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RETURN TO MAIN INDEX
SVM135-B
July,2001
P Po ow we er r W Wa av ve e 4 45 55 5/ /P Po ow we er r F Fe ee ed d 1 10 0
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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RETURN TO MAIN INDEX v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . .
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SECTION A-1 SECTION A-1 INSTALLATION TABLE OF CONTENTS -INSTALLATION SECTION- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . . A-2 Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Saf
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND CONTROL BOX WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC # TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1540-1 Power Feed 10 50-800 IPM .025 - 3/32 in. .035 - .125 in. 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in. Wire Drive (1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) K1538-1 Power Feed 10 50-800
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A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS – POWER WAVE 455 INPUT AT RATED OUTPUT - THREE PHASE ONLY Rated Output @ Input Rated Output @ Input Input Volts 100% Duty Cycle Current 60% Duty Cycle Current 208V - 60Hz 450A@38V 100% 70 570A@43V 60% 87 230V - 60Hz 450A@38V 100% 65 570A@43V 60% 82 400V - 60Hz 450A@38V 100% 39 570A@43V 60% 50 460V - 60Hz 450A@38V 100% 35 570A@43V 60% 48 200V - 50Hz 450A@38V 100% 72 500A@40V 60% 79 220V - 50Hz 450A@38V 100% 67 500A@40V 60% 74 400V - 50Hz 450A
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A-4 A-4 INSTALLATION LIFTING SAFETY PRECAUTIONS Lift the machine by the lift bail only. The lift bail is WARNING designed to lift the power source only. Do not attempt to lift the Power Wave with accessories ELECTRIC SHOCK attached to it. can kill. • Only qualified personnel should per- form this installation. FEEDER AND CONTROL BOX MOUNTING • Turn off the input power to the power source at the disconnect switch or fuse box before working on this equip- SEPARATION FROM BENCH MODE
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A-5 A-5 INSTALLATION 6. Replace all option panels removed from front of 3. Loosen the four screws inside the Control Box Control Box. located along the sides of the back of the Control Box, two near the bottom and two near the mid- 7. Place plug button saved in step 2 into hole in dle. back panel of Control Box. 4. Push the Control Box upwards and then pull the Control Box away from the wire drive. CONTROL BOX POWER SOURCE MOUNTING 5. Remove plug button taped to inside of Control The
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A-6 A-6 INSTALLATION INPUT FUSE AND SUPPLY WIRE ELECTRICAL CONNECTIONS CONSIDERATIONS WARNING Refer to the Technical Specifications at the begin- ning of this Installation section for recommended fuse Only a qualified electrician should connect the and wire sizes. Fuse the input circuit with the recom- input leads to the Power Wave. Connections mended super lag fuse or delay type breakers (also should be made in accordance with all local and called “inverse time” or “thermal/magnetic”
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A-7 A-7 INSTALLATION FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR. INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE=200-208V W / L3 200-208V V / L2 CR1 . Disconnect input power before 220-230V inspecting or servicing machine. U / L1 'A' . Do not operate with covers 380-415V removed. 440-460V . Do not touch electrically live parts. Only qualified persons should install, use or service this equipment. VOLTAGE=220-230V VOLTAGE=380-415V VOLTAGE=440-460V 200-208V 200-208V 200-208V 2
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A-8 A-8 INSTALLATION When using an inverter type power source, use the CONTROL CABLE SPECIFICATIONS largest welding (electrode and ground) cables that are practical. At least 2/0 copper wire — even if the The cable is a five copper conductor cable in a SO- average output current would not normally require it. type rubber jacket. There is one 20 gauge twisted When pulsing, the pulse current can reach very high pair for network communications. This pair has an levels. Voltage drops can becom
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A-9 A-9 INSTALLATION SELECTING THE PROPER GEAR RATIO ELECTRODE AND WORK LEADS — ELECTRODE NEGATIVE APPLICATIONS See the Technical Specifications at the front of this section for feed speed and wire size capabilities with When negative electrode polarity is required, such as high and low speed gear ratios. To determine in some Innershield™ applications, install as above, whether you should be using the high or low speed except reverse the output connections at the power ratio, use th
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A-10 A-10 INSTALLATION 6. Tighten the screw on lower right face of feed RATIO CHANGE PROCEDURE plate. 1. Pull open the pressure door. 7. Re-attach feed plate to wire feeder if removed in Step 2. 2. Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear. 8. Feed plate will be rotated out-of-position due to If the gear is not easily accessible or difficult to the gear change. Adjust the angle of the feed remove, remove the feed plate from the gearbox.
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A-11 A-11 INSTALLATION ON S1 1 2 3 4 5 6 7 8 DIP SWITCH SETUP SETTING DIP SWITCHES IN THE CONTROL BOX ON S2 1 2 3 4 5 6 7 8 There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and FIGURE A.3 are located and oriented as shown in Figure A.3. S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) Switch Off On 1 US 4-Step Trigger Logic Euro 4-Step Trigger Logic 2 WFS Display = inches/minute WFS Display = meters/min
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A-12 A-12 INSTALLATION S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) Switch Off On 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position. Left Display is always p
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A-13 A-13 INSTALLATION S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) Switch Off On 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position. Left Display is always preset w
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A-14 A-14 INSTALLATION Setting Wire Drive Acceleration Rate Using (All software versions) DIP Switch S1 on the Control Box Motherboard DIP SWITCH 6 DIP SWITCH 7 DIP SWITCH 8 Acceleration 1 (slow) Off Off On Acceleration 2 Off On Off Acceleration 3 Off On On Acceleration 4 On Off Off Acceleration 5 (fast ) (factory setting) Off Off Off SETTING DIP SWITCHES IN THE WIRE ON 1 2 3 4 5 6 7 8 DRIVE There is one DIP switch bank on the control board of the wire drive. It’s labeled S1 and is located an
