Lincoln Electric IM690-A User Manual
IM690-A
R
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POWER WAVE 455/R
For use with machines having Code Numbers:
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. And, most
importantly, think before you act
and be careful.
™
10675; 10676
May, 2001
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
IEC 60974-1
OPERATOR’S MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS 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 the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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
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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
POWER WAVE 455/R
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
ARC RAYS 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 and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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 working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
vapors
Mar ‘95
to
POWER WAVE 455/R
iii
SAFETY
iii
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.
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 Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
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 Code and the manufacturer’s recommendations.
Mar ‘95
POWER WAVE 455/R
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 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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-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, pantalons 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
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
POWER WAVE 455/R
for selecting a QUALITY product by Lincoln Electric. We want you
Thank 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. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - Power Wave 455/R ..............................................A-1,A-2
Safety Precautions.................................................................................................A-3
Select Suitable Location ........................................................................................A-3
Lifting...............................................................................................................A-3
Stacking ..........................................................................................................A-3
Machine Grounding ...............................................................................................A-3
High Frequency Protection ....................................................................................A-3
Input Connection....................................................................................................A-3
Input Fuse and Supply Wire Considerations .........................................................A-4
Input Voltage Change Over Procedure..................................................................A-4
Welding with Multiple Power Waves......................................................................A-5
Electrode and Work Cable Connections................................................................A-6
Negative Electrode Polarity ..................................................................................A-6
Voltage Sensing at the Work Piece .......................................................................A-7
Power Wave / Power Feed Wire Feeder Interconnections....................................A-8
Control Cable Specifications ...........................................................................A-8
External I/O Connector....................................................................................A-8
High Speed Gear Box .....................................................................................A-9
Dip Switch Settings and Locations...............................................................A-10
Control Board Dip Switch ..............................................................................A-10
Feed Head Board Dip Switch........................................................................A-10
Devicenet/Gateway Board Dip Switch, Bank (S1) ........................................A-10
Bank (S2) ......................................................................................................A-11
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precuations.................................................................................................B-1
Graphic Symbols that appear on this machine or in this manual...........................B-2
General Description...............................................................................................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
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance, Periodic, Calibration Specification.....................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to use Troubleshooting Guide .......................................................................E-1
Using the Status LED to Troubleshoot System Problems .....................................E-2
Troubleshooting Guide.............................................................................E-3 thru E-6
Error Codes for the Power Wave ....................................................................E-7,E-8
________________________________________________________________________
Wiring Diagram ....................................................................................Section F-1, F-2
Connector Pin Definitions ...........................................................................Section F-3
Connection Diagrams...........................................................................Section F-4, F-5
Dimension Print............................................................................................Section F-6
________________________________________________________________________
Parts Lists .....................................................................................................P377Series
________________________________________________________________________
vi
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
(K1761-1)
208/230/460V - 60HZ.
200/220/440V - 50HZ.
(K1761-2)
208/230/460/575V-60HZ.
208/230/460/575V-50HZ.
OPEN
CIRCUIT
VOLTAGE
CURRENT
RANGE
OUTPUT
CONDITIONS
450A@38V.100%
570A@43V. 60%
400A@36V.100%
500A@40V. 60%
450@38V.100%
570@43V.60%
400@36V.100%
500A@40V. 60%
PULSE
FREQUENCY
VOLTAGE
INPUT
CURRENT
AMPS
70/65/35
87/82/48
72/67/36
79/74/41
58/53/25/22
82/78/37/31
49/45/23/18
67/61/31/25
OUTPUT
PULSE
RANGE
IDLE
POWER
400 Watts
Max.
PULSE AND
BACKGROUND
TIME RANGE
POWER FACTOR
@ RATED OUPUT
.89 MIN.
.95 MIN.
STT PARAMETERS
EFFICIENCY
@ RATED OUPUT
88%
AUXILIARY POWER
(CIRCUIT BREAKER
PROTECTED)
A-1
75 VDC
5 - 570
PROCESS CURRENT RANGES (DC)
