Lincoln Electric Power Wave 455M Operator's Manual
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Lincoln Electric Power Wave 455M Operator's Manual

Lincoln Electric Power Wave 455M Operator's Manual

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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10302
| Issue D ate July-15
© Lincoln Global, Inc. All Rights Reserved.
455M
®
For use with machines having Code Numbers:
125 6
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
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no later than the following business day.
For Service outside the USA:
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  • Page 1 Operator’s Manual Power Wave 455M ® For use with machines having Code Numbers: 125 6 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page 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-3 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...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page 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 List ......................parts.lincolnelectric.com...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-7) ® INPUT AT RATED OUTPUT - THREE PHASE ONLY DUTY INPUT VOLTS- INPUT IDLE POWER FACTOR EFFICIENCY CYCLE CURRENT FREQUENCY @RATED OUTPUT POWER @ RATED OUTPUT AMPS 60% RATING 48/44 400 Watts .95 MIN.

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS Read LIFTING this entire installation section before you start Lift the machine by the lift bail only. The lift bail is installation. designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it.

  • Page 10: Input Connection

    INSTALLATION INPUT CONNECTION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS WARNING Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and Only a qualified electrician should wire sizes. Fuse the input circuit with the connect the input leads to the Power recommended super lag fuse or delay type breakers Wave .

  • Page 11: Cable Inductance, And Its Effects On Pulse Welding

    INSTALLATION CABLE INDUCTANCE, AND ITS EFFECTS For additional Safety information regarding the ON PULSE WELDING electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the For Pulse Welding processes, cable inductance will Instruction Manuals. cause the welding performance to degrade.

  • Page 12: Power Wave To Semi-Automatic Power Feed Wire Feeder Interconnections

    INSTALLATION Electrode Voltage Sensing Enable the voltage sense leads as follows: TABLE A.2 Enabling or disabling electrode voltage sensing is Process Electrode Voltage Work Voltage automatically configured through software. The 67 Sensing 67 lead * Sensing 21 lead electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder GMAW 67 lead required 21 lead optional...

  • Page 13: Configuring The System

    INSTALLATION 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 The power source will “Auto Map” the system “Auto-mappable”, then consult the instruction manual eliminating most of the need to set DIP switches to for the accessory being used for configuration...

  • Page 14: Alternate Hard Automatic Application

    INSTALLATION ALTERNATE HARD AUTOMATIC APPLICATION (using a UI, WD Module, and PF-10R) POWER WAVE 455M PF-10R ® WIRE DRIVE MODULE (FH1) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto, WD Module, and PF-10R) POWER WAVE 455M PF-10R ® WIRE DRIVE MODULE DUAL HEAD (FH1) System that is NOT "Auto Mappable"...

  • Page 15: Welding With Multiple Power Waves

    INSTALLATION WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS WAVES It is recommended that genuine Lincoln control cables ® be used at all times. Lincoln cables are specifically CAUTION designed for the communication and power needs of the Power Wave / Power Feed system.

  • Page 16: Multiple Arc Unsynchronized

    INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 455M ®...

  • Page 17: I / O Receptacle Specifications

    INSTALLATION A-10 A-10 I / O RECEPTACLE SPECIFICATIONS switch 7 auto mapping off(default) auto mapping enable TABLE A.3 WIRE FEEDER RECEPTACLE S1 auto mapping disabled LEAD# FUNCTION Communication Bus L Communication Bus H switch 8 work sense lead Electrode Voltage Sense *off(default) work sense lead not connected 0vdc work sense lead connected...

  • Page 18: Operation

    OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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. •...

  • Page 19: Graphic Symbols That Appear On This Machine Or In This Manual

    OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SMAW INPUT POWER GMAW FCAW HIGH TEMPERATURE GTAW OPEN CIRCUIT MACHINE STATUS VOLTAGE CIRCUIT BREAKER INPUT VOLTAGE WIRE FEEDER OUTPUT VOLTAGE POSITIVE OUTPUT INPUT CURRENT NEGATIVE OUTPUT OUTPUT CURRENT PROTECTIVE 3 PHASE INVERTER GROUND...

  • Page 20: Definition Of Welding Terms

    OPERATION DEFINITION OF WELDING TERMS SMAW • Shielded Metal Arc welding NON-SYNERGIC WELDING MODES • Stud Arc Welding • A Non-synergic welding mode requires all welding process variables to be set by the operator. • Submerged Arc Welding SYNERGIC WELDING MODES SAW-S •...

  • Page 21: General Description

    OPERATION GENERAL DESCRIPTION DeviceNet Interface Module This module can be used for DeviceNet capability. The Power Wave semi-automatic power source is ® It has a 5 pin sealed mini connector per ANSI designed to be a part of a modular, multi-process B93.55M-1981.

