RETURN TO MAIN MENU POWER WAVE For use with machines having Code Numbers: ™ IM716 455/STT October, 2003 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY WELDING SPARKS can 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. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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.
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455 ....................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Lifting.............
vii vii TABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems .....................................E-2 Troubleshooting Guide.............................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT (K1518-4) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS INPUT CURRENT AMPS 208/230/460/575V - 60HZ. 450A@38V.100% 570A@43V. 60% 58/53/25/22 82/78/37/31 200/220/440/575V - 50HZ. 400A@36V.100% 500A@40V. 60% 49/45/23/18 67/61/31/25 IDLE POWER POWER FACTOR @ RATED OUPUT EFFICIENCY @ RATED OUPUT 400 Watts Max. .95 MIN.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS LIFTING Read this entire installation section before you start installation. 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 WARNING CAUTION ELECTRIC SHOCK can kill. FALLING EQUIPMENT can cause injury. • Only qualified personnel should perform this installation.
A-3 A-3 INSTALLATION INPUT SUPPLY CONNECTION DIAGRAM . Disconnect input power before inspecting or servicing machine. . ELECTRIC . SHOCK CAN KILL VOLTAGE = 200-208V W / L3 WARNING V / L2 200-208V CR1 220-230V U / L1 440-460V Do not operate with covers removed. 'A' 550-575V Do not touch electrically live parts. Only qualified persons should install, use or service this equipment. .
A-4 A-4 INSTALLATION 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.
A-5 A-5 INSTALLATION Enable the voltage sense leads as follows: TABLE A.
A-6 INSTALLATION SYSTEM DESCRIPTION The Power Wave 455/STT and Power Feed 10/11 family of products utilize a digital communication system called Linc-Net. Simply put, Linc-Net allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communication, and because of its bus-like structure, the components may be connected to the network in any order, thus simplifying the system set-up.
A-7 INSTALLATION A-7 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. • Each system has only one power source. For network purposes, the PS belongs to Group 3, which is why group 3 is only allowed 6 feed heads in addition it’s user interface. • No two feed heads can have identical Group and Feed Head numbers.
A-8 INSTALLATION A-8 Multiple Group System FIGURE A.9 No “FH0 Alllowed! Single Group Multi-Head System FIGURE A.10 No “FH0 Alllowed! The Dual Head option allows the ability to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings.
A-9 INSTALLATION A-9 Single Group Multi-Head System (Alternate Method) FIGURE A.11 No “FH0 Alllowed! When a standard User Iterface is used in a group with multiple Feed Heads, all of the Feed Heads use a single set of procedures.
A-10 A-10 INSTALLATION CAUTION CAUTION FIGURE A.
A-11 A-11 INSTALLATION MULTIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES BAD Power Source #1 Ø Current flow from Arc #1 affects sense lead #2 Work #1 Sense #1 Arc #1 Current Flow Ø Current flow from Arc #2 affects sense lead #1 Power Source #2 Work #2 Sense #2 Ø Arc #2 Power Source #2 Arc #1 Power Source #1 Current Flow Work #2 Sense #2 Arc #2 Power Source #1 Ø Sense #2 is only affected by weld current from Arc #2 BEST Ø Both Sense leads are out of the current paths.
A-12 A-12 INSTALLATION I / O RECEPTACLE SPECIFICATIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc E 51 +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 PIN LEAD# FUNCTION 2 253 RS232 Receive 3 254 RS232 Transmit 4 # S3 Pin5 5 # S3 Pin4 6 ## S3 Pin20 20 ## S3 Pin6 7 251 RS232 Commom DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P.C.
B-1 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 clothing, gloves or work area is damp or if working on, under or inside workpiece. Use the following equipment: -DC manual (stick) welder.
