Lincoln Electric IM845-A - Manual

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 fumesoutdoors. ...

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

iii SAFETY 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 manufacturerʼsrecommendations. 8.c. Ground the ...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

iv SAFETY iv Mar. ʻ93 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 LʼArc 1. Protegez-vous contr...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

v v 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...

Page 7 - TABLE OF CONTENTS

vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Safety Precautions..............

Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS -; INPUT AC VOLTAGE & DC OUTPUT; POWER; POWER WAVE 355M INPUT CURRENT

A-1 INSTALLATION POWER WAVE 355M A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 355M INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous) 200 350A / 34V / 60% 14.8” x 13.3” x P...

Page 9 - SELECT SUITABLE LOCATION; CAUTION

A-2 INSTALLATION POWER WAVE 355M A-2 SELECT SUITABLE LOCATION The Invertec POWER WAVE 355M will operate inharsh environments. Even so, it is important that sim-ple preventative measures are followed in order toassure long life and reliable operation. • The machine must be located where there is free...

Page 10 - NEGATIVE ELECTRODE POLARITY

Output connections on some Power Waves are madevia 1/2-13 threaded output studs located beneath thespring loaded output cover at the bottom of the casefront. Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-trode cable between the wire feed...

Page 11 - VOLTAGE SENSING

A-4 INSTALLATION POWER WAVE 355M A-4 VOLTAGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence theapparent voltage at the studs of the welder. Voltagese...

Page 12 - SYSTEM DESCRIPTION

P O W E R WAV E T O S E M I - A U T O M AT I CPOWER FEED WIRE FEEDER INTERCON-NECTIONS The POWER WAVE 355M and semi-automatic PowerFeed family communicate via a 5 conductor controlc a b l e ( K 1 5 4 3 ) . T h e c o n t r o l c a b l e c o n s i s t s o f t w opower leads, one twisted pair for digit...

Page 13 - CONFIGURING THE SYSTEM; SINGLE HEAD FEEDER

A-6 INSTALLATION A-6 POWER WAVE 355M CONFIGURING THE SYSTEM The power source will “Auto Map” the system eliminat-ing most of the need to set DIP switches to configurethe system. If a system can not be “Auto Mapped” then the statuslight on the power source will blink green fast and thewelder output w...

Page 15 - TWO POWER WAVES

A-8 INSTALLATION POWER WAVE 355M A-8 Connect All WorkSense Leads at the Endof the Joint Connect All WeldingWork Leads at theBeginning of the Joint Travel Direction POWER WAVE 355M POWER WAVE 355M TWO POWER WAVES FIGURE A.6 CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control c...

Page 17 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS; CONTROL BOARD DIP SWITCH:

A-10 INSTALLATION POWER WAVE 355M A-10 I / O RECEPTACLE SPECIFICATIONS TABLE A.2 WIRE FEEDER RECEPTACLE PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc - E 51 +40vdc + TABLE A.3 VOLTAGE SENSE RECEPTACLE PIN LEAD# FUNCTION 3 21A Work Voltag...

Page 18 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; • This Power Wave is not recommended for processes; OPERATION; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.

GENERAL DESCRIPTION The Power Wave 355M semi-automatic power sourceis designed to be a part of a modular, multi-processwelding system. Depending on configuration, it cansupport constant current, constant voltage, constantpower and pulse welding modes. The Power Wave 355M power source is designed tob...

Page 20 - WELDING ADJUSTMENTS; • WELDING MODE; NOMINAL PROCEDURES

WELDING ADJUSTMENTS All adjustments are made on the system componentknown as the User Interface (Control Box), which con-tains the switches, knobs, and digital displays neces-sary to control both the Power Wave and a PowerFeed wire feeder. Typically, the Control Box is sup-plied as part of the wire ...

