Lincoln Electric IM924 manual

IEC 60974-1 PO WER W A VE 455M/S TT ™ OPERA TOR’S MANUAL IM924 January , 2007 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQU[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ii SAFETY ii ARC RA YS 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. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

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vii vii 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference.[...]

viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A T echnical Specifications - POWER WA VE 455M/STT .........................................A-1 Safety Precautions .............................................................................[...]

ix ix T ABLE OF CONTENTS Page T roubleshooting ..............................................................................................Section E How to use T roubleshooting Guide .......................................................................E-1 Using the Status LED to T roubleshoot System Problems ....................................[...]

A-1 INST ALLA TION POWER W A VE 455M/STT (CE) A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 455M/STT (CE) (K2203-4) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOL TS 380V - 60Hz. 380V - 50Hz. 415V - 60Hz. 415V - 50Hz. OPEN CIRCUIT VOL T AGE 75 VDC INPUT VOL T[...]

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 W ave with accessories attached to it. ST ACKING Power W ave machines can be stacked to a maximum of 3 high. The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machi[...]

A-3 INST ALLA TION POWER W A VE 455M/STT (CE) A-3 INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power W ave 455M/STT (CE). Connections should be made in accordance with all local and national electrical codes and the con- nection diagram located on the inside of the reconnect/input access door of the machine. F[...]

A-4 INST ALLA TION POWER W A VE 455M/STT (CE) A-4 CABLE INDUCT ANCE, 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 15.24m (50 ft.) , traditional welding cables may be used without any effects on welding performance. For the to[...]

A-5 INST ALLA TION POWER W A VE 455M/STT (CE) A-5 Electrode V oltage 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. I mportant: The electrode polarity must be config- ured[...]

A-6 INST ALLA TION POWER W A VE 455MSTT (CE) A-6 CONFIGURING THE SYSTEM For codes below 1 1 100, consult the semi-automatic Power Feed instruction manual for configuration infor- mation about DIP switch settings. For codes above 1 1 100 the power source will “ Auto Map ” the system eliminating most of the need to set DIP switches to configure t[...]

A-7 INST ALLA TION POWER W A VE 455M/STT (CE) A-7 In this case the individual feed heads need to be assigned to the dual head control and the PW455M/STT (CE) auto mapping disabled and the Equipment Groups set. (See the Feeder documentation for information on setting the feeder DIP switches) System that is NOT "Auto Mappable" POWER W A VE [...]

A-8 INST ALLA TION POWER W A VE 455M/STT (CE) A-8 WELDING WITH MUL TIPLE POWER W A VES Special care must be taken when more than one Power W ave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of [...]

A-9 INST ALLA TION POWER W A VE 455M/STT (CE) A-9 MUL TIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES[...]

A-10 INST ALLA TION POWER W A VE 455M/STT (CE) A-10 I / O RECEPT ACLE SPECIFICA TIONS T ABLE 3 WIRE FEEDER RECEPT ACLE S1 PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode V oltage Sense D 52 0vdc E 51 +40vdc T ABLE 4 VOL T AGE SENSE RECEPT ACLE S2 PIN LEAD# FUNCTION 3 21A Work V oltage Sense T ABLE 5 RS232 RECEPT[...]

B-1 OPERA TION B-1 POWER W A VE 455M/STT (CE) SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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. • D[...]

B-2 OPERA TION B-2 POWER W A VE 455M/STT (CE) INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING OR[...]

B-3 OPERA TION B-3 POWER W A VE 455M/STT (CE) DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator . SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amp[...]

DeviceNet Interface Module This module can be used for DeviceNet capability . It will be a 5 pin sealed mini connector per ANSI B93.55M-1981. EtherNet/DeviceNet Module This module includes the DeviceNet and EtherNet capability The DeviceNet uses a 5 pin sealed mini connector per ANSI B93.55M-1981. The EtherNet uses a RJ5 connector . RECOMMENDED EQU[...]

B-5 OPERA TION POWER W A VE 455M/STT (CE) B-5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power W ave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power W ave. 2. ST A TUS LIGHT : A two color light that indicates sys- tem errors. Normal operation is a steady green light. Error con[...]

B-6 OPERA TION B-6 NOMINAL PROCEDURES The Power W ave is designed to operate with 3/4" elec- trode stick-out for CV and Pulse processes. FRINGE PROCEDURES Excessively short or long electrode stick-outs may function only on a limited basis, if at all. MAKING A WELD The serviceability of a product or structure utilizing the welding programs is a[...]

W a v e Con tr o l 0. 0 0 W a ve C o n trol + 10. 0 W a ve C o n trol - 10.0 Current T ime CURRENT W A VE FORM (CV) B-7 OPERA TION B-7 • 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 characterist[...]

B-8 OPERA TION B-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 [...]

B-9 OPERA TION B-9 STT WELDING The pictures illustrate the wave shape of current for the process. They are not drawn to scale, and are intend- ed only for the purpose of showing how the variables effect the waveform. T rim in the STT mode adjusts the tail out and back- ground portion of the waveform. For open root processes, the tail out is fixed, [...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACT OR Y INST ALLED None Available. FIELD INST ALLED Work V oltage Sense Lead Kit, K940 Dual Cylinder Undercarriage, K1570-1. Gas Guard Regulator , K659-1 Coaxial welding Cable, K1796 Cool Arc 40 W ater Flow Sensor , K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-1 Ethernet In[...]

D-1 MAINTENANCE D-1 POWER W A VE 455M/STT (CE) SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T urn 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 per[...]

E-1 TROUBLESHOOTING E-1 POWER W A VE 455M/STT (CE) 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. CAUTION This T roubleshooting Guide is provided to help you locat[...]

E-2 TROUBLESHOOTING E-2 POWER W A VE 455M/STT (CE) USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power W ave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors display[...]

E-3 TROUBLESHOOTING E-3 POWER W A VE 455M/STT (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAU[...]

E-4 TROUBLESHOOTING E-4 POWER W A VE 455M/STT (CE) Observe all Safety Guidelines detailed throughout this manual 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. PROBLEMS (SYMPTOMS)[...]

E-5 TROUBLESHOOTING E-5 POWER W A VE 455M/STT (CE) Observe all Safety Guidelines detailed throughout this manual 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. PROBLEMS (SYMPTOMS)[...]

E-6 TROUBLESHOOTING E-6 POWER W A VE 455M/STT (CE) Observe all Safety Guidelines detailed throughout this manual 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. PROBLEMS (SYMPTOMS)[...]

E-7 TROUBLESHOOTING E-7 POWER W A VE 455M/STT (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAU[...]

F-1 DIAGRAMS F-1 POWER W A VE 455M/STT (CE) NOTE: This diagram is for refer ence only . It may not be accurate for all machines cover ed by this manual. The specific diagram 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 r eplacement. Give the equ[...]

F-2 CONNECTION DIAGRAM F-2 POWER W A VE 455M/STT (CE) Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER CONTROL CABLE K1543 TO WORK WORK SENSE[...]

F-3 CONNECTION DIAGRAM F-3 POWER W A VE 455/STT 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[...]

F-4 DIAGRAMS F-4 POWER W A VE 455M/STT (CE) 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 1 1-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455M[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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