Lincoln Electric POWER WAVE IM690-A manual

PO WER W A VE 455/R ™ OPERA TOR’S MANUAL IM690-A May, 2001 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 T[...]

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. ________________________________________________[...]

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. 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[...]

iv SAFETY iv PRÉCA UTIONS 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 [...]

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 par[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455/R ..............................................A-1,A-2 Safety Precautions..............................................................................[...]

A-1 INST ALLA TION POWER WAVE 455/R A-1 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/R (K1761-1),(K1761-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT INPUT A T RA TED OUTPUT - THREE PHASE ONL Y 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 CI[...]

A-2 INST ALLA TION POWER WAVE 455/R A-2 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 26.10 in 663 mm WIDTH 19.86 in 505 mm DEPTH 32.88 in 835 mm 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[...]

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 so[...]

A-4 INST ALLA TION POWER WAVE 455/R A-4 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 FUSE AND SUPPL Y WIRE CONSIDERA TIONS Refer to the Technical Specifications at the beginning of this Installation section for [...]

A-5 INST ALLA TION POWER WAVE 455/R A-5 WELDING WITH MUL TIPLE PO WER W A VES 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 l[...]

A-6 INST ALLA TION POWER WAVE 455/R A-6 ELECTR ODE AND W ORK 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 [...]

Work Voltage Sensing The Power Waves are shipped from the factory with the work sense lead enabled. For processes requiring work voltage sensing, con- nect 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 volt- age sensing in the Power Wave as foll[...]

A-8 INST ALLA TION POWER WAVE 455/R A-8 PO WER W A VE / PO WER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Waves is located under the spring loaded output cover, near the bottom of the case front. The control cable is keyed and polarized to pre[...]

A-9 INST ALLA TION POWER WAVE 455/R A-9 HIGH SPEED GEAR BO X Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. To change Gear ratio see Power Feed 10/R In[...]

A-10 INST ALLA TION POWER WAVE 455/R A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches: • Turn off power at the disconnect switch. ------------------------------------------------------------------------ • Remove the top four screws securing the fr[...]

A-11 INST ALLA TION POWER WAVE 455/R A-11 Bank (S2) : switc h Description 1 De vicenet Baud Rate 2( see table 2 ) T ABLE 2 Prior to S24958-6 software s witch 1 switch 2 baud rate off off Programmab le v alue on off 125K off on 250K on on 500K S24958-6 and later software s witch 1 switch 2 baud rate off off 125K off on 250K on off 500K on on Progr a[...]

B-1 OPERA TION B-1 POWER WAVE 455/R SAFETY PRECUA TIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always elec- trically energized and could remain energized several seconds after th[...]

B-2 OPERA TION B-2 POWER WAVE 455/R INPUT PO WER ON OFF HIGH TEMPERA TURE MA CHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT PO WER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT V O LTA G E INPUT V OL T A GE OUTPUT V OL T A GE INPUT CURRENT OUTPUT CURRENT PRO TECTIVE GROUND W ARNING OR[...]

RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through software for the robotic Power Waves. FANUC robots equipped with RJ-3 controllers may communi- cate directly to the Power Wave. Other pieces of equipment such as PLC ’ s or computers can commu- nicate to the Power Wave using DeviceNET. All wire weldi[...]

B-4 OPERA TION POWER WAVE 455/R B-4 CASE FRONT CONTR OLS 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 ind[...]

B-5 OPERA TION B-5 CONST ANT V OL T A GE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes the Power Wave will automatically [...]

B-6 OPERA TION B-6 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-7 OPERA TION B-7 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 variables effect the waveform. For most programs, peak current is adjusted by wave control values. A value of +10.0 maximizes the peak current, while a wave control of[...]

C-1 A CCESSORIES C-1 OPTIONAL EQUIPMENT F A CT OR Y INST ALLED There are no factory installed options available for the Power Wave 455R. FIELD INST ALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive unit. Install the 5/8-18 male outlet on the regulator to the pr[...]

D-1 MAINTENANCE D-1 POWER WAVE 455/R 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 b[...]

E-1 TR OUBLESHOO TING E-1 POWER WAVE 455/R 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. CA UTION This Troubleshooting Guide is provided to help you locate and rep[...]

E-2 TR OUBLESHOO TING E-2 POWER WAVE 455/R USING THE ST A TUS LED T O TR OUBLESHOO T SYSTEM PROBLEMS The Status LED on the pow er source case front can help diagnose problems do wn to the system component (pow er source, wire f eeder , wire drive , etc.) lev el. If , f or any reason, the system does not appear to be working properly , alwa ys check[...]

E-3 TR OUBLESHOO TING E-3 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING 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 Lin[...]

E-4 TR OUBLESHOO TING E-4 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING 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 Lin[...]

E-5 TR OUBLESHOO TING E-5 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING 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 Lin[...]

E-6 TR OUBLESHOO TING E-6 POWER WAVE 455/R 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. CA UTION PRO[...]

E-7 TR OUBLESHOO TING E-7 POWER WAVE 455/R 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. CA UTION ERR[...]

E-8 TR OUBLESHOO TING E-8 POWER WAVE 455/R 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. CA UTION Err[...]

F-1 DIA GRAMS F-1 POWER WAVE 455/R 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 n[...]

F-2 DIA GRAMS F-2 POWER WAVE 455/R - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WI RE FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 C8 TO D5 289D R2 2 Ω 288C 288D 289E 288E TM J1 4 5 TO 3R 3R 3W 238 15 5 J10 TO SSR RECT THERM 223 222 CHOPPER BD SEC (BOTTOM LEFT) POWER BD RECTI FIER AC EMITTER 212 213 813 811 216 4 CONT ROL BOARD + TO [...]

T ABLE 5 DEVICENET CONNECT OR S5 Pin Lead # Function 2 894 +24vdc De vicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-3 CONNECT OR PIN DEFINITIONS F-3 POWER WAVE 455/R T ABLE 1 INTERF ACE CONNECT OR S6 Pin Lead # Function A 841 +15vdc T ach v oltage B 844 T ach common C 842 T ach 1A diff erential signal D 843 T ach 1B diff eren[...]

F-4 CONNECTION DIA GRAM F-4 POWER WAVE 455/R Hard A utomation, Electrode P ositiv e, STT Configuration - + WO RK SE NSE LEA D K940 W A TERCOO LED TO RCH ELEC T RO DE L E AD CO NT RO L CA BLE K1795 W A TE R CO OLER PO WER CO NNE CT IO N SHIE L DING G AS TO S HIE LDING G AS DE V ICE NE T CA B LE TO P LC/CO NTRO LL E R DEVICENET CABLE TO PLC/CONTROLLE[...]

F-5 CONNECTION DIA GRAM F-5 POWER WAVE 455/R K1796 COAXIAL WELD CABLE User supplied work lead User supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE Robotic Set Up , Electrode P ositiv e, CV/Pulse Configuration Use r sup p lie d wor k le [...]

F-6 DIA GRAMS F-6 POWER WAVE 455/R 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[...]

NO TES POWER WAVE 455/R[...]

W ARNING A VISO DE PRECA UCION 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 [...]

W ARNING A VISO DE PRECA UCION 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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