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IM641
May, 1999
™
POWER WAVE 455 STT
For use with machines having Code Numbers: 10552, 10554
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 caref
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455..........................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Stacking
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS INPUT OUTPUT CONDITIONS INPUT EXCEPT STT PROCESS EXCEPT STT PROCESS CURRENT CURRENT 450A@38V. 100% 70 570A@43V. 60% 87 208V - 60HZ. 230V - 60HZ. 450A@38V. 100% 65 570A@43V. 60% 82 460V - 60HZ. 450A@38V. 100% 35 570A@43V. 60% 48 450A@38V. 100% 29 570A@43V. 60% 38 575V - 60HZ. 200V - 50HZ. 400A@36V. 100% 72 500A@40V. 60% 79 400A@36V. 100% 67 500A@40V. 60% 74
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A-2 A-2 INSTALLATION Read this entire installation section before you any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety start installation. hazard. The best practice is to keep the machine in a SAFETY PRECAUTIONS dry, sheltered area. WARNING LIFTING ELECTRIC SHOCK can kill. Lift the machine by the lift bail only. The lift bail is � Only qualified personnel should designed to lift the power source only. Do not attempt perform this instal
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A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
6
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A-4 A-4 INSTALLATION VOLTAGE SENSING AT THE POWER WAVE / POWER FEED WIRE WORKPIECE FEEDER INTERCONNECTIONS A four-pin work piece voltage sense lead connector is ELECTRODE & WORK LEADS — located beneath the output stud cover. The use of a ELECTRODE POSITIVE APPLICATIONS work piece sense lead is optional for most welding modes, but it is strongly recommended for use with Most welding applications run with the electrode being the STT welding mode. positive (+). For those applications, connect t
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A-5 A-5 INSTALLATION 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 Feed Instruction Manual. Once separated, mounting instructions are a
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. � Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. � Insulate yourself from the work and ground. � Always wear dry insulating gloves. FUMES AND GASES can be dangerous. � Keep your head out of fumes. � Use ventilation or exhaust to remove fumes from breathing zone. WELDING
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B-2 B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SMAW INPUT POWER ON GMAW OFF FCAW HIGH TEMPERATURE GTAW OPEN CIRCUIT MACHINE STATUS U 0 VOLTAGE CIRCUIT BREAKER U INPUT VOLTAGE 1 WIRE FEEDER U OUTPUT VOLTAGE 2 POSITIVE OUTPUT I INPUT CURRENT 1 NEGATIVE OUTPUT I OUTPUT CURRENT 2 PROTECTIVE 3 PHASE INVERTER GROUND INPUT POWER THREE PHASE WARNING DIRECT CURRENT POWER WAVE 455 STT
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B-3 B-3 OPERATION Parameter Examples GENERAL DESCRIPTION Welding Stick Crisp, Stick Soft, Flux Cored with Gas, The POWER WAVE 455 STT is a high performance, Mode Flux Cored without Gas, CV, Synergic CV, digitally controlled inverter welding power source .035 Stainless Pulse, .045 Steel Pulse, 5356 capable of complex, high-speed waveform control. Aluminum Pulse, STT (Synergic) Properly equipped, it can support the GMAW, GMAW- P, FCAW, SMAW, GTAW, CAC-A and STT process- Output Current (CC modes),
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B-4 B-4 OPERATION CASE FRONT CONTROLS WELDING CAPABILITY All operator controls and adjustments are located on The POWER WAVE 455 STT is rated at 60 Hz. the case front of the Power Wave. 450A@ 38V. 100% duty cycle or 570A@ 43V 60% duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or 1. POWER SWITCH: Controls input power to the 500A@40V 60% duty cycle. The machine is capable Power Wave. of higher outputs at lower duty cycles. For the STT process only, the machine is rated at 325 amps, 100% 2. ST
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B-5 B-5 OPERATION 4. ARC CONTROL: WELDING ADJUSTMENTS Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from “soft” All adjustments are made on the system component to “harsh” in all weld modes. It is adjustable from - known as the control box, which contains the switch- 10.0 to +10.0, with a nominal setting of 00.0. (The es, knobs and digital displays necessary to control nominal setting of 00.0 may be displayed as OFF both the Power Wave and a Power
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B-6 B-6 OPERATION Instead, an arc length adjustment is provided. The The Arc Control adjusts the arc force. Increasing the machine “knows” what the best arc length is at the Arc Control setting increases the arc force, making given wire feed speed but allows the operator to the arc more harsh but less likely to stick. Decreasing change it. the Arc Control setting decreases the arc force, mak- ing the arc softer and smoother. The arc length trim (usually referred to simply as “trim”) can be ad
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C-1 C-1 ACCESSORIES OPTIONS / ACCESSORIES FACTORY INCLUDED ACCESSORIES K940-10 & -25 Voltage Sense Lead Kits- used for voltage sensing at the workpiece. See the INSTALLA- TION section for more details on proper use. FIELD INSTALLED The following options/accessories are available for your Power Wave from your local Lincoln Distributor. K1570-1 Dual Cylinder Undercarriage K940-50 Voltage Sense Lead Kit- 50 foot voltage sense lead kit, if additional length is required. POWER WAVE 455 STT
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. � Only Qualified personnel should perform this maintenance. � Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. � 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 m