  • Page 22: Case Front Controls

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

  • Page 23: Nominal Procedures

    It is adjustable from 0.500 to 1.500. A Trim and will meet most needs. If a special welding setting of 1.000 is a good starting point for most program is desired, contact the local Lincoln Electric conditions. sales representative.

  • Page 24: Constant Voltage Welding

    OPERATION • WELDING MODE Non Synergic CV: May be selected by name (CV/MIG, CC/Stick Crisp, This type of CV mode behaves more like a Gouge, etc.) or by a mode number (10, 24, 71, etc.) conventional CV power source. Voltage and WFS are depending on the Control Box options.

  • Page 25: Pulse Welding

    OPERATION PULSE WELDING The Power Wave utilizes "adaptive control" to ® compensate for changes in electrical stick-out while welding. (Electrical stick-out is the distance from the Pulse welding procedures are set by controlling an contact tip to the work piece.) The Power Wave overall "arc length"...

  • Page 26: Accessories

    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 K1813-1 (115VAC) Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-1 COMPATIBLE LINCOLN EQUIPMENT Any Arc-Link compatible semi-automatic wire feeding...

  • Page 27: Maintenance

    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 grid, and certified actual meters for voltage and current.

  • Page 28: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 29: Using The Status Led To Troubleshoot System Problems

    TROUBLESHOOTING USING THE STATUS LED TO Included in this section is information about the power TROUBLESHOOT SYSTEM PROBLEMS source Status LED, and some basic troubleshooting charts for both machine and weld performance. The Power Wave / Power Feed are best diagnosed The STATUS LIGHT is a two color light that indicates ®...
  • Page 30 TROUBLESHOOTING 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 can output via the status light (see ® "Troubleshooting the Power Wave / Power Feed System Using the Status LED."...

  • Page 31: Troubleshooting

    40VDC supply. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE 455M ®...
  • Page 32 570 Amps to 325 Amps. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE 455M ®...
  • Page 33 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE 455M ®...
  • Page 34 DIAGRAMS REAR OF MACHINE POWER WAVE 455M ®...

