Lincoln Electric IM690-A User Manual

POWER WAVE 455/R ™OPERATOR’S MANUALIM690-AMay, 2001Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith

Where there is a combustible surface directly understationary or fixed electrical equipment, that surfaceshall be covered with a steel plate at least.

A-4INSTALLATION POWER WAVE 455/RA-4Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on theinside of the i

A-5INSTALLATION POWER WAVE 455/RA-5WELDING WITH MULTIPLE POWERWAVESSpecial care must be taken when more than onePower Wave is welding simultaneously

A-6INSTALLATION POWER WAVE 455/RA-6ELECTRODE AND WORK CABLECONNECTIONSConnect a work lead of sufficient size and length (PerTable 1) between the pro

Work Voltage SensingThe Power Waves are shipped from the factory withthe work sense lead enabled.For processes requiring work voltage sensing, con-nec

A-8INSTALLATION POWER WAVE 455/RA-8POWER WAVE / POWER FEED WIREFEEDER INTERCONNECTIONSConnect the control cable between the power sourceand wire fee

A-9INSTALLATION POWER WAVE 455/RA-9HIGH SPEED GEAR BOXChanging the ratio requires a gear change and a PCboard switch change. The Power Feed Wire Fee

A-10INSTALLATION POWER WAVE 455/RA-10DIP Switch Settings and LocationsDIP switches on the P.C. Boards allow for customconfiguration of the Power Wav

A-11INSTALLATION POWER WAVE 455/RA-11Bank (S2):switch Description1 Devicenet Baud Rate2(see table 2)TABLE 2Prior to S24958-6 softwareswitch 1 swit

B-1OPERATIONB-1POWER WAVE 455/RSAFETY PRECUATIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kil

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-2OPERATIONB-2POWER WAVE 455/RINPUT POWERONOFFHIGH TEMPERATUREMACHINE STATUSCIRCUIT BREAKERWIRE FEEDERPOSITIVE OUTPUTNEGATIVE OUTPUT3 PHASE INVERTERI

RECOMMENDED EQUIPMENT• Automatic OperationAll welding programs and procedures are set throughsoftware for the robotic Power Waves. FANUCrobots equippe

B-4OPERATIONPOWER WAVE 455/RB-4CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave. (See Figure A.

B-5OPERATIONB-5CONSTANT VOLTAGE WELDINGFor each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at

B-6OPERATIONB-6PULSE WELDINGPulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc volt

B-7OPERATIONB-7STT WELDINGThe pictures illustrate the waveshape of current forthe process. They are not drawn to scale, and areintended only for the p

C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDThere are no factory installed options available for thePower Wave 455R.FIELD INSTALLED• Gas Guard

D-1MAINTENANCED-1POWER WAVE 455/RSAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn the inp

E-1TROUBLESHOOTINGE-1POWER WAVE 455/RIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, co

E-2TROUBLESHOOTINGE-2POWER WAVE 455/RUSING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe Status LED on the power source case frontcan help diagnose

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-3TROUBLESHOOTINGE-3POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-4TROUBLESHOOTINGE-4POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-5TROUBLESHOOTINGE-5POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-6TROUBLESHOOTINGE-6POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

E-7TROUBLESHOOTINGE-7POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

E-8TROUBLESHOOTINGE-8POWER WAVE 455/RObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

F-1DIAGRAMSF-1POWER WAVE 455/RNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif

F-2DIAGRAMSF-2POWER WAVE 455/R-TO J9202WORK202ATO R1TO TP6TO TP3TOCB1S1WIREFEEDERRECEPTACLEJ47+ELECTRODE223221206AR3C8TO D5289DR2 2Ω288C288D289E288ET

TABLE 5 DEVICENET CONNECTOR S5Pin Lead # Function2 894 +24vdc Devicenet3 893 Commom Devicenet+4 892 Devicenet H5 891 Devicenet LF-3CONNECTOR PIN DEFIN

F-4CONNECTION DIAGRAMF-4POWER WAVE 455/RHard Automation, Electrode Positive, STTConfiguration- +WORKSENSELEADK940WATERCOOLEDTORCHELECTRODE LEADCONTROL

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

F-5CONNECTION DIAGRAMF-5POWER WAVE 455/RK1796 COAXIAL WELD CABLEUser suppliedwork leadUser suppliedelectrode lead-+POWERWAVECONTROL CABLE K1805-1WORK

F-6DIAGRAMSF-6POWER WAVE 455/R32.8826.1022.6312.3519.0019.9019.169.48 14.6223.1223.5111-14-97M18241DIMENSION PRINT - POWER WAVE 455

NOTES POWER WAVE 455/R

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much p

viviTABLE OF CONTENTSPageInstallation ...Section A

A-1INSTALLATION POWER WAVE 455/RA-1TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2)OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZES FOR M

A-2INSTALLATION POWER WAVE 455/RA-2PHYSICAL DIMENSIONSTEMPERATURE RANGESHEIGHT26.10 in663 mmWIDTH19.86 in505 mmDEPTH32.88 in835 mmWEIGHT(K1761-1) 2