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

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Operator's Manual
Power Wave
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10301
| Issue D ate July-15
© Lincoln Global, Inc. All Rights Reserved.
455M/STT
®
For use with machines having Code Numbers:
125 7
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?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual Power Wave 455M/STT ® For use with machines having Code Numbers: 125 7 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 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 ..................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 Voltage Sensing ....................
  • Page 7 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-7 ________________________________________________________________________ Wiring Diagram ....................Section F-1 Connection Diagrams................Section F-2, F-3 Dimension Print....................Section F-4 ________________________________________________________________________ Parts List ......................parts.lincolnelectric.com...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (K2203-3) ® ® INPUT AT RATED OUTPUT - THREE PHASE ONLY DUTY INPUT VOLTS INPUT IDLE POWER FACTOR EFFICIENCY CYCLE CURRENT @ RATED OUTPUT POWER @ RATED OUTPUT AMPS 60% Rating 48/44 400 Watts .95 MIN.

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING Read this entire installation section before you Lift the machine by the lift bail only. The lift bail is start installation. designed to lift the power source only. Do not attempt WARNING 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 Only a qualified electrician should of this Installation section for recommended fuse and connect the input leads to the Power wire sizes. Fuse the input circuit with the Wave .

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

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

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

    INSTALLATION Enable the voltage sense leads as follows: Electrode Voltage Sensing 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 GMAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder...

  • 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 INSTALLATION ALTERNA TERNATE HARD TE HARD AUT AUTOMA OMATION TION APPLICA APPLICATION TION (using a UI, WD Module, and PF-10R) (using a UI, WD Module, and PF-10R) POWER W POWER WA A VE ® PF-10R PF-10R 455M/STT 455M/STT ® WIRE WIRE DRIVE DRIVE...

  • Page 15: Welding With Multiple Power Waves

    INSTALLATION WELDING WITH MULTIPLE CONTROL CABLE SPECIFICATIONS POWER WAVES ® It is recommended that genuine Lincoln control cables CAUTION be used at all times. Lincoln cables are specifically 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 Source Current flow from Arc #1 fl affects sense lead #2 Work #1 Sense #1 Arc #1 Current flow from Arc #2 fl Power affects sense lead #1 Work #2 Source Sense # 2...

  • 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 work sense lead not connected 0vdc *on (default) 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. It The Power Wave semi-automatic power source is will 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

    If a special welding arc length. It is adjustable from 0.500 to 1.500. A program is desired, contact the local Lincoln Electric Trim setting of 1.000 is a good starting point for most 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: Stt Welding

    OPERATION WELDING For most programs, peak current is adjusted by arc ® control, also referred to as wave control. A wave control value of +10.0 maximizes the peak current, The pictures illustrate the wave shape of current for while a wave control of -10.0 minimizes peak current. the process.

  • Page 27: 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 Power Wave Water Cooler, K1767-1 * ® Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-1 Ethernet Interface Module, K2207-1 *The Dual Cylinder Undercarriage, K1570-1 is not...

  • Page 28: 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 resistive load bank, and certified actual meters for voltage and current.

  • Page 29: Troubleshooting

    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 30: Using The Status Led To Troubleshoot System Problems

    TROUBLESHOOTING USING THE STATUS LED TO Included in this section is information about the power source Status LED, and some basic troubleshooting TROUBLESHOOT SYSTEM charts for both machine and weld performance. PROBLEMS The STATUS LIGHT is a two color light that indicates system errors.
  • Page 31 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/STT can output via the status light ® ® (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED."...
  • Page 32 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/STT ®...
  • Page 33 Status LED" section of this text. 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/STT ®...
  • Page 34 Reset. 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/STT ®...
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION General degradation of the weld 1.Check for feeding problems, bad performance connections, excessive loops in cabling, etc. 2. Verify weld mode is correct for processes.
  • Page 36 DIAGRAMS REAR OF MACHINE POWER WAVE 455M/STT ® ®...
  • Page 37 CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455M/STT ® ®...
  • Page 38 CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, STT Configuration shown) ® POWER WAVE / STT STT STUD WIRE FEEDER WORK WORK SENSE CONTROL CABLE K1543 POWER WAVE 455/STT ®...

