Lincoln Electric IM808-A manual Welding with Multiple Power Waves, Control Cable Specifications

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A-8

INSTALLATION

A-8

 

 

 

WELDING WITH MULTIPLE POWER WAVES

CAUTION

Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified.

Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. The welding travel directions should be in the direction moving away from the work lead as shown below. Connect all of the work sense leads from each power source to the work piece at the end of the weld.

For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves. When these parameters are identical, the puls- ing frequency will be the same, helping to stabilize the arcs.

Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas cover- age.

Do not attempt to supply shielding gas for two or more guns from only one regulator.

If an anti-spatter system is in use then each gun must have its own anti-spatter system. (See Figure A.2)

CONTROL CABLE SPECIFICATIONS

It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system.

CAUTION

The use of non-standard cables, especially in lengths greater than 7.6m(25 ft)., can lead to com- munication problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).

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The K1543 series of control cables can be connected end to end for ease of extension. Do not exceed more than 30.5 m(100 ft.) total control cable length.

FIGURE A.2

POWER WAVE

 

POWERWAVE

 

-

+

TWO POWER WAVES

 

POWER WAVE

POWERWAVE

-

+

Travel

 

Direction

 

 

Connect All Work

 

Sense Leads at the End

 

of the Joint

Connect All Welding

Work Leads at the

Beginning of the Joint

POWER WAVE 455M/STT (CE)

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Contents Power Wave 455M/STT Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Safety Thank You Table of Contents Table of Contents Installation Technical Specifications Power Wave 455M/STT CE K2203-2Lifting Machine GroundingHigh Frequency Protection StackingElectrode and Work Cable Connections Input Fuse and Supply Wire ConsiderationsInput Connection Table A.1Negative Electrode Polarity Voltage SensingCable INDUCTANCE, and ITS Effects on Pulse Welding Work Voltage Sensing System DescriptionTable A.2 Electrode Voltage SensingSingle Head Boom Feeder Configuring the SystemSingle Head Feeder UP to 4 Feeders AllowedDual Head Boom Feeder using two single heads Welding with Multiple Power Waves Control Cable SpecificationsInstallation Control Board DIP Switch Receptacle SpecificationsDIP Switch Settings and Locations Water Flow SensorSafety Precautions OperationPower Wave 455M/STT CE Definition of Welding Terms Recommended Equipment General DescriptionRecommended Processes and Equipment Required EquipmentPower Wave 455M/STT CE Case Front ControlsCase Front Layout Welding Adjustments Nominal ProceduresFringe Procedures Making a WeldWelding Mode Constant Voltage WeldingARC Control Pulse Welding Figure A.6 Current Wave Form PulseSTT Welding Figure A.7Field Installed AccessoriesFactory Installed Optional EquipmentMaintenance Routine MaintenanceTroubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Error Codes for the Powerwave Error Code # Description IndicationAuthorized Field Service Facility Contact your local LincolnIf the Thermal LED is also lit, see Exceeding the 325 amp limit on STT output terminal WFS Power Wave 455M/STT CE Wiring Diagram 455M/STTConnection Diagram Connection Diagram Semi-automatic Simple SystemWire Feeder Work Sense Power Wave 455/STTDiagrams Dimension Print Power Wave 455MPage Precaucion Aviso DE