Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455/R ..............................................A-1,A-2Safety Precautions.................................
Page 8 - INSTALLATION; OUTPUT; FCAW
A-1 INSTALLATION POWER WAVE 455/R A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS (K1761-1) 208/230/460V - 60HZ. 200/220/440V - 50HZ. (K1761-2) 208/230/460/5...
Page 9 - PHYSICAL DIMENSIONS
A-2 INSTALLATION POWER WAVE 455/R A-2 PHYSICAL DIMENSIONS TEMPERATURE 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
Page 10 - MACHINE GROUNDING; Read this entire installation section before you; SELECT SUITABLE LOCATION; DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly understationary or fixed electrical equipment, that surfaces h a l l b e c o v e r e d w i t h a s t e e l p l a t e a t l e a s t.06”(1.6mm) thick, which shall extend not less than5.90”(150mm) beyond the equipment on all sides. LIFTING Lift the machine ...
Page 11 - Fuse the input circuit with the recommend-; do so will result in damage to the machine.
A-4 INSTALLATION POWER WAVE 455/R A-4 Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on theinside of the input access door or refer to Figure A.1on the following page. I N P U T F U S E A N D S U P P LY W I R E CONSIDERATIONS Refer to the Technical Specif...
Page 12 - Travel; TWO POWER WAVES
A-5 INSTALLATION POWER WAVE 455/R A-5 WELDING WITH MULTIPLE POWERWAVES Special care must be taken when more than onePower Wave is welding simultaneously on a singlepart. Arc blow and arc interference may occur orbe magnified. Each power source requires a work lead from thework stud to the welding fi...
Page 13 - TABLE 1; NEGATIVE ELECTRODE POLARITY; ELECTRIC SHOCK can kill.; Turn off power to the power source at the disconnect
A-6 INSTALLATION POWER WAVE 455/R A-6 E L E C T RO D E A N D WO R K C A B L ECONNECTIONS Connect a work lead of sufficient size and length (PerTable 1) between the proper output terminal on thepower source and the work. Be sure the connection tothe work makes tight metal-to-metal electrical contact....
Page 14 - VOLTAGE SENSING; TABLE 2
Work Voltage SensingThe Power Waves are shipped from the factory withthe work sense lead enabled. For processes requiring work voltage sensing, con-nect the (21) work voltage sense lead from the PowerWave to the work. Attach the sense lead to the workas close to the weld as practical. Enable the wor...
Page 15 - CONTROL CABLE SPECIFICATIONS; slave; CAUTION
A-8 INSTALLATION POWER WAVE 455/R A-8 POWER WAVE / POWER FEED WIREFEEDER INTERCONNECTIONS Connect the control cable between the power sourceand wire feeder. The wire feeder connection on therobotic Power Waves is located under the springloaded output cover, near the bottom of the case front.The cont...
Page 16 - HIGH SPEED GEAR BOX
A-9 INSTALLATION POWER WAVE 455/R A-9 HIGH SPEED GEAR BOX Changing the ratio requires a gear change and a PCboard switch change. The Power Feed Wire Feedersare shipped with both high speed and a low speedgears. As shipped from the factory, the low speed( h i g h t o r q u e ) g e a r i s i n s t a l...
Page 17 - Turn off power at the disconnect switch.
A-10 INSTALLATION POWER WAVE 455/R A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for customconfiguration of the Power Wave. To access the DIPswitches: • Turn off power at the disconnect switch. ------------------------------------------------------------------------ • ...
Page 18 - TABLE 2
A-11 INSTALLATION POWER WAVE 455/R A-11 Bank (S2):switch Description 1 Devicenet Baud Rate 2 (see table 2) TABLE 2 Prior to S24958-6 softwareswitch 1 switch 2 baud rate off off Programmable value on off 125K off on 250K on on 500K S24958-6 and later softwareswitch 1 switch 2 baud rate off off 125K o...