  • Page 39: Dimension Print

    DIMENSION PRINT POWER WAVE 455M/STT ® ®...
  • Page 40 Index of Sub Assemblies - 12507 PART NUMBER DESCRIPTION P-450-A Index of Sub Assemblies P-450-B.2 Miscellaneous items P-450-C Case Front Assembly P-450-D Control Box & Horizontal Divider Plate P-450-E Base Lift Bale & Fan Assembly P-450-F Input Assembly P-450-G Transformer & Output Rectifier Assembly P-450-H Switch Board Heatsink Assembly P-450-J...
  • Page 41 Index of Sub Assemblies - 12507 P-450-A.jpg Power Wave 455M - 12507...
  • Page 42 Miscellaneous items PART NUMBER DESCRIPTION 9SG4215-5 MAIN HARNESS ASBLY 9SS12021-73 BOX RECEPTACLE SOLID SHELL 9SS18657 SQUARE FLANGE FEMALE RECEPTACLE 9ST11577-58 CAPACITOR-CERAMIC DISC 9SS23740-3 LED PANEL MOUNT ASBLY 9ST13657-7H24 LED-T-1 3/4BI-COLORRED/GREEN 9ST13657-4FA YELLOW LED 9ST12380-4 BUSHING Power Wave 455M - 12507...
  • Page 43 Case Front Assembly PART NUMBER DESCRIPTION 9SL11890-1 Case Front Welded Assembly 9SL11889 CONTROL PANEL 9SS9225-61 THREAD FORMING SCREW (ROLLING) 9SS21094-1 INSULATOR 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SS16656-4 OUTPUT TERMINAL ASBLY 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9ST3960 FLANGE NUT 9SS19654-1 CONTINENTAL EUROPEAN 220V RECEPTALE 9ST11525-1...
  • Page 44 Case Front Assembly PART NUMBER DESCRIPTION 9SS9262-1 PLAIN WASHER 9SS18504-6 CURRENT TRANSDUCER 9SS9225-36 THREAD FORMING SCREW (CUTTING) 9SS24042 STANDOFF 9SS22753-1 Switch Decal 9SS29541 MAIN POWER SWITCH 9SL11907 FRONT DECAL 9SL11907 FRONT DECAL 9ST13086-137 DECAL-DOOR 9SL11907 FRONT DECAL 9ST13086-153 DECAL (STT/POWERWAVE) 9SS18250-667 PLUG &...
  • Page 45 Case Front Assembly P-450-C.jpg Power Wave 455M - 12507...
  • Page 46 Control Box & Horizontal Divider Plate PART NUMBER DESCRIPTION 9SL10039 CONTROL BOX FRONT 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SS18543-4 INPUT CABLE GROMMET 9SL10040-2 CONTROL BOX REAR 9SS25615-16 CONTROL BOARD ASBLY 9SCF000122 #10-24X1.50RHS 9ST9695-1 LOCKWASHER 9SS25139-1 SERRATED FLANGE NUT 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SG5632-2 DIGITAL POWER PC BD ASBLY 9SCF000122...
  • Page 47 Control Box & Horizontal Divider Plate PART NUMBER DESCRIPTION 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 9SCF000096 #8-32X.75RHS 9SS9262-3 PLAIN WASHER 9ST4291-A LOCKWASHER 9SCF000042 #8-32HN 9SL11745-1 40V DC BUS HEATSINK ASBLY 9SS14020-10 PLASTIC EXPANSION NUT 9SS8025-98 SELF TAPPING SCREW 9SS19222-26 TWISTED LEAD ASSEMBLY 9SS10404-132 RESISTORWW25W105% 9SCF000009 #10-24X3.00RHS 9ST9695-1...
  • Page 48 Control Box & Horizontal Divider Plate P-450-D.jpg Power Wave 455M - 12507...
  • Page 49 Base, Lift Bale & Fan Assembly PART NUMBER DESCRIPTION 9SG2970 LOWER BASE 9ST12380-4 BUSHING 9SS22431 STRAIN RELIEF 9SS9225-90 THREAD FORMING SCREW As Req 9SL9964 UPPER BASE 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SS9225-53 THREAD FORMING SCREW 9SL10027 LIFT BALE WELDED ASBLY 9SS9225-53 THREAD FORMING SCREW 9SM18030...
