Lincoln Electric IM808-A User Manual

IEC 60974-1POWER WAVE 455M/STT™OPERATOR’S MANUALIM808-AJune, 2004Safety Depends on YouLincoln arc welding and cuttingequipment is designed and buil

ixixTABLE OF CONTENTSPageTroubleshooting ...Section EHow to

A-1INSTALLATION POWER WAVE 455M/STT (CE)A-1TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2)OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZESP

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 455M/STT (CE)A-3INPUT CONNECTIONOnly a qualified electrician should connect theinput leads to the Power Wave 455M/STT (CE

A-4INSTALLATION POWER WAVE 455M/STT (CE)A-4CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDINGFor Pulse Welding processes, cable inductance will cause

A-5INSTALLATION POWER WAVE 455M/STT (CE)A-5Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured throu

A-6INSTALLATION POWER WAVE 455MSTT (CE)A-6CONFIGURING THE SYSTEMFor codes below 11100, consult the semi-automaticPower Feed instruction manual for c

A-7INSTALLATION POWER WAVE 455M/STT (CE)A-7In this case the individual feed heads need to be assigned to the dual head control and the PW455M/STT (C

A-8INSTALLATION POWER WAVE 455M/STT (CE)A-8WELDING WITH MULTIPLE POWERWAVESSpecial care must be taken when more than onePower Wave is welding simult

A-9INSTALLATION POWER WAVE 455M/STT (CE)A-9MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

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

A-10INSTALLATION POWER WAVE 455M/STT (CE)A-10I / O RECEPTACLE SPECIFICATIONSTABLE 3WIRE FEEDER RECEPTACLE S1PIN LEAD# FUNCTIONA 53 Communication B

B-1OPERATIONB-1POWER WAVE 455M/STT (CE)SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK

B-2OPERATIONB-2POWER WAVE 455M/STT (CE)INPUT POWERONOFFHIGH TEMPERATUREMACHINE STATUSCIRCUIT BREAKERWIRE FEEDERPOSITIVE OUTPUTNEGATIVE OUTPUT3 PHASE I

B-3OPERATIONB-3POWER WAVE 455M/STT (CE)DEFINITION OF WELDING TERMSNON-SYNERGIC WELDING MODES• A Non-synergic welding mode requires all weldingprocess

DeviceNet Interface ModuleThis module can be used for DeviceNet capability. Itwill be a 5 pin sealed mini connector per ANSIB93.55M-1981.EtherNet/Devi

B-5OPERATIONPOWER WAVE 455M/STT (CE)B-5CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave. (See F

B-6OPERATIONB-6NOMINAL PROCEDURESThe Power Wave is designed to operate with 3/4" elec-trode stick-out for CV and Pulse processes.FRINGE PROCEDURE

Wave Control 0.00Wave Control +10.0Wave Control -10.0CurrentTimeCURRENT WAVE FORM (CV)B-7OPERATIONB-7• WELDING MODEMay be selected by name (CV/MIG, CC

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 wave shape of current for theprocess. They are not drawn to scale, and are intend-ed only for th

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 455M/STT (CE)SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn

E-1TROUBLESHOOTINGE-1POWER WAVE 455M/STT (CE)If for any reason you do not understand the test procedures or are unable to perform the tests/repairs sa

E-2TROUBLESHOOTINGE-2POWER WAVE 455M/STT (CE)USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe Power Wave / Power Feed are best diagnosed asa sys

E-3TROUBLESHOOTINGE-3POWER WAVE 455M/STT (CE)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the

E-4TROUBLESHOOTINGE-4POWER WAVE 455M/STT (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understa

E-5TROUBLESHOOTINGE-5POWER WAVE 455M/STT (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understa

E-6TROUBLESHOOTINGE-6POWER WAVE 455M/STT (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understa

E-7TROUBLESHOOTINGE-7POWER WAVE 455M/STT (CE)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the

F-1DIAGRAMSF-1POWER WAVE 455M/STT (CE)NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Th

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 455M/STT (CE)Connection Diagram Semi-automatic "Simple System"(Electrode Positive, CV/Pulse Configuration

F-3CONNECTION DIAGRAMF-3POWER WAVE 455/STTConnection Diagram Semi-automatic "Simple System"(Electrode Positive, STT Configuration shown)POWE

F-4DIAGRAMSF-4POWER WAVE 455M/STT (CE)32.8826.1022.6312.3519.0019.9019.169.48 14.6223.1223.5111-14-97M18241DIMENSION PRINT - POWER WAVE 455M

NOTES

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

vSAFETYv

viSAFETYvi

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

viiiviiiTABLE OF CONTENTSPageInstallation ..........................Secti