0.15 - 1000 Hz
MIG/MAG
FCAW
SMAW
Pulse
STT
5 - 55 VDC
100 MICRO SEC. -
3.3 SEC.
40-325 AMPS
CURRENT
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
40-325 Average Amps
40 VDC @10 AMPS
115VAC @10 AMPS
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
(HZ)
(K1761-1)
208/50/60
230/50/60
460/50/60
(K1761-2)
208/50/60
230/50/60
460/50/60
575/50/60
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)
GROUND WIRE IN CON-
TYPE 75°C
DUIT AWG[IEC] SIZES
(MM2)
6 (10)
6 (10)
10 (6)
6 (10)
6 (10)
10 (6)
10 (6)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
110
110
50
110
100
50
40
POWER WAVE 455/R
A-2
HEIGHT
26.10 in
663 mm
INSTALLATION
PHYSICAL DIMENSIONS
WIDTH
19.86 in
505 mm
TEMPERATURE RANGES
DEPTH
32.88 in
835 mm
A-2
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
POWER WAVE 455/R
A-3
INSTALLATION
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
WARNING
ELECTRIC SHOCK 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 working on the equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door)
to a proper safety (Earth) ground.
A-3
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not less than
5.90”(150mm) beyond the equipment on all sides.
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.
STACKING
Power Wave machines can be stacked to a maximum
of 3 high.
CAUTION
The bottom machine must always be placed on a
firm, secure, level surface. There is a danger of
machines toppling over if this precaution is not
taken.
----------------------------------------------------------
SELECT SUITABLE LOCATION
Do not use Power Waves in outdoor environments.
The Power Wave power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice
is to keep the machine in a dry, sheltered area.
Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at
a minimum. Do not use air filters on the air intake
because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N.
(fan as needed) circuitry. The fan runs whenever the
output is enabled, whether under loaded or open circuit
conditions. The fan also runs for a period of time
(approximately 5 minutes) after the output is disabled,
to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing
the fan to run whenever the power source is on). To
disable F.A.N., connect leads 444 and X3A together at
the output of the solid state fan control relay, located
on the back of the Control PC board enclosure. (See
Wiring Diagram)
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
MACHINE GROUNDING
The frame of the welder must be grounded. A ground
terminal marked with the symbol is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.
CAUTION
The normal operation of the Power Wave may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.
INPUT CONNECTION
WARNING
Only a qualified electrician should connect the
input leads to the Power Wave. Connections
should be made in accordance with all local and
national electrical codes and the connection diagram located on the inside of the reconnect/input
access door of the machine. Failure to do so may
result in bodily injury or death.
-----------------------------------------------------------------------Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
POWER WAVE 455/R
A-4
INSTALLATION
(K1761-1) FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
A-4
INPUT SUPPLY CONNECTION DIAGRAM
WARNING
.
Disconnect input power before
inspecting or servicing machine.
.
Do not operate with covers
removed.
ELECTRIC
SHOCK
CAN KILL
.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=220-230V
200-208V
220-230V
380-415V
440-460V
’A’
W / L3
V / L2
U / L1
VOLTAGE=380-415V
200-208V
220-230V
380-415V
440-460V
CR1
’A’
VOLTAGE=200-208V
200-208V
220-230V
380-415V
440-460V
VOLTAGE=440-460V
200-208V
220-230V
380-415V
440-460V
(K1761-2) FIGURE B.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
WARNING
Disconnect input power before
inspecting or servicing machine.
Do not operate with covers
ELECTRIC
SHOCK
CAN KILL
removed.
Do not touch electrically live parts.
Only qualified persons should install,
use or service this equipment.
W / L3
V / L2
U / L1
CR1
VOLTAGE = 200-208V
200-208V
220-230V
440-460V
550-575V
'A'
S23847
’A’
’A’
11-14-97
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
XA
S25198
VOLTAGE = 220-230V
200-208V
220-230V
440-460V
550-575V
'A'
VOLTAGE = 440-460V
200-208V
220-230V
440-460V
550-575V
'A'
VOLTAGE = 550-575V
200-208V
220-230V
440-460V
550-575V
'A'
XA
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to
do so will result in damage to the machine.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1
on the following page.
INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)
Welders are shipped connected for the highest input
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
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-
voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram
located on the inside of the input access door. If the
main reconnect switch or link position is placed in the
wrong position, the welder will not produce output
power.
ed super lag fuse or delay type breakers (also called
“inverse time” or “thermal/magnetic” circuit breakers).
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in a
position higher than the applied line voltage, the
welder may not come on at all. If the Auxiliary (A) lead
is placed in a position lower than 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.
POWER WAVE 455/R
A-5
INSTALLATION
WELDING WITH MULTIPLE POWER
WAVES
A-5
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves.
CAUTION
Special care must be taken when more than one
Power Wave 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
the work leads into one lead. The welding travel directions should be in the direction moving away from the
work lead as shown below. Connect all of the work
sense leads from each power source to the work
piece at the end of the weld.
