Lincoln Electric POWER WAVE 455TM IM583-A Operator's Manual
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Lincoln Electric POWER WAVE 455TM IM583-A Operator's Manual

Lincoln Electric POWER WAVE 455TM IM583-A Operator's Manual

Lincoln electric home safety product user manual
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POWER WAVE 455
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
RETURN TO MAIN MENU
10372, 10553, 10555
THIS
R
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
IM583-A
December, 1999

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Summary of Contents for Lincoln Electric POWER WAVE 455TM IM583-A

  • Page 1 POWER WAVE 455 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.

  • Page 2: Electric And Magnetic Fields

    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: Fumes And Gases

    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.
  • 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 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Installation ...Section A Technical Specifications - Power Wave 455...A-1 Safety Precautions...A-2 Select Suitable Location ...A-2 Stacking ...A-2 Environmental Protection ...A-2 Lifting...A-2 Machine Grounding ...A-2 High Frequency Protection ...A-2 Input Connection...A-2 Input Fuse and Supply Wire Considerations ...A-3 Input Voltage Reconnect Procedure...A-3 Output Connections ...A-3 Voltage Sensing at the Work Piece ...A-4...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - POWER WAVE 455 INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS 208V - 60HZ. 450A@38V. 100% 230V - 60HZ. 450A@38V. 100% 400V - 60HZ. 450A@38V. 100% 460V - 60HZ. 450A@38V. 100% 575V - 60HZ. 450A@38V.

  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. •...

  • Page 10: Input Fuse And Supply Wire Considerations

    FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM W / L3 V / L2 Disconnect input power before inspecting or servicing machine. U / L1 Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use or service this equipment.

  • Page 11: Voltage Sensing At The Workpiece

    VOLTAGE SENSING AT THE WORKPIECE 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. Sense Lead Kits (K490-10, -25 or -50) are available for this purpose.

  • Page 12: Power Feed Control Box Mounting

    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 nec- essary to control the Power Wave / Power Feed weld- ing system.) Complete details for separating the con- trol box from the wire drive are contained in the Power...

  • Page 13: Operating Instructions

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.

  • Page 14: Graphic Symbols That Appear On This Machine Or In This Manual

    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 SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE...

  • Page 15: Operation

    GENERAL DESCRIPTION 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. RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave can be set up in a number of config- urations, some requiring optional equipment.

  • Page 16: Welding Capability

    WELDING CAPABILITY 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 out- puts at lower duty cycles.

  • Page 17: Welding Adjustments

    WELDING ADJUSTMENTS All adjustments are made on the system component known as the control box, which contains the switch- es, 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.
  • Page 18 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.

  • Page 19: Options & Accessories

    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.

  • Page 20: Maintenance

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • 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.

  • Page 21: Troubleshooting

    Power source cannot communicate with the wire feeder and/or its components due to a problem within the power source. Contact an authorized Lincoln Electric Service facility. If the Thermal LED is also lit, see “Yellow Thermal LED Lit” in the Main Troubleshooting Chart.

  • Page 22: How To Use Troubleshooting Guide

    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. TROUBLESHOOTING WARNING Step 3.

  • Page 23: Troubleshooting Guide

    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 detailed in the beginning of this manual.
  • Page 24 (CR1 will not pull in.) 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 detailed in the beginning of this manual.
  • Page 25 . 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 detailed in the beginning of this manual.
  • Page 26 DIAGRAMS REAR OF MACHINE MACHINE FRONT POWER WAVE 455...
  • Page 27 DIAGRAMS REAR OF MACHINE MACHINE FRONT POWER WAVE 455...
  • Page 28 DIAGRAMS POWER WAVE 455...
  • Page 29 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 30 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
  • Page 31 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
  • Page 32 • 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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