Page 21 - • ARC CONTROL; CONSTANT VOLTAGE WELDING; Synergic CV

Non Synergic CV: This type of CV mode behaves more like a conven-tional CV power source. Voltage and WFS are inde-pendent adjustments. Therefore to maintain the arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS. All CV Modes: Arc Control, often ref...

Page 22 - PULSE WELDING; Current

PULSE-ON-PULSE™ (GMAW-PP) Pulse on Pulse™ is a Lincoln process specificallydesigned for use in welding relatively thin, less than1/4"(6.4mm) thick aluminum (See Table B.3). It givesweld beads with very consistent uniform ripple. In Pulse on Pulse modes, two distinct pulse types areused, instead ...

Page 23 - TIG GTAW; SMAW

B-6 OPERATION B-6 POWER WAVE 355M BENEFITS OF PULSE ON PULSE FROMLINCOLN ELECTRIC • Excellent appearance of the weld bead• Improved cleaning action• Reduced porosity Table B.2 shows WFS and Trim settings for commonaluminum types and wire sizes when welding withPulse-on-Pulse. The welds made to obtai...

Page 24 - POWER MODETM; Recommended Welding Procedures for Power Mode - Table B.3

B-7 OPERATION B-7 POWER WAVE 355M POWER MODE™ T h e P o w e r M o d e ™ p r o c e s s w a s d e v e l o p e d b yLincoln to maintain a stable and smooth arc at lowprocedure settings which are needed to weld thinmetal without pop-outs or burning-through. For alu-minum welding, it provides excellent c...

Page 25 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED; Any; ArcLink compatible; wire feeding equipment.

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead KitK1764-1-Undercarriage*K1838-1-Valet Style UndercarriageK1796-Coaxial Welding Cable-(Requires Adapter K2176-1)K2176-1 Twist-mate to Lug Adapters* Dual Cylinder Kit for K1764-1 is K...

Page 26 - MAINTENANCE; CAPACITOR DISCHARGE PROCEDURE; Hold resistor body with electrically insulated glove.; ROUTINE MAINTENANCE; PERIODIC MAINTENANCE

D-1 MAINTENANCE D-1 POWER WAVE 355M SAFETY PRECAUTIONS CAPACITOR DISCHARGE PROCEDURE 1. Obtain a power resistor (25 ohms, 25 watts). 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resis-tor terminals across the two studs in the positionshown. Hold in eac...

Page 27 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE

E-1 TROUBLESHOOTING E-1 POWER WAVE 355M 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. CAUTION This Troubleshootin...

Page 28 - Read the

E-2 TROUBLESHOOTING E-2 POWER WAVE 355M USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed asa system. Each component (power source, user inter-face, and feedhead) has a status light, and when aproblem occurs it is important to note the condition ofeac...

Page 29 - ERROR CODES FOR THE POWERWAVE; Indication

E-3 TROUBLESHOOTING E-3 POWER WAVE 355M 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 troubleshoot...

Page 30 - Observe all Safety Guidelines detailed throughout this manual; TROUBLESHOOTING GUIDE; Observe Safety Guidelines

E-4 TROUBLESHOOTING E-4 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safel...

Page 33 - PROBLEMS

E-7 TROUBLESHOOTING E-7 POWER WAVE 355M 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 troubleshoot...

Page 34 - WIRING DIAGRAMS

F-1 WIRING DIAGRAMS F-1 POWER WAVE 355M 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...

Page 35 - DIAGRAMS

F-2 DIAGRAMS F-2 POWER WAVE 355M 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 Depart...

Page 36 - CONNECTION DIAGRAM

F-3 CONNECTION DIAGRAM F-3 POWER WAVE 355M Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK

Page 37 - DIMENSION PRINT

F-4 DIMENSION PRINT F-4 POWER WAVE 355M 1 4.7 9 1 2.4 4 3.44 21.60 27.82 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 13.1 0 1/4- 20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 10/01 N NOT PROTR UDE MORE THAN 0.5 IN CHES INSIDE THE MACHINE. 11.8 4 3.50

Page 38 - NOTES