

1

28

9E

28

9D

28

9C

28

9B

288E

28

8D

28

8C

28

8B

28

9C

R4

28

9A

  2

Y

TO

 C1

0

289

B

NEG

ST

T

X1

+

8

G

60

1

TO J6

0

L1

20

NE

G

19

C

T1

RE

A

R

 OF M

A

CHINE

TO J6,J1

0B

6

TO

 S

O

LI

D

 ST

AT

E R

E

LA

Y

3

2

TO

 S

O

LI

D

 ST

AT

E R

E

LAY

44

4

FAN

THIS AR

EA 

VIE

W

E

D

 FR

OM

28

8F

RECO

NNEC

T

PAN

EL

TO CR1 J6

231

AUX #

1

J61

5 6 7 8 9

PO

S

D1

TO MAI

N

TR

A

N

S

FORME

R

50

TO L2

CB1

10A CIRCUIT

BREAKER

R 1

TO W

ORK

BUSS

 BD

TP

3

TO

 R1

CB2

10

A CIRCUIT BREAKER

1B

TP

2

20

6

TO

 J9

202A

TO S4

31

AUX 2

TP

5

33

W

ORK

20

6A

NEG

7

PRI

(BOT

TOM

RIGHT)

TO SW

IT

C

H

BD #

2

15

14

12

18

TO SW

ITCH

BD  

#1

TO SW

IT

C

H

BD #

2

MAIN

TRANSF

ORMER

LEF

T SIDE

X2

NEG

PO

S

C3

.0

5/

60

0V

2W

403

28

8A

2B

604

14

7

9

8

1

12

16

7

10

8

CONNEC

TOR CAV

IT

Y

 NUM

B

ERING SEQUENC

E

(V

IE

W

E

D

 FROM COM

PONEN

T S

IDE OF BO

ARD)

1

1

6

5

6

1

3

TO S

W

1

200

-2

08

V

220

-2

30

V

440

-4

60

V

550

-5

75

V

PO

S

PO

S

AC 1

TO

 SUP

P

LY

 L

INES

S2

VOLTAGE

SENSE

RECEPTAC

LE

TO

 A

 S

Y

S

TEM GROUND P

E

R

NAT

IONAL E

LECTRICAL 

CODE

.

S3

RS2

32

CONNECTOR

115V

R

E

C

EPTA

C

LE

TO RECONN

ECT

 P

A

N

E

L

12

PRI

(BOT

TOM

LEFT)

11

12

20

C

++

TO AUX#

1

404

405

406

21

A

2

51

3 4

54

E

53

J9

TO

8

3

1

16

67

A

TO C

3

4

J46

3

2

1

PO

S

PO

S

DC BUS  B

OARD

12

J41

E

LEC

TRODE

C6

TO

 T

P

6

50

Y

C2

N.

A

.

.0

5/

60

0V

S

TA

TUS L

E

D (R/G)

TO

 J7

N.

A

.

THERM

A

L L

E

(Y)

TO

 J7

1W

TO J4 J11

C4

13

14

+

SW

ITCH B

OARD

#1

1

4

5

X3A

19

TO

 FAN

POW

ER

 W

AVE

  455/ST

T  W

IR

IN

G

 D

IAGR

AM

X1

22

4A

29

1

CB

4

AUXIL

IARY

 TRANSF

ORMER 

#1

SEC

(BOT

TO

M

RIGHT)

TO INPU

T R

ECT

IFIER

PO

S

TO S

W

IT

CH BD

 #

1

11

12

20

D

TO S

W

ITCH BD

 #

2

TO  R

E

CON

NE

CT 

SW

IT

CH

H5

H6

CAP

AC

ITORS=

MFD/VO

LT

S

RES

IS

TORS=OH

MS/W

A

TTS

H1

(20

0-2

08

)

H2

(22

0-2

30

)

PRI (TOP LEFT)

R

(11

5V

)

N

(24

V)

X4

COL

LE

CT

OR

2

6

TO

 J61

H1D

(T

OP)

LO

AD L

INE

TO

 CB3 61

2B

TO CON

TACTOR

L3A

L1

A

TO

 CON

TACT

OR

S4

TO

TO

 TP

3

31

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6

8

7

9

23

2

X3

60

4

23

8

601

INPUT

 BOARD

NEG

H3

H2

TO

 AUX 

#1

H2

A

H3

A

H1

H2

H3

81

2

81

3

28

7

81

1

816

F3

F3

++

F2

F2

19

C

17

11

TO S

W

ITCH

BD #

1

514

1

AUXIL

IARY

 TRANSF

ORMER 

#2

N

O

TES:

  N.A.  PI

N N

EAR

EST T

H

E FL

AT E

D

GE 

O

F L

E

D LE

NS (C

AT

H

O

D

E

)

          ALIG

N

S W

ITH 

B

LA

C

K L

E

AD OF LE

D SO

C

K

ET.

  N.B.  PL

A

C

E S

W

ITCH 

IN

 APPROPR

IA

TE

 P

OSI

TI

O

N

 FO

IN

P

U

T

    

    

  OPER

AT

IO

N.

  N.C.  PLA

CE "

A" 

LE

AD ON APPR

OPRIAT

E C

O

NN

E

C

TI

O

N

 FO

R

    

    

  OPER

AT

IO

N.

