RETURN TO MAIN MENU POWER WAVE 455 ™ For use with machines having Code Numbers: IM583-A December, 1999 10372, 10553, 10555 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v 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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455..........................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Stacking ..........
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455 INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS INPUT CURRENT OUTPUT CONDITIONS INPUT CURRENT 208V - 60HZ. 230V - 60HZ. 400V - 60HZ. 460V - 60HZ. 575V - 60HZ. 200V - 50HZ. 220V - 50HZ. 400V - 50HZ. 440V - 50HZ. 550V - 50HZ. 450A@38V. 100% 450A@38V. 100% 450A@38V. 100% 450A@38V. 100% 450A@38V. 100% 400A@36V. 100% 400A@36V. 100% 400A@36V. 100% 400A@36V. 100% 400A@36V. 100% 70 65 39 35 29 72 67 40 36 29 570A@43V.
A-2 A-2 INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. ENVIRONMENTAL PROTECTION The Power Wave power source is rated IP21S and should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area. • Only qualified personnel should perform this installation.
A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR S24196 INPUT SUPPLY CONNECTION DIAGRAM 440-460V not touch electrically live parts. Only qualified persons should install, use or service this equipment. . VOLTAGE=220-230V VOLTAGE=380-415V 200-208V 200-208V 220-230V 380-415V 200-208V 220-230V ’A’ 380-415V 220-230V ’A’ 380-415V 440-460V 440-460V ’A’ not touch electrically live parts.
A-4 INSTALLATION A-4 VOLTAGE SENSING AT THE WORKPIECE POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS A four-pin work piece voltage sense lead connector is located beneath the output stud cover. The use of a work piece sense lead is optional for most welding modes, but may be used if desired. ELECTRODE & WORK LEADS — ELECTRODE POSITIVE APPLICATIONS Sense Lead Kits (K490-10, -25 or -50) are available for this purpose.
A-5 INSTALLATION POWER FEED CONTROL BOX MOUNTING In some installations, it may be desirable to mount the Wire Feeder control box directly to the front of the Power Wave power source. (The control box is the box containing the knobs, switches and displays necessary to control the Power Wave / Power Feed welding system.) Complete details for separating the control box from the wire drive are contained in the Power Feed Instruction Manual. Once separated, mounting instructions are as follows: 1.
B-1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER SMAW ON GMAW OFF FCAW HIGH TEMPERATURE GTAW MACHINE STATUS U0 OPEN CIRCUIT VOLTAGE CIRCUIT BREAKER U1 INPUT VOLTAGE WIRE FEEDER U2 OUTPUT VOLTAGE POSITIVE OUTPUT I1 INPUT CURRENT NEGATIVE OUTPUT I2 OUTPUT CURRENT 3 PHASE INVERTER PROTECTIVE GROUND INPUT POWER THREE PHASE WARNING DIRECT CURRENT POWER WAVE 455 B-2
B-3 B-3 OPERATION GENERAL DESCRIPTION Parameter The Power Wave 455 is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW and CAC-A processes. Welding Mode Stick Crisp, Stick Soft, Flux Cored with Gas, Flux Cored without Gas, CV, Synergic CV, .035 Stainless Pulse, .
B-4 B-4 OPERATION WELDING CAPABILITY CASE FRONT CONTROLS The POWER WAVE 455 is rated at 60 Hz. 450A@ 38V. 100% duty cycle or 570A@ 43V 60% duty cycle 50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V 60% duty cycle. The machine is capable of higher outputs at lower duty cycles. All operator controls and adjustments are located on the case front of the Power Wave. If the duty cycle is exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature. 2.
B-5 OPERATION WELDING ADJUSTMENTS All adjustments are made on the system component known as the control box, which contains the switches, knobs and digital displays necessary 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, or mounted separately, as might be done in a welding boom installation.
B-6 OPERATION The arc length trim (usually referred to simply as “trim”) can be adjusted between 0.500 and 1.500 on the control box’s Volts/Trim display. A Trim of 1.000 means that no adjustments will be made to the preset arc lengths. A Trim greater than 1.000 increases the preset arc lengths. A Trim setting less than 1.000 decreases the preset arc lengths. The arc length trim adjustment is factored in at all wire feed speed settings.
C-1 ACCESSORIES OPTIONS / ACCESSORIES FACTORY INSTALLED There are no factory installed options available for the Power Wave machines. FIELD INSTALLED The following options/accessories are available for your Power Wave from your local Lincoln Distributor. K1570-1 Dual Cylinder Undercarriage K940-10 Voltage Sense Lead Kit- 10 foot voltage sense lead kit. K940-25 Voltage Sense Lead Kit- 25 foot voltage sense lead kit, if additional length is required.
D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING 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. ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine, using a low pressure airstream, to remove accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in the machine.
E-1 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case front can help diagnose problems down to the system component (power source, wire feeder, wire drive, etc.) level. If, for any reason, the system does not appear to be working properly, always check the E-1 color of the Status LED, and refer to the following chart to help you determine which system component (power source, wire feeder, wire drive, etc.) may be faulty.
E-2 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS RECOMMENDED COURSE OF ACTION Major physical or electrical damage Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service facilicovers are removed. ty for technical assistance.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Wire feeder won’t work. No lights, 1. apparently no power to wire feeder. 2. 3. Thermal LED is lit. 1. 2. Machine won’t weld, can’t get any output. (CR1 will not pull in.) 1. 2. 3.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Machine often “noodle welds” (output is limited to approximately 100 amps) when running a particular procedure Secondary current limit has been exceeded, and the machine has phased back to protect itself.
3 LINE LOAD TO R1 206A 206 52A A 1 33 31 251 32 206A 202A TP3 612B TO CB3 TO J61 H1D TO RECONNECT PANEL TO TP3 C2 .05/600V L3A J81 TO S4 ELECTRODE WORK TO TO J81 CB2 ELECTRODE WORK TO POWER BD L2 TO J25 TO NOTES: N.D N.C. N.B. N.A. 2B 228 8 N.D.
POWER WAVE 455 (TOP) 32 TO J81 CB2 L2 N.C. N.B. POWER BD RECTIFIER POWER BOARD SOLID STATE RELAY CONNECTION SHOWN IS FOR 550-575V OPERATION. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
POWER WAVE 455 19.00 12.35 19.16 19.90 9.48 22.63 23.12 23.51 26.10 DIMENSION PRINT - POWER WAVE 455 32.88 14.
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● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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