Lincoln Electric IM716 User Manual

POWER WAVE 455/STT ™OPERATOR’S MANUALIM716October, 2003Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwit

LIFTINGLift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave with acces

A-3INSTALLATION POWER WAVE 455/STTA-3INPUT FUSE AND SUPPLY WIRE CONSIDERATIONSRefer to the Technical Specifications at the beginningof this Installa

A-4INSTALLATION POWER WAVE 455/STTA-4CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDINGFor Pulse Welding processes, cable inductance will causethe we

A-5INSTALLATION POWER WAVE 455/STTA-5Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured through sof

A-6INSTALLATION POWER WAVE 455/STTA-6SYSTEM DESCRIPTIONThe Power Wave 455/STT and Power Feed 10/11family of products utilize a digital communication

A-7INSTALLATION POWER WAVE 455/STTA-7FIGURE A.8Simple SystemSYSTEM SET-UPBasic Rules• Each group is required to have one user interface.No group may

A-8INSTALLATION POWER WAVE 455/STTA-8FIGURE A.9Multiple Group SystemNo “FH0 Alllowed!FIGURE A.10Single Group Multi-Head SystemNo “FH0 Alllowed!The D

A-9INSTALLATION POWER WAVE 455/STTA-9FIGURE A.11Single Group Multi-Head System (Alternate Method)No “FH0 Alllowed!When a standardUser Iterface is us

A-10INSTALLATION POWER WAVE 455/STTA-10FIGURE A.2-+POWERWAVE-+POWERWAVEConnect All WorkSense Leads at the Endof the JointConnect All WeldingWork Lea

A-11INSTALLATION POWER WAVE 455A-11MULTIPLE ARC SENSE LEAD AND WORKLEAD PLACEMENT GUIDELINESWork #2Sense #2PowerSource#2PowerSource#1Arc #1Arc #2Wor

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

A-12INSTALLATION POWER WAVE 455/STTA-12I / O RECEPTACLE SPECIFICATIONSTABLE 3WIRE FEEDER RECEPTACLE S1PIN LEAD# FUNCTIONA 53 Communication Bus LB

B-1OPERATIONB-1POWER WAVE 455/STTSAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can k

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

RECOMMENDED EQUIPMENTPower Wave 455/STT – Semi-Automatic OperationSemi Automatic Power Waves can only be used withLinc-Net compatible Power Feed semi-

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

B-5OPERATIONB-5NOMINAL PROCEDURESThe Power Wave is designed to operate with 3/4"electrode stick-out for CV and Pulse processes and a1/2" sti

B-6OPERATIONB-6• VOLTS / TRIM:In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage.In pulse synergic welding mo

B-7OPERATIONB-7CONSTANT VOLTAGE WELDINGSynergic CV:For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special

B-8OPERATIONB-8PULSE WELDINGPulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc volt

B-9OPERATIONB-9STT WELDINGThe pictures illustrate the waveshape of current forthe process. They are not drawn to scale, and areintended only for the p

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

C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDNone Available.FIELD INSTALLED Work Voltage Sense Lead Kit, K940Dual Cylinder Undercarriage, K1570

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

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

E-2TROUBLESHOOTINGE-2POWER WAVE 455/STTUSING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe Power Wave / Power Feed are best diagnosed asa system. E

E-3TROUBLESHOOTINGE-3POWER WAVE 455/STTObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test p

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

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

E-6TROUBLESHOOTINGE-6POWER WAVE 455/STTObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdet

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

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

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-2CONNECTION DIAGRAMF-2POWER WAVE 455/STTConnection Diagram Semi-automatic "Simple System"(Electrode Positive,CV/Pulse Configuration shown

F-3DIAGRAMSF-3POWER WAVE 455Connection Diagram Semi-automatic "Simple System"(Electrode Positive, STT Configuration shown)POWER WAVE / STT

F-4DIAGRAMSF-4POWER WAVE 455/STT32.8826.1022.6312.3519.0019.9019.169.48 14.6223.1223.5111-14-97M18241DIMENSION PRINT - POWER WAVE 455

NOTESPOWER WAVE 455/STT

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

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

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

viviTABLE OF CONTENTSPageInstallation ...Section A

viiviiTABLE OF CONTENTSPageTroubleshooting.......Section EHow t

A-1INSTALLATION POWER WAVE 455/STTA-1TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT (K1518-4)OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM