Lincoln Electric IM808-A manual Case Front Controls, Case Front Layout, Power Wave 455M/STT CE

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B-5

 

OPERATION

 

 

 

B-5

 

 

 

 

 

 

 

CASE FRONT CONTROLS

 

FIGURE B.1

 

 

All operator controls and adjustments are located on

 

 

 

 

 

 

 

 

the case front of the Power Wave. (See Figure B.1)

 

 

 

 

 

2

3

 

 

 

 

 

 

1. POWER

SWITCH: Controls input power to the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

Power Wave.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

2. STATUS LIGHT: A two color light that indicates sys-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tem errors. Normal operation is a steady green

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

light. Error conditions are indicated, per table 3.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE: The POWER WAVE 455M/STT (CE) status

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

light will flash green, and sometimes red and green, for

 

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

up to one minute when the machine is first turned on.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This is a normal situation as the machine goes through

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

a self test at power up.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

Light

Meaning

 

 

4

 

 

5

 

 

 

 

 

 

Condition

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Steady Green

System OK. Power source communicating normal-

 

 

 

 

 

 

 

 

 

 

 

ly with wire feeder and its components.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Blinking

Occurs during a reset, and indicates the

 

 

 

 

CASE FRONT LAYOUT

 

 

 

Green

POWER WAVE 455M/STT (CE) is mapping

 

 

 

POWER WAVE 455M/STT (CE)

 

 

 

 

(identifying) each component in the system.

 

 

 

 

 

 

 

Normal for first 1-10 seconds after power is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

turned on, or if the system configuration is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

changed during operation

 

5. 5 AMP AUXILIARY POWER CIRCUIT BREAKER:

 

 

 

 

A l t e r n a t i n g

Non-recoverable system fault. If the PS

 

 

Protects 220 volt AC case front receptacle auxiliary

Green and

Status light is flashing any combination of

 

 

supply.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Red

red and green, errors are present in the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER WAVE 455M/STT (CE) Read the

 

6. LEAD CONNECTOR S2 (SENSE LEAD)

 

 

 

 

error code before the machine is turned

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

off.

 

7. DIAGNOSTIC CONNECTOR (RS-232)

 

 

 

 

Error Code interpretation through the Status

 

8. WIRE FEEDER RECEPTACLE (S1 5-PIN)

 

 

 

 

light is detailed in the Service Manual.

 

 

 

 

 

Individual code digits are flashed in red with

 

9. NEGATIVE STUD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a long pause between digits. If more than

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

one code is present, the codes will be sepa-

 

10. POSITIVE STUD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

rated by a green light.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

To clear the error, turn power source off, and

 

11. AUXILIARY OUTPUT

 

 

 

 

back on to reset. See Troubleshooting

 

12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)

 

Section.

 

Steady Red

Non recoverable hardware fault. Generally

 

13. ROBOTIC WIRE FEEDER RECEPTACLE

 

 

 

 

indicates nothing is connected to the Power

 

 

(OPTIONAL)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wave 455M 455M/STT (CE) wire feeder

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

receptacle. See Trouble Shooting Section.

 

 

14. I/O CONNECTOR (OPTIONAL)

 

 

 

Blinking Red

Not applicable.

 

 

 

 

15. STT STUD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. HIGH

TEMPERATURE LIGHT (thermal overload):

 

16. ETHERNET CONNECTOR (OPTIONAL)

 

 

 

A yellow light that comes on when an over temper-

 

 

 

 

ature situation occurs. Output is disabled and the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

fan continues to run, until the machine cools down.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

When cool, the light goes out and output is enabled.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.10 AMP WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.

POWER WAVE 455M/STT (CE)

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Contents Power Wave 455M/STT California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Safety Thank You Table of Contents Table of Contents Technical Specifications Power Wave 455M/STT CE K2203-2 InstallationHigh Frequency Protection Machine GroundingLifting StackingInput Connection Input Fuse and Supply Wire ConsiderationsElectrode and Work Cable Connections Table A.1Voltage Sensing Negative Electrode PolarityCable INDUCTANCE, and ITS Effects on Pulse Welding Table A.2 System DescriptionWork Voltage Sensing Electrode Voltage SensingSingle Head Feeder Configuring the SystemSingle Head Boom Feeder UP to 4 Feeders AllowedDual Head Boom Feeder using two single heads Control Cable Specifications Welding with Multiple Power WavesInstallation DIP Switch Settings and Locations Receptacle SpecificationsControl Board DIP Switch Water Flow SensorOperation Safety PrecautionsPower Wave 455M/STT CE Definition of Welding Terms Recommended Processes and Equipment General DescriptionRecommended Equipment Required EquipmentCase Front Controls Power Wave 455M/STT CECase Front Layout Fringe Procedures Nominal ProceduresWelding Adjustments Making a WeldConstant Voltage Welding Welding ModeARC Control Figure A.6 Current Wave Form Pulse Pulse WeldingFigure A.7 STT WeldingFactory Installed AccessoriesField Installed Optional EquipmentRoutine Maintenance MaintenanceHOW to USE Troubleshooting Guide TroubleshootingUsing the Status LED to Troubleshoot System Problems Error Code # Description Indication Error Codes for the PowerwaveContact your local Lincoln Authorized Field Service FacilityIf the Thermal LED is also lit, see Exceeding the 325 amp limit on STT output terminal WFS 455M/STT Power Wave 455M/STT CE Wiring DiagramConnection Diagram Semi-automatic Simple System Connection DiagramPower Wave 455/STT Wire Feeder Work SenseDimension Print Power Wave 455M DiagramsPage Precaucion Aviso DE