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RETURN TO MAIN MENU
IM807-A
POWER WAVE
455 M
June, 2004
11007, 11203
For use with machines having Code Numbers:
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. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
IEC 60974-1
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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.lincolnelectric.com

Summary of Contents

  • Page 1

    RETURN TO MAIN MENU IM807-A POWER WAVE 455 M June, 2004 ™ 11007, 11203 For use with machines having Code Numbers: 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 ...

  • Page 2

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3

    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.

  • Page 4

    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.

  • Page 5

    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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6

    SAFETY...

  • Page 7

    SAFETY...

  • Page 8

    The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 9: Table Of Contents

    Installation ...Section A Technical Specifications - POWER WAVE 455M ...A-1 Safety Precautions...A-2 Select Suitable Location ...A-2 Lifting...A-2 Stacking ...A-2 Machine Grounding ...A-2 High Frequency Protection ...A-2 Input Connection...A-2 Input Fuse and Supply Wire Considerations ...A-3 Electrode and Work Cable Connections...A-3 Cable Inductance, and its Effects on Pulse Welding ...A-4 Negative Electrode Polarity ...A-4 Voltage Sensing ...

  • Page 10

    Troubleshooting ...Section E How to use Troubleshooting Guide ...E-1 Using the Status LED to Troubleshoot System Problems ...E-2 Error Codes For Power Waves...E-3 Troubleshooting Guide...E-4 thru E-6 ________________________________________________________________________ Wiring Diagram ...Section F-1 Connection Diagrams ...Section F-2 Dimension Print...Section F-3 ________________________________________________________________________ Parts Lists ...P438 Series ________________________________________________________________________ TABLE OF CONTENTS...

  • Page 11: Technical Specifications - Power Wave 455m

    TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT OUTPUT CONDITIONS VOLTS AMPS / VOLTS / DUTY CYCLE 400A@36V. 100% 380V - 60HZ. 400A@36V. 100% 380V - 50HZ. 400A@36V. 100% 415V - 60HZ. 400A@36V.

  • Page 12: Safety Precautions, Select Suitable Location, Lifting, Stacking, Machine Grounding, High Frequency Protection

    Dirt, dust, or any foreign mater- ial that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted.

  • Page 13: Input Connection, Input Fuse And Supply Wire Considerations, Electrode And Work Cable Connections

    FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do so will result in damage to the machine.

  • Page 14: Negative Electrode Polarity, Voltage Sensing

    Depending upon the process, inductance within the electrode and work lead cables can influence the apparent voltage at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.

  • Page 15: Power Wave To Semi-automatic Power Feed Wire Feeder Interconnections, System Description

    Enable the voltage sense leads as follows: TABLE A.2 Process Electrode Voltage Work Voltage Sensing 67 lead * Sensing 21 lead GMAW 67 lead required 21 lead optional GMAW-P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional GTAW Voltage sense at studs Voltage sense at studs...

  • Page 16: Configuring The System

    If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the welder output will be disabled. If a system is not “Auto-mappable”, then consult the instruction manual for the accessory being used for configuration infor- mation about DIP switch settings, or consult your local Lincoln sales representative.

  • Page 17: Alternate Hard Automatic Application, Dual Head Boom Feeder

    ALTERNATE HARD AUTOMATIC APPLICATION (using a UI, WD Module, and PF-10R) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto, WD Module, and PF-10R) DUAL HEAD System that is NOT "Auto Mappable" DUAL HEAD BOOM FEEDER (using two single heads) POWER WAVE 455M (CE) In this case the individual feed heads need to be assigned to the dual head control and the PW455M auto map- ping disabled and the Equipment Groups set.

  • Page 18: Welding With Multiple Power Waves, Control Cable Specifications

    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.

  • Page 19: Multiple Arc Unsynchronized

    INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 455M (CE)

  • Page 20: I / O Receptacle Specifications, Dip Switch Settings And Locations, Control Board Dip Switch

    A-10 I / O RECEPTACLE SPECIFICATIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 0vdc +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 LEAD# FUNCTION Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 LEAD# FUNCTION RS232 Receive...

  • Page 21

    • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not use AC welder if your cloth- ing, gloves or work area is damp or if working on, under or inside work- piece.

  • Page 22

    GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPERATION POWER WAVE 455M (CE) SMAW GMAW FCAW GTAW...

  • Page 23: Definition Of Welding Terms

    DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage based on the wire feed speed (WFS) set by the operator.

  • Page 24: General Description, Recommended Processes And Equipment, Required Equipment, Limitations, Duty Cycle And Time Period

    GENERAL DESCRIPTION The Power Wave 455M (CE) semi-automatic power source is designed to be a part of a modular, multi- process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes. The Power Wave 455M (CE) power source is designed to be used with the semi automatic family of Power Feed wire feeders, operating as a system.

  • Page 25: Case Front Controls

    CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave 455m (CE). (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors.

  • Page 26: Nominal Procedures, Fringe Procedures, Making A Weld, Welding Adjustment

    (CE) encompasses a wide range of common process- es and will meet most needs. If a special welding pro- gram is desired, contact the local Lincoln Electric sales representative. To make a weld, the Power Wave needs to know the desired welding parameters.

  • Page 27: Constant Voltage Welding

    • WELDING MODE May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characteristics of the Power Wave power source. For a more complete description of the welding modes available in the Power Wave, see the explanation below.

  • Page 28: Pulse Welding

    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. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known.

  • Page 29: Compatible Lincoln Equipment

    ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED Work Voltage Sense Lead Kit, K940 Dual Cylinder Undercarriage, K1570-1. Gas Guard Regulator, K659-1 Coaxial welding Cable, K1796 Cool-Arc 40 K2187-1 (230V AC) Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-1 Ethernet Interface Module, K2207-1 COMPATIBLE LINCOLN EQUIPMENT...

  • Page 30: Routine Maintenance, Safety Precautions, Periodic Maintenance, Calibration Specification

    Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a resistive load bank, and certified actual meters for volt- age and current.

  • Page 31: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 32: Using The Status Led To Troubleshoot System Problems

    USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each.

  • Page 33

    Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE The following is a list of possible error codes that the Power Wave 455M (CE) can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006"...

  • Page 34

    Thermal LED is lit. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...

  • Page 35

    WFS. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...

  • Page 36

    Excessively long and erratic arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...

  • Page 37

    DIAGRAMS REAR OF MACHINE MACHINE FRONT POWER WAVE 455M (CE)

  • Page 38

    CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER WORK CONTROL CABLE K1543 POWER WAVE 455M (CE)

  • Page 39

    DIAGRAMS POWER WAVE 455M (CE)

  • Page 40

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...

  • Page 41

    ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...

  • Page 42

    • World's Leader in Welding and Cutting Products • • 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.lincolnelectric.com...

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