Page 19 - OPERATION; SAFETY PRECUATIONS
B-1 OPERATION B-1 POWER WAVE 455/R SAFETY PRECUATIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and coul...
Page 21 - RECOMMENDED EQUIPMENT; Automatic Operation; REQUIRED EQUIPMENT; DUTY CYCLE AND TIME PERIOD; GENERAL DESCRIPTION; RECOMMENDED PROCESSES
RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set throughs o f t w a r e f o r t h e r o b o t i c P o w e r W a v e s . F A N U Crobots equipped with RJ-3 controllers may communi-cate directly to the Power Wave. Other pieces ofequipment such as PLC ’ s or compu...
Page 22 - CASE FRONT CONTROLS; NOTE: The robotic Power Waves
B-4 OPERATION POWER WAVE 455/R B-4 CASE FRONT CONTROLS All operator controls and adjustments are located onthe 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 ...
Page 23 - CONSTANT VOLTAGE WELDING; Current
B-5 OPERATION B-5 CONSTANT VOLTAGE WELDING For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The preprogrammed voltage is thebest average voltage for a given wire feed speed.With synergic programs, when the wire feed speedcha...
Page 24 - PULSE WELDING
B-6 OPERATION B-6 PULSE WELDING Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. The...
Page 25 - STT WELDING; The ranges on Wave Control and Trim are
B-7 OPERATION B-7 STT WELDING The pictures illustrate the waveshape of current forthe process. They are not drawn to scale, and areintended only for the purpose of showing how thevariables effect the waveform. For most programs, peak current is adjusted by wavecontrol values. A value of +10.0 maximi...
Page 26 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED; Coaxial welding Cable, K1796
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for thePower Wave 455R. FIELD INSTALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an optionalaccessory for the Power Feed Robotic wire driveunit. Install the 5/8-18 ...
Page 27 - MAINTENANCE; SAFETY PRECAUTIONS; • Only Qualified personnel should; ROUTINE MAINTENANCE
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 d i s c o n n e c t s w i t c h o r f u s e b o xbefore working on this equipment. • Do not touch electrically hot parts. ROU...
Page 28 - TROUBLESHOOTING; Look under the column labeled; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshootin...
Page 30 - Observe all Safety Guidelines detailed throughout this manual; TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS; Contact your local authorized
E-3 TROUBLESHOOTING E-3 POWER WAVE 455/R 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/repa...
Page 33 - PROBLEMS
E-6 TROUBLESHOOTING 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...
Page 34 - Indication
E-7 TROUBLESHOOTING 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...
Page 35 - 1 Secondary overcurrent error
E-8 TROUBLESHOOTING 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...
Page 36 - DIAGRAMS; PO
F-1 DIAGRAMS 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 diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Depar...
Page 38 - TABLE 5 DEVICENET CONNECTOR S5; CONNECTOR PIN DEFINITIONS; TABLE 1 INTERFACE CONNECTOR S6
TABLE 5 DEVICENET CONNECTOR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-3 CONNECTOR PIN DEFINITIONS F-3 POWER WAVE 455/R TABLE 1 INTERFACE CONNECTOR S6 Pin Lead # Function A 841 +15vdc Tach voltage B 844 Tach common C 842 Tach 1A differ...
Page 39 - CONNECTION DIAGRAM
F-4 CONNECTION DIAGRAM F-4 POWER WAVE 455/R Hard Automation, Electrode Positive, STTConfiguration - + W ORKS ENS ELE ADK 940 WA TE RCOO LEDTORCH E LE CTRODE LEA D CONTRO L CAB LE K 1795 W A TER CO OLE RP OW E RCO NNECT ION S HIELDING G A S TO SHIE LDING GA S DE VICE NE T CA BLETO PLC/CO NTROLLE R DE...
Page 41 - WER
F-6 DIAGRAMS 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
Page 42 - NOTES
Page 43 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...