RIGHT

 S

IDE

 OF M

ACHINE

J8

J9

228 226

1

224 220

504 503 406

505

4

506

2

3

211

2

3

81

6

7 8

21

A

41

8

51

4

1

27

3

27

4

5 6

2 1

TO

 J6,

 J1

0B

RIGH

T S

IDE

13

4R

4W

TO

IN

PU

T RE

CT

IF

IER

D4

J40

F4

403

F4

THERM

9

1 2 3 4

11

J42

TO J

5

6

5

4

3

2

+

22

5

1

SE

C

(TOP RIGHT)

15

16

2

3

5

J50

C5

J60

10

10

9

8

7

6

5

4

27

3

3

22

8

27

4

22

6

TO

 J8

4

TO S3

1 2

J43

251

253 254

J1

9

7

14

8

6

5

4

1

3

2

NEG

DIG

ITA

L PO

W

E

R

SUPP

LY

 B

OARD

3R

TO

3W

J7

MAIN CHOK

E

L1

221

4 3

231 232

29

1

X3A

.0

5/

60

0V

C1

TP

1

TO

 C8

28

8A

34

5

28

7

TP

7

R

E

CTIF

IER

16

414

H4

’A ’

LEF

S

IDE

 OF M

ACHINE

RECO

NNEC

T S

W

IT

C

H

H4

A

6

5

1

1

TP

4

44

4

TO FAN

TO J47

47

5

47

7

1 2

47

6

216

47

8

211

3

213 212

4

5

6

4

4

W

1

1

W=

WH

IT

E

U=

B

LU

E

R=R

ED

COMPON

ENT V

A

LU

E

S

:

N=

BROW

N

REAR OF MACHINE

G=GRE

EN

B=

BL

A

C

K

LE

AD COLOR COD

ING

EL

E

C

TR

IC

AL

 SY

M

B

O

LS P

E

E1

53

7

J10

,J2

V

S

2

1

3

4

TO S

W

1

X5

TO

 AUX#

1

2 1

OUT

PUT

RECT

D2

J6

5 6

253

7

2

25

4

8

3

9

4

13

B

11

A

10

L2

TO

 J46

1 2 3 4

PO

W

E

R BD R

E

CT

1 2 3 4

TO WOR

K

E

LEC

TRODE

J10A

J11

ST

T CURRENT

TRANSDUCER

81

2

TO

 J8

X2

U

TO J42 J43

TO POW

ER 

BD

.

REC

TI

FIER

(51

V)

(38

0-4

15

)

X3

W

H3

TO

X3

AUX #

2

X5

RECONN

ECT P

A

NE

L

TO

M

A

IN

 T

R

A

N

S

FOR

ME

R

TO

 D5

3

4-

TO J4

SO

LI

D

STA

TE

RELA

Y

2

1

W

H5 (44

0-4

60

)

H5

A

H4

H5

  2

Y

10

15

14

11 12 13

16

10

11 12

10

14 15

11 12 13

16

10

2.7  10W  

.022 80

0V

PRI (TOP RIGHT)

PO

S

PO

S

NEG

NEG

AC

J10CH

.022 800V

2.7  1

0W  

2.7  1

0W  

.022 800V

N.C.

    

    

  INP

UT 

VOLT

AGE.  CON

NE

CTI

O

N

 SHO

W

N

 IS

 FO

R 55

0-57

5V

51

1

50

3

47

5

5

47

6

6

47

7

7

47

8

8

52

S2

J2

P9

0

P91

N.B.

1W 1B

1

2

22

2

L4

2B

2W

267 266 268

THERM

TO J40 J50

67

A

TO J43, S

1

26

7

26

6

268

A

227

22

7

J73

TO

S1

D6

TO

J11

J47

IFAC

E

ROBO

T

TO

J2,J5,J11,

J41,J4

J1VS,J9,J1

0CH,

J14,J40J4

2,

J50

J8,

J47,J60

J3,J61

J4,J13,

J43

J1,J6,J7

J10

W

ATER

CO

OLE

R

 RE

CEPTACL

E

2

1

35

0

35

2

TO J9 J11 CB1 J47

6

5

1 2 3 4

H6 (55

0-5

75

)

H6

A

H6

TO CR1 J60

CHOKE THERM

TO

 REC

T

THERM

TO

RECONN

EC

T

SWITCH

B

G4046

    

    

  VOL

TA

GE.  C

O

NN

E

CTI

O

N

 SH

O

W

IS

 FO

R 4

40-57

5V

S8

ST

T SNUBBER

CAPACI

TOR B

ANK

S

TT SNUB

B

E

R

20uF 400V

20uF 400V

418

518

1

51

8

2

41

4

J10B

TO S

SR, J1

0 CHOP

P

ER BD.

405

40

4

RES

IS

TOR BAN

K

DIODE D5

TO

J40,J50

34

6

34

5

R5

TO

26

2

26

8

26

8A

R5

22

0A

29

2

26

2

R5

W

R

4

1

(1

15

V)

TO S4 CB

2

35

0

35

2

P5

2

4

32

33

1

2

33

A

2

(2

30

V)

3 4

33

A

22

4A

22

4

22

0

22

0A

TO J4 J43

TO

 REC

T

THERM

DC BUS THERM

L5

TO AUX #

2

S1

100

V

240

0

o

F

50

0V

35

00

o

F

500V

3500

o

F

2

4

P1

6

USER

INTER

FCE

51

A

53

A

54

A

67

B

52

A

53

A

54

A

51

A

67

B

52

A

PO

S

NEG

54 53

TO HA

RM

ON

IC

 F

IL

TER

TO HA

RM

ON

IC

 F

ILT

ER

TO

RE

CONN

EC

T

SW

ITCH

19

20

HAR

M

ONI

C

FILTER

19D

20C

Содержание POWER WAVE 455/STT

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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 __________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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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