FIGURE A.2
TWO POWER WAVES
When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.
Every welding gun requires a seperate shielding gas
regulator for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.2.)
POWERWAVE
-
POWERWAVE
+
-
+
Travel
Direction
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
POWER WAVE 455/R
A-6
INSTALLATION
ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (Per
Table 1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths and do not coil excess cable. Do
not tightly bundle the electrode and work cables
together.
Use K1796 Coaxial welding cables wherever possible.
(See Section F-5 Connection Diagram).
Minimum work and electrode cables sizes are as follows:
TABLE 1
(Current (60% Duty Cycle)
400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)
NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long distance Pulse
and STT applications up to 300 amps.
When using an inverter type power source like the
Power Waves, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not
normally require it.
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To-100 Ft. Length (30 m)
CAUTION
When pulsing, the pulse current can reach very
high levels. Voltage drops can become excessive,
leading to poor welding characteristics, if undersized welding cables are used.
-----------------------------------------------------------------------Most welding applications run with the electrode being
positive (+). For those applications, connect one end
of the electrode cable to the positive (+) output stud
on the power source (located beneath the spring
loaded output cover near the bottom of the case
front). Connect the other end of the electrode cable to
the wire drive feed plate using the stud, lockwasher,
and nut provided on the wire drive feed plate. The
electrode cable lug must be against the feed plate. Be
sure the connection to the feed plate makes tight
metal-to-metal electrical contact. The 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.
A-6
CAUTION
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
-------------------------------------------------------------------------
When welding with the STT process, use the positive
output connection labeled (STT) for STT welding. (If
desired, other welding modes can be used on this
stud; however, their average output current will be limited to 325 amps.) For non-STT processes, use the
positive output connection labeled (Power Wave), so
that the full output range of the machine is available.
CAUTION
Do not connect the STT and Power Wave stud
together. Paralleling the studs will bypass STT circuitry and severely deteriorate STT welding performance. (See Section F-3 Connection Diagram)
-------------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the positive (+)
stud).
When operating with electrode polarity negative the
switch 7 must be set to ON on the Wire Feed Head PC
Board. The default setting of the switch is OFF to represent positive electrode polarity.
Set the Negative Polarity switch on Wire Feed Head
PC board as follows:
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.
------------------------------------------------------------------
1. Turn off power to the power source at the disconnect
switch.
2. Remove the front cover from the power source.
3. The wire feed head board is on the right side of
the power source. Locate the 8-position DIP
switch and look for switch 7 of the DIP switch.
4. Using a pencil or other small object, slide the
switch right to the OFF position for positive
electrode polarity. Conversely, slide the switch
left to the ON position for negative electrode
polarity.
123456 78
O
N
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.
INSTALLATION
A-7
Work Voltage Sensing
The Power Waves are shipped from the factory with
the work sense lead enabled.
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 voltage apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.
CAUTION
If the voltage sensing is enabled but the sense
leads are missing or improperly connected,
extremely high welding outputs may occur.
------------------------------------------------------------------------
Do not tightly bundle the work sense lead to the work
lead.
The ELECTRODE sense lead (67) is built into the
K1795 control cable. The WORK sense lead (21) connects to the Power Wave at the four-pin connector
located underneath the output stud cover. Enable the
voltage sense leads as follows:
TABLE 2
Process Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional**
GMAW-P
FCAW 67 lead required 21 lead optional**
STT 67 lead required 21 lead required**
GTAW
SAW 67 lead required 21 lead optional**
* The electrode voltage 67 sense lead is part of to the
control cable to the wire feeder.
67 lead required 21 lead optional**
Voltage sense at studs Voltage sense at studs
For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power
Wave to the work. Attach the sense lead to the work
as close to the weld as practical. Enable the work voltage sensing in the Power Wave as follows:
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.
-----------------------------------------------------------
1. Turn off power to the power source at the disconnect switch.
2. Remove the front cover from the power source.
3. The control board is on the left side of
the power source. Locate the 8-position
DIP switch and look for switch 8 of the
DIP switch.
4. Using a pencil or other small object,
slide the switch right to the OFF position
if the work sense lead is NOT connected. Conversely, slide the switch left to
the ON position if the work sense lead is
present.
123456 78
O
N
** For consitent weld quality work voltage sensing is
recommended.
POWER WAVE 455/R
5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.
Electrode Voltage Sensing
Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead must be connected at the wire
feeder.
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