General Description; Recommended Processes And Equipment; Required Equipment; Limitations - Lincoln Power Wave 455 Operator's Manual

B-3

GENERAL DESCRIPTION

The Power Wave 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, Surface Tension Transfer
and pulse welding modes.
The Power Wave power source is designed to be
used with the family of Power Feed wire feeders,
operating as a system. Each component in the system
has special circuitry to "talk with" the other system
components, so each component (power source, wire
feeder, electrical accessories) knows what the other is
doing at all times. The components communicate
using Arc-Link protocol.
Robotic systems can communicate with other industri-
al machines via DeviceNET protocol. The result is a
highly intrigated and flexible welding cell.
GENERAL DESCRIPTION - POWER WAVE 455/R
The Power Wave 455/R is a high performance, digital-
ly controlled inverter welding power source capable of
complex, high-speed waveform control. Properly
equipped, it can support the GMAW, GMAW-P,
FCAW, GTAW and STT processes. It carries an out-
put rating of either 450 amps, 38 volts; or 400 amps,
36 volts (both at 100% duty cycle), depending on input
voltage and frequency. The Surface Tension transfer
process (STT) is supported at currents up to 325
amps, at 100% duty cycle.
If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
The Power Wave 455/R can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory prepro-
grammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW and STT
for a variety of materials, including mild steel, stain-
less steel, cored wires, and aluminum. The STT
process supports mild steel and stainless steel weld-
ing.
The Power Wave 455/R is recommended only for
automatic or mechanized applications such as robotic
welding.
OPERATION
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. All wire
welding processes require a robotic Power Feed wire
feeder.

REQUIRED EQUIPMENT

• PF-10/R Wire Feeder, K1780-1
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100
• Control Cables (for use on FANUC robot arm, 22 pin to 14
pin, 10 ft), K1804-1
• Control Cables (for use on FANUC robot arm, 22 pin to 14
pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin to 14
pin, 18 in), K1804-2

LIMITATIONS

• The Power Wave 455/R is not suitable for SMAW,
CAC-A or other processes not listed.
• Power Waves are not to be used in outdoor environ-
ments.
• Only Arc-Link Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIOD

The Power Feed wire feeders are capable of welding
at a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that the duty cycle is based
upon a ten minute period. A 60% duty cycle repre-
sents 6 minutes of welding and 4 minutes of idling in a
ten minute period.
POWER WAVE 455/R
B-3