  • Page 35: Connection Diagram

    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 ®...
  • Page 36 DIAGRAMS POWER WAVE 455M ®...
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  • Page 39 Case Front Assembly P-702-D Control Box & Horizontal Divider Plate P-702-E Base Lift Bale & Fan Assembly P-702-F Input Assembly P-702-G Transformer & Output Rectifier Assembly P-702-H Switch Board Heatsink Assembly P-702-J Cover Assembly Power Wave 455M (CE) - 12506...
  • Page 40 Index of Sub Assemblies - 12506 P-702-A.jpg Power Wave 455M (CE) - 12506...
  • Page 41 Miscellaneous Items PART NUMBER DESCRIPTION 9SG4215 MAIN HARNESS ASBLY 9SS19316-3 CORETOROIDAL 9SS23740-3 LED PANEL MOUNT ASBLY 9SS12021-73 BOX RECEPTACLE SOLID SHELL Power Wave 455M (CE) - 12506...
  • Page 42 Miscellaneous Items No Image Power Wave 455M (CE) - 12506...
  • Page 43 COVER PLATE 9SS9225-61 THREAD FORMING SCREW (ROLLING) 9SS25610 ADAPTER PLATE 9SS8025-96 SELF TAPPING SCREW 9ST10397-20 PLUG BUTTON 9ST10397-23 PLUG BUTTON 9SS24017-6 CONNECTORMOLEXMINILDS6-PIN 9SS24019-6 CONNECTORLOCKING POSTFOR 6-CAVITY 9SS18858-2 SUPPRESSOR ASBLY As Req 9SS9262-27 PLAIN WASHER Power Wave 455M (CE) - 12506...
  • Page 44 THREAD FORMING SCREW (ROLLING) 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9ST9695-1 LOCKWASHER 9ST12287-30 CIRCUIT BREAKER-5.0A 9ST12287-20 CIRCUIT BREAKER-10A250VAC 9SS9225-61 THREAD FORMING SCREW (ROLLING) 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS25506 ADAPTER COVER 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT Power Wave 455M (CE) - 12506...
  • Page 45 Case Front Assembly PART NUMBER DESCRIPTION 9SS8025-96 SELF TAPPING SCREW 9SS9262-27 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9SS24194-2 TOROID ASBLY 9SS24194-1 TOROID ASBLY Power Wave 455M (CE) - 12506...
  • Page 46 Case Front Assembly P-702-C.jpg Power Wave 455M (CE) - 12506...
  • Page 47 9SS18250-850 PLUG & LEAD ASBLY 9SS11604-65 SET SCREW 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SCF000198 1/4-28HN 9SL9969 VERTICAL DIVIDER PANEL 9ST12380-2 BUSHING 9SS18543-4 INPUT CABLE GROMMET 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SM18139 CONTROL BOX COVER Power Wave 455M (CE) - 12506...
  • Page 48 PC BD PANEL 9SM18784-3 POWER LINE FILTER ASBLY 9SS8025-91 SELF TAPPING SCREW 9SS15317-5 RELAY 9SCF000033 #8-32X.50RHS 9SS9262-3 PLAIN WASHER 9ST4291-A LOCKWASHER 9ST15120 MOV ASBLY 9ST13086-124 DECAL-STATIC SENSITIVE WARNING 9SS25251 INSULATION 9ST10097-3 TINNERMAN SPEED GRIP NUT RETAINER Power Wave 455M (CE) - 12506...
  • Page 49 Control Box & Horizontal Divider Plate P-702-D.jpg Power Wave 455M (CE) - 12506...
  • Page 50 PLUG & LEAD ASBLY 9SS8025-96 SELF TAPPING SCREW 9ST13086-140 DECAL-115 VOLT 9ST13086-139 DECAL-115VOLT 15A 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9SCF000010 #10-24HN 9ST9695-1 LOCKWASHER 9ST13086-141 DECAL-FEEDER 9ST11019-3 RUBBER CHANNEL 9ST10397-4 PLUG BUTTON 9ST13086-95 DECAL 220V-2A Power Wave 455M (CE) - 12506...
  • Page 51 Base, Lift Bale & Fan Assembly P-702-E.jpg Power Wave 455M (CE) - 12506...
  • Page 52 SELF TAPPING SCREW 9SM20288-2 Line Switch & Lead Assembly 9SS18543-4 INPUT CABLE GROMMET 9ST12380-4 BUSHING 9ST12380-10 BUSHING 9SS20763-3 TERMINAL BLOCK 9SCF000193 #8-32X1.25RHS 9ST13260-4 DECAL-EARTH GROUND CONN 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SM18790 SWITCH LEAD FILTER ASBLY Power Wave 455M (CE) - 12506...
  • Page 53 Input Assembly P-702-F.jpg Power Wave 455M (CE) - 12506...
  • Page 54 9SCF000067 3/8-16HN 9SL10052-1 CHOKE ASBLY 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SCF000105 3/8-16X1.25HHCS 9SCF000067 3/8-16HN 9SS24444 SNUBBER ASBLY 9SS19457-3 MOV ASBLY 9ST11545-1 NYLON SCREW 9ST7028-52 INSULATING TUBE 9ST9695-1 LOCKWASHER 9SS8053-36 TERMINAL 9SS19222-25 TWISTED LEAD ASBLY Power Wave 455M (CE) - 12506...
  • Page 55 Transformer & Output Rectifier Assembly PART NUMBER DESCRIPTION 9SS19222-18 TWISTED LEAD ASBLY 9SS19222-26 TWISTED LEAD ASSEMBLY Power Wave 455M (CE) - 12506...
  • Page 56 Transformer & Output Rectifier Assembly P-702-G.jpg Power Wave 455M (CE) - 12506...
  • Page 57 INSULATING TUBE 9SCF000013 1/4-20X.625HHCS 9SE106A-2 LOCKWASHER 9SS9262-98 PLAIN WASHER 9SS16139-5 GEAR BOX INSULATION 9SS18469 DECAL-WARNING 9SS25118 INSULATOR 9ST10097-4 NUT RETAINER 9SS22168 HEAT SINK HOLDER 9SS9225-45 THREAD FORMING SCREW 9SS9262-27 PLAIN WASHER 9SCF000015 1/4-20X1.00HHCS 9ST9860-6 LOCKWASHER Power Wave 455M (CE) - 12506...
  • Page 58 Switch Board Heatsink Assembly PART NUMBER DESCRIPTION 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN Power Wave 455M (CE) - 12506...
  • Page 59 Switch Board Heatsink Assembly P-702-H.jpg Power Wave 455M (CE) - 12506...
  • Page 60 THREAD FORMING SCREW (ROLLING) 9SL9982 CASE SIDE (RIGHT) 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SS22127-2 DECAL-WARRANTY 9SL8064-1 WARNING DECAL (INTERNATIONAL) 9SG4420 Wiring Diagram 9ST13259-4 GROUNDING DECAL 9SS24190 Reconnect Diagram 9SS22752-35 Rating Plate 9SG4253 SIDE DECAL Power Wave 455M (CE) - 12506...
  • Page 61 Cover Assembly P-702-J.jpg Power Wave 455M (CE) - 12506...
  • Page 62 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAUCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa...
  • Page 63 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAUCION Los humos fuera de la zona de Desconectar el cable de No operar con panel abierto o respiración.
  • Page 64 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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