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Lincoln Electric IM716 manual

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Table of contents for the manual

  • Page 1

    PO WER W A VE 455/S TT ™ OPERA TOR’S MANUAL IM716 October, 2003 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn 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. ________________________________________________[...]

  • Page 3

    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[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn 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 C[...]

  • Page 5

    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 ?[...]

  • Page 6

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

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455 ....................................................A-1 Safety Precautions..............................................................................[...]

  • Page 8

    vii vii T ABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems .....................................[...]

  • Page 9

    A-1 INST ALLA TION POWER WAVE 455/STT A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 455/STT (K1518-4) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 208/230/460/575V - 60HZ. 200/220/440/575V - 50HZ. OPEN CIRCUIT VOLTAGE 75 VDC INPU[...]

  • Page 10

    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 Wave with accessories attached to it. LIMIT ON ST ACKING F ALLING EQUIPMENT can cause injury. • Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.[...]

  • Page 11

    A-3 INST ALLA TION POWER WAVE 455/STT A-3 INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommend- ed super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” c[...]

  • Page 12

    A-4 INST ALLA TION POWER WAVE 455/STT 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 50 feet, traditional welding cables may be used without any effects on welding performance. For the total welding loop [...]

  • Page 13

    A-5 INST ALLA TION POWER WAVE 455/STT A-5 Electrode Voltage 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 at the f[...]

  • Page 14

    A-6 INST ALLA TION POWER WAVE 455/STT A-6 SYSTEM DESCRIPTION The Power Wave 455/STT and Power Feed 10/11 family of products utilize a digital communication sys- tem 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 f[...]

  • Page 15

    A-7 INST ALLA TION POWER WAVE 455/STT A-7 FIGURE A.8 Simple System 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. [...]

  • Page 16

    A-8 INST ALLA TION POWER WAVE 455/STT A-8 FIGURE A.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 used, odd # ’ s use FH1 settings, even # ’ s use FH2 settings.[...]

  • Page 17

    A-9 INST ALLA TION POWER WAVE 455/STT A-9 FIGURE A.1 1 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 single set of procedures.[...]

  • Page 18

    A-10 INST ALLA TION POWER WAVE 455/STT A-10 FIGURE A.2 - + PO WERW A VE - + PO WERW A VE Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint Tr a v e l Direction - + POWER W A VE - + POWER W A VE TWO POWER W A VES CAUTION CAUTION[...]

  • Page 19

    A-11 INST ALLA TION POWER WAVE 455 A-11 MUL TIPLE ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Wor k # 2 Se ns e # 2 Pow er Source #2 Pow er Sourc e #1 Arc # 1 Arc #2 Wor k #1 Se ns e #1 Work # 2 Power Source #2 Powe r Source #1 A rc #1 A rc #2 Work # 1 Sens e # 1 Se n se # 2 Current Flow Pow er Source #1 Pow er Source #2 Work #1 Sens e # 1 Wo[...]

  • Page 20

    A-12 INST ALLA TION POWER WAVE 455/STT A-12 I / O RECEPT ACLE SPECIFICA TIONS 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#[...]

  • Page 21

    B-1 OPERA TION B-1 POWER WAVE 455/STT 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. • Do not us[...]

  • Page 22

    B-2 OPERA TION B-2 POWER WAVE 455/STT 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 CAUTION[...]

  • Page 23

    RECOMMENDED EQUIPMENT Power Wave 455/STT – Semi-Automatic Operation Semi Automatic Power Waves can only be used with Linc-Net compatible Power Feed semi-automatic wire feeders. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or [...]

  • Page 24

    B-4 OPERA TION POWER WAVE 455/STT B-4 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure A.4) 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 in[...]

  • Page 25

    B-5 OPERA TION B-5 NOMINAL PROCEDURES 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. 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 stru[...]

  • Page 26

    B-6 OPERA TION B-6 • 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 set- ting of 1.000 is a good starting point for most condi- t[...]

  • Page 27

    B-7 OPERA TION B-7 CONST ANT VOL T AGE WELDING Synergic CV : For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The nominal preprogrammed volt- age is the best average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, [...]

  • Page 28

    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 [...]

  • Page 29

    B-9 OPERA TION B-9 STT WELDING 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 vari- ables effect the waveform. Trim in the STT mode adjusts the tailout and back- ground portion of the waveform. For open root processes, the tailout is fixed, and [...]

  • Page 30

    C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED 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 com[...]

  • Page 31

    D-1 MAINTENANCE D-1 POWER WAVE 455/STT SAFETY PRECAUTIONS 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[...]

  • Page 32

    E-1 TROUBLESHOOTING E-1 POWER WAVE 455/STT 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 Troubleshooting Guide is provided to help you locate and repa[...]

  • Page 33

    E-2 TROUBLESHOOTING E-2 POWER WAVE 455/STT USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, 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 [...]

  • Page 34

    E-3 TROUBLESHOOTING E-3 POWER WAVE 455/STT 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. CAUTION ERRO[...]

  • Page 35

    E-4 TROUBLESHOOTING E-4 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linc[...]

  • Page 36

    E-5 TROUBLESHOOTING E-5 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linc[...]

  • Page 37

    E-6 TROUBLESHOOTING E-6 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linc[...]

  • Page 38

    E-7 TROUBLESHOOTING E-7 POWER WAVE 455/STT 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. CAUTION PROB[...]

  • Page 39

    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 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 replacement. Give the equipment code [...]

  • Page 40

    F-2 CONNECTION 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 WORK SENSE[...]

  • 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 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 11-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455[...]

  • Page 43

    NOTES POWER WAVE 455/STT[...]

  • Page 44

    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[...]

  • Page 45

    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 [...]

  • Page 46

    • 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 •[...]