Lincoln Electric IM808-A manual Nominal Procedures, Fringe Procedures, Making a Weld

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B-6

OPERATION

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NOMINAL PROCEDURES

The Power Wave is designed to operate with 3/4" elec- trode stick-out for CV and Pulse processes.

FRINGE PROCEDURES

Excessively short or long electrode stick-outs may function only on a limited basis, if at all.

MAKING A WELD

WARNING

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

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The steps for operating the Power Wave will vary depending upon the options installed in the user inter- face (control box) of the welding system. The flexibility of the Power Wave system lets the user customize operation for the best performance.

First, consider the desired welding process and the part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAW- P, etc.)

Second, find the program in the welding software that best matches the desired welding process. The stan- dard software shipped with the Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative.

To make a weld, the Power Wave needs to know the desired welding parameters. The Power Feed (PF) family of feeders communicate settings to the Power Wave through control cable connection. Arc length, wire feed speed, arc control, etc. are all communicated digitally via the control cable.

WELDING ADJUSTMENTS

All adjustments are made on the system component known as the User Interface (Control Box), which con- tains the switches, knobs, and digital displays neces- sary to control both the Power Wave and a Power Feed wire feeder. Typically, the Control Box is supplied as part of the wire feeder. It can be mounted directly on the wire feeder itself, the front of the power source, or mounted separately, as might be done in a welding boom installation.

Because the Control Box can be configured with many different options, your system may not have all of the following adjustments. Regardless of availability, all controls are described below. For further information, consult the Power Feed wire feeder instruction manu- al.

WFS / AMPS:

In synergic welding modes (synergic CV, pulse GMAW, STT), WFS (wire feed speed) is the dominant control parameter, controlling all other variables. The user adjusts WFS according to factors such as weld size, penetration requirements, heat input, etc. The Power Wave then uses the WFS setting to adjust its output characteristics (output voltage, output current) accord- ing to pre-programmed settings contained in the POWER WAVE 455M/STT (CE). In non-synergic modes, the WFS control behaves more like a conven- tional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the volt- age to compensate for any changes made to the WFS.

In constant current modes (stick, TIG) this control adjusts the output current, in amps.

VOLTS / TRIM:

In constant voltage modes (synergic CV, standard CV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting to adjust the arc length. It is adjustable from 0.500 to 1.500. A Trim set- ting of 1.000 is a good starting point for most condi- tions.

Power Wave 455M/STT (CE) Only: In STT modes, the user can adjust the Trim setting to change the overall heat input to the weld.

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.1Cable INDUCTANCE, and ITS Effects on Pulse Welding Negative Electrode PolarityVoltage Sensing 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 EquipmentCase Front Layout Power Wave 455M/STT CECase Front Controls Welding Adjustments Nominal ProceduresFringe Procedures Making a WeldARC Control Welding ModeConstant Voltage Welding 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