  • Page 50 Base, Lift Bale & Fan Assembly PART NUMBER DESCRIPTION 9ST13086-141 DECAL-FEEDER 9SM18798 RESISTOR ASBLY 9SS21367-1 RESISTOR MTG BRKT 9ST11267-A INSULATOR 9SS19742 CENTERING WASHER 9SS10404-112 RESISTOR-WW300W2.010% 9ST11827-47 CARRIAGE BOLT 9SS9262-27 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9SS8025-92 SELF TAPPING SCREW Power Wave 455M - 12507...
  • Page 51 Base, Lift Bale & Fan Assembly P-450-E.jpg Power Wave 455M - 12507...
  • Page 52 Input Assembly PART NUMBER DESCRIPTION 9SG3366-6 INPUT ASBLY 9SS22437 FAN SHROUD WELDED ASBLY 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SS11604-48 SET SCREW 9SL9967 RECONNECT SHELL 9SS8025-92 SELF TAPPING SCREW 9SM12161-94 CONTACTOR 9SS8025-92 SELF TAPPING SCREW 9SM15454-13 DIODE-BRIDGE160A1600VF-W3 PH 9SS25930-1 142TORX BUTTON HEAD SCREW 1/4-20X.88 9ST12735-4 SPRING WASHER 9SM18134...
  • Page 53 Input Assembly P-450-F.jpg Power Wave 455M - 12507...
  • Page 54 Transformer & Output Rectifier Assembly PART NUMBER DESCRIPTION 9SG3844-2 TRANSFORMER & OUTPUT RECTIFIER ASBLY 9SG2971-1 MAIN TRANSFORMER ASBLY 9SL9980-1 OUTPUT RECTIFIER HEATSINK 9SCF000014 1/4-20X.75HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SM15454-11 DIODE-MODULE240A400VSRDUALCK 9SCF000013 1/4-20X.625HHCS 9SS9262-98 PLAIN WASHER 9ST12735-4 SPRING WASHER 9ST9447-91 SOCKET HEAD CAP SCREW #8-32X.50 SS 9SCF000060...
  • Page 55 Transformer & Output Rectifier Assembly PART NUMBER DESCRIPTION 9ST13359-23 THERMOSTAT 9SCF000105 3/8-16X1.25HHCS 9SCF000067 3/8-16HN 9SS24444 SNUBBER ASBLY 9SS19457-3 MOV ASBLY 9ST11545-5 NYLON SCREW 9ST7028-52 INSULATING TUBE 9ST9695-1 LOCKWASHER Power Wave 455M - 12507...
  • Page 56 Transformer & Output Rectifier Assembly P-450-G.jpg Power Wave 455M - 12507...
  • Page 57 Switch Board Heatsink Assembly PART NUMBER DESCRIPTION 9SG3010-3 SWITCH BOARD HEATSINK ASBLY 9SM18037 HEAT SINK MACHINING IGBT 9SM16737 CAPACITOR BRKT 9SG3734-3 SWITCH PC BD ASBLY 9ST9447-8 SOCKET HEAD CAP SCREW 9SE106A-2 LOCKWASHER 9SS22168 HEAT SINK HOLDER 9SCF000015 1/4-20X1.00HHCS 9SE106A-2 LOCKWASHER 9SS9262-98 PLAIN WASHER 9SS13490-185...
  • Page 58 Switch Board Heatsink Assembly PART NUMBER DESCRIPTION 9SCF000017 1/4-20HN Power Wave 455M - 12507...
  • Page 59 Switch Board Heatsink Assembly P-450-H.jpg Power Wave 455M - 12507...
  • Page 60 Covers Assembly PART NUMBER DESCRIPTION 9SS22433 ROOF WELDED ASBLY 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SS12934 COVER SEAL 9ST13470-3 DECAL-WARNING 9SS22426 CASE BACK WELDED ASBLY 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SM18240 ACCESS DOOR 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SL13523 LEFT CASE SIDE ASBLY 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SS27368-3...
  • Page 61 Covers Assembly P-450-J.jpg Power Wave 455M - 12507...
  • 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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