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IM807-A
June, 2004
™
POWER WAVE 455 M
For use with machines having Code Numbers: 11007, 11203
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 you act
and be
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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 zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v SAFETY
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vi vi SAFETY
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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 shipm
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ix ix TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455M .................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Lifting......
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x x TABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems .....................................E-2 Error Codes For Power Waves..............................................................................E-3 Troubleshooting Guide.....................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT OUTPUT CONDITIONS INPUT CURRENT OUTPUT CONDITIONS INPUT CURRENT VOLTS AMPS / VOLTS / DUTY CYCLE AMPS AMPS / VOLTS / DUTY CYCLE AMPS 400A@36V. 100% 36A 500A@40V. 60% 48A 380V - 60HZ. 400A@36V. 100% 36A 500A@40V. 60% 48A 380V - 50HZ. 400A@36V. 100% 33A 500A@40V. 60% 44A 415V - 60HZ. 400A@36V. 100% 33A 500A@40V. 60% 44A 415V - 50HZ. OUTPUT OPEN CURRENT PULSE PULSE PULSE A
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS Read this LIFTING entire installation section before you start installa- Lift the machine by the lift bail only. The lift bail is tion. designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it. WARNING STACKING ELECTRIC SHOCK can kill. Power Wave machines can be stacked to a maximum • Only qualified personnel should of 3 high. perform this installation. • Turn the input power OFF at the WARNING discon
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A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM . Disconnect input power before inspecting or servicing machine. . Do not operate with covers removed. . Do not touch electrically live parts. Only qualified persons should install, use or service this equipment. W / L3 V / L2 CR1 U / L1 THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. XA S24190 NOTE: Turn main input power to the machine OFF before performing connection proc
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A-4 A-4 INSTALLATION For additional Safety information regarding the elec- CABLE INDUCTANCE, AND ITS AFFECT trode and work cable set-up, See the standard "SAFE- ON PULSE WELDING TY INFORMATION" located in the front of the For Pulse Welding processes, cable inductance will Instruction Manuals. cause the welding performance to degrade. For the total welding loop length less than 15.24m (50 ft.), tra- CAUTION ditional welding cables may be used without any effects on welding performance. For the
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A-5 A-5 INSTALLATION Enable the voltage sense leads as follows: Electrode Voltage Sensing TABLE A.2 Enabling or disabling electrode voltage sensing is Process Electrode Voltage Work Voltage automatically configured through software. The 67 Sensing 67 lead * Sensing 21 lead electrode sense lead is internal to the cable to the GMAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder GMAW-P 67 lead required 21 lead optional is present. FCAW 67 lead required 21
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A-6 A-6 INSTALLATION If a system can not be “Auto Mapped” then the status CONFIGURING THE SYSTEM light on the power source will blink green fast and the welder output will be disabled. If a system is not For codes below 11100, consult the semi-automatic “Auto-mappable”, then consult the instruction manual Power Feed instruction manual for configuration infor- for the accessory being used for configuration infor- mation about DIP switch settings. mation about DIP switch settings, or consult y
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A-7 A-7 INSTALLATION ALTERNATE HARD AUTOMATIC APPLICATION (using a UI, WD Module, and PF-10R) POWER WAVE 455M (CE) PF-10R WIRE DRIVE MODULE (FH1) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto, WD Module, and PF-10R) POWER WAVE 455M (CE) PF-10R WIRE DRIVE MODULE DUAL HEAD (FH1) System that is NOT "Auto Mappable" DUAL HEAD BOOM FEEDER (using two single heads) POWER WAVE 455M (CE) DUAL HEAD FH-1 FH-2 In this case the individual feed heads need to be assigned to the dual head control and
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A-8 A-8 INSTALLATION WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables WAVES be used at all times. Lincoln cables are specifically designed for the communication and power needs of CAUTION the Power Wave / Power Feed system. Special care must be taken when more than one Power Wave is welding simultaneously on a single CAUTION part. Arc blow and arc interference may occur or The use of non-standard cables, especially in be magnified
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A-9 A-9 INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 455M (CE)
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A-10 A-10 INSTALLATION switch 7 auto mapping I / O RECEPTACLE SPECIFICATIONS off auto mapping enable-default TABLE 3 WIRE FEEDER RECEPTACLE S1 on auto mapping disabled PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H switch 8 work sense lead C 67A Electrode Voltage Sense off work sense lead not connected-default D 52 0vdc E 51 +40vdc on work sense lead connected TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Voltage S