B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER SMAW ON GMAW OFF FCAW HIGH TEMPERATURE GTAW MACHINE STATUS U0 OPEN CIRCUIT VOLTAGE CIRCUIT BREAKER U1 INPUT VOLTAGE WIRE FEEDER U2 OUTPUT VOLTAGE POSITIVE OUTPUT I1 INPUT CURRENT NEGATIVE OUTPUT I2 OUTPUT CURRENT 3 PHASE INVERTER PROTECTIVE GROUND INPUT POWER WARNING OR CAUTION THREE PHASE DIRECT CURRENT POWER WAVE 455/STT B-2
B-3 B-3 OPERATION GENERAL DESCRIPTION RECOMMENDED EQUIPMENT 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.
B-4 CASE FRONT CONTROLS B-4 OPERATION All operator controls and adjustments are located on the case front of the Power Wave. (See Figure A.4) 2 3 1 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 status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on.
B-5 OPERATION B-5 NOMINAL PROCEDURES WELDING ADJUSTMENTS 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. All adjustments are made on the system component known as the User Interface (Control Box), which contains the switches, knobs, and digital displays necessary to control both the Power Wave and a Power Feed wire feeder. Typically, the Control Box is supplied as part of the wire feeder.
B-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 from 0.500 to 1.500. A Trim setting of 1.000 is a good starting point for most conditions. Power Wave 455/STT Only: In STT modes, the user can adjust the Trim setting to change the overall heat input to the weld.
B-7 OPERATION CONSTANT VOLTAGE WELDING Synergic CV: For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The nominal preprogrammed voltage 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 automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range.
B-8 OPERATION 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 impractical, and instead the arc length is set by adjusting "trim".
B-9 STT WELDING B-9 OPERATION 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 variables effect the waveform. For most programs, peak current is adjusted by arc control, also referred to as wave control. A wave control 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.
C-1 ACCESSORIES 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 Flow Sensor, K1536-1 *The Dual Cylinder Undercarriage, K1570-1 is not compatible in combination with the Power Wave WaterCooler K1767-1. COMPATIBLE LINCOLN EQUIPMENT Any Linc-Net compatible semi-automatic wire feeding equipment.
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. • 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.
E-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.
E-2 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user interface, 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 interface in most cases indicate only that a problem exists in the power source, not what the problem may be.
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. 11 12 Error Code # CAN communication bus off.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Major physical or electrical damage is evident when the sheet metal covers are removed. 1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. Input fuses keep blowing, or input breaker keeps tripping. 1.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Thermal LED is lit. 1. Fan thermostat has opened. Check for proper fan operation. (Fan should run whenever output power is on.) Check for material blocking intake or exhaust louvers, or for excessive dirt clogging cooling channels in machine. 2.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Machine often “noodle welds” (output is limited to approximately 100 amps) when running a particular procedure, especially a procedure with high WFS. 1. Secondary current limit has been exceeded, and the machine has phased back to protect itself. 2.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION General degradation of the weld per- 1.Check for feeding problems, bad formance connections, excessive loops in cabling, etc. 2. Verify weld mode is correct for processes. 3. The power source may require calibration. 4. Check the actual current displayed on the Power Feed 10 vs. actual current measured via external meter. 5.
- 2W 2B SW1 POWER ELECTRODE 33 31 206A TO CB3 612B TO J61 H1D (TOP) TP5 TO S4 AUX 2 TO WORK ELECTRODE TO AUX 2 CB2 TO WORK STT TO WORK ELECTRODE TO L2 BUSS BD TO J2 TO J9 TO S1 TO J9 J11 CB1 J47 L2 STT C6 .05/600V TO CONTACTOR L1A LOAD LINE TO CONTACTOR L3A TO RECONNECT PANEL A TO TP3 C2 .05/600V N.A.
F-2 F-2 CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive,CV/Pulse Configuration shown) POWER WAVE / STT CV/PULSE STUD WIRE FEEDER TO WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455/STT
F-3 F-3 DIAGRAMS Connection Diagram Semi-automatic "Simple System" (Electrode Positive, STT Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER TO WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455
POWER WAVE 455/STT 19.00 12.35 19.16 19.90 9.48 22.63 23.12 23.51 26.10 DIMENSION PRINT - POWER WAVE 455 32.88 14.
NOTES POWER WAVE 455/STT
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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