Manuel d'utilisation / d'entretien du produit POWER WAVE IM690-A du fabricant Lincoln Electric
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PO WER W A VE 455/R ™ OPERA TOR’S MANUAL IM690-A May, 2001 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1.
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455/R ..............................................A-1,A-2 Safety Precautions.
A-1 INST ALLA TION POWER WAVE 455/R A-1 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/R (K1761-1),(K1761-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS (K1761-1) 208/230/460V - 60HZ.
A-2 INST ALLA TION POWER WAVE 455/R A-2 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 26.10 in 663 mm WIDTH 19.86 in 505 mm DEPTH 32.88 in 835 mm WEIGHT (K1761-1) 247 lbs.
Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.
A-4 INST ALLA TION POWER WAVE 455/R A-4 Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A.
A-5 INST ALLA TION POWER WAVE 455/R A-5 WELDING WITH MUL TIPLE PO WER W A VES 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.
A-6 INST ALLA TION POWER WAVE 455/R A-6 ELECTR ODE AND W ORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact.
Work Voltage Sensing The Power Waves are shipped from the factory with the work sense lead enabled. For processes requiring work voltage sensing, con- nect the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as close to the weld as practical.
A-8 INST ALLA TION POWER WAVE 455/R A-8 PO WER W A VE / PO WER FEED WIRE FEEDER INTERCONNECTIONS Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Waves is located under the spring loaded output cover, near the bottom of the case front.
A-9 INST ALLA TION POWER WAVE 455/R A-9 HIGH SPEED GEAR BO X Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder.
A-10 INST ALLA TION POWER WAVE 455/R A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave.
A-11 INST ALLA TION POWER WAVE 455/R A-11 Bank (S2) : switc h Description 1 De vicenet Baud Rate 2( see table 2 ) T ABLE 2 Prior to S24958-6 software s witch 1 switch 2 baud rate off off Programmab le.
B-1 OPERA TION B-1 POWER WAVE 455/R SAFETY PRECUA TIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill.
B-2 OPERA TION B-2 POWER WAVE 455/R INPUT PO WER ON OFF HIGH TEMPERA TURE MA CHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT PO WER THREE PHASE DIREC.
RECOMMENDED EQUIPMENT • Automatic Operation All welding programs and procedures are set through software for the robotic Power Waves. FANUC robots equipped with RJ-3 controllers may communi- cate directly to the Power Wave. Other pieces of equipment such as PLC ’ s or computers can commu- nicate to the Power Wave using DeviceNET.
B-4 OPERA TION POWER WAVE 455/R B-4 CASE FRONT CONTR OLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure A.4) 1 . POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors.
B-5 OPERA TION B-5 CONST ANT V OL T A GE WELDING For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed.
B-6 OPERA TION B-6 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage.
B-7 OPERA TION B-7 STT WELDING The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the variables effect the waveform. For most programs, peak current is adjusted by wave control values.
C-1 A CCESSORIES C-1 OPTIONAL EQUIPMENT F A CT OR Y INST ALLED There are no factory installed options available for the Power Wave 455R. FIELD INST ALLED • Gas Guard Regulator (K659-1) The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive unit.
D-1 MAINTENANCE D-1 POWER WAVE 455/R SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts.
E-1 TR OUBLESHOO TING E-1 POWER WAVE 455/R If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-2 TR OUBLESHOO TING E-2 POWER WAVE 455/R USING THE ST A TUS LED T O TR OUBLESHOO T SYSTEM PROBLEMS The Status LED on the pow er source case front can help diagnose problems do wn to the system component (pow er source, wire f eeder , wire drive , etc.
E-3 TR OUBLESHOO TING E-3 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
E-4 TR OUBLESHOO TING E-4 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
E-5 TR OUBLESHOO TING E-5 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
E-6 TR OUBLESHOO TING E-6 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-7 TR OUBLESHOO TING E-7 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-8 TR OUBLESHOO TING E-8 POWER WAVE 455/R Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1 DIA GRAMS F-1 POWER WAVE 455/R NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement.
F-2 DIA GRAMS F-2 POWER WAVE 455/R - TO J9 202 WORK 202A TO R1 TO TP6 TO TP3 TO CB1 S1 WI RE FEEDER RECEPTA CLE J47 + ELECT RODE 223 221 206A R3 C8 TO D5 289D R2 2 Ω 288C 288D 289E 288E TM J1 4 5 TO .
T ABLE 5 DEVICENET CONNECT OR S5 Pin Lead # Function 2 894 +24vdc De vicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L F-3 CONNECT OR PIN DEFINITIONS F-3 POWER WAVE 455/R T ABLE 1 IN.
F-4 CONNECTION DIA GRAM F-4 POWER WAVE 455/R Hard A utomation, Electrode P ositiv e, STT Configuration - + WO RK SE NSE LEA D K940 W A TERCOO LED TO RCH ELEC T RO DE L E AD CO NT RO L CA BLE K1795 W A.
F-5 CONNECTION DIA GRAM F-5 POWER WAVE 455/R K1796 COAXIAL WELD CABLE User supplied work lead User supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE .
F-6 DIA GRAMS F-6 POWER WAVE 455/R 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 11-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455.
NO TES POWER WAVE 455/R.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Lincoln Electric POWER WAVE IM690-A c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Lincoln Electric POWER WAVE IM690-A - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Lincoln Electric POWER WAVE IM690-A, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Lincoln Electric POWER WAVE IM690-A va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Lincoln Electric POWER WAVE IM690-A, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Lincoln Electric POWER WAVE IM690-A.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Lincoln Electric POWER WAVE IM690-A. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Lincoln Electric POWER WAVE IM690-A ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
