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IM583-A
December, 1999
™
POWER WAVE 455
For use with machines having Code Numbers: 10372, 10553, 10555
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
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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 INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT OUTPUT INPUT CONDITIONS CURRENT CONDITIONS CURRENT 208V - 60HZ. 450A@38V. 100% 70 570A@43V. 60% 87 230V - 60HZ. 450A@38V. 100% 65 570A@43V. 60% 82 400V - 60HZ. 450A@38V. 100% 39 570A@43V. 60% 50 460V - 60HZ. 450A@38V. 100% 35 570A@43V. 60% 48 575V - 60HZ. 450A@38V. 100% 29 570A@43V. 60% 38 200V - 50HZ. 400A@36V. 100% 72 500A@40V. 60% 79 220V - 50HZ. 400A@36V. 100% 6
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A-2 A-2 INSTALLATION Read this entire installation section before you ENVIRONMENTAL PROTECTION start installation. The Power Wave power source is rated IP21S and should not be subjected to falling water, nor should SAFETY PRECAUTIONS any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety WARNING hazard. The best practice is to keep the machine in a ELECTRIC SHOCK can kill. dry, sheltered area. � Only qualified personnel should perform this ins
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A-3 A-3 INSTALLATION FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM W / L3 INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE=200-208V V / L2 CR1 W / L3 . Disconnect input power before inspecting or servicing machine. U / L1 200-208V V / L2 CR1 . . Do not operate with covers Disconnect input power before 220-230V removed. inspecting or servicing machine. U / L1 . ’A’ . Do not touch electrically live parts. Do not operate with covers 380-415V removed. Onl
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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 may be used if desired. Most welding applications run with the electrode being positive (+). For those applications, connect the elec- Sense Lead Kits (K490-10, -25
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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 S
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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
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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 is a high performance, digitally Mode Flux Cored without Gas, CV, Synergic CV, controlled inverter welding power source capable of .035 Stainless Pulse, .045 Steel Pulse, 5356 complex, high-speed waveform control. Properly Aluminum Pulse equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW and CAC-A processes. Output Current (CC modes), Voltage (CV modes), Wir
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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 is rated at 60 Hz. 450A@ the case front of the Power Wave. 38V. 100% duty cycle or 570A@ 43V 60% duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V 1. POWER SWITCH: Controls input power to the 60% duty cycle. The machine is capable of higher out- Power Wave. puts at lower duty cycles. 2. STATUS LIGHT: A two color light that indicates If the duty cycle is e
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B-5 B-5 OPERATION 10.0 to +10.0, with a nominal setting of 00.0. (The WELDING ADJUSTMENTS nominal setting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels.) All adjustments are made on the system component See the Welding Mode descriptions, below, for known as the control box, which contains the switch- detailed explanations of how the Arc Control affects es, knobs and digital displays necessary to control each mode. both the Power Wave and a Power Feed wire feeder.
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B-6 B-6 OPERATION The arc length trim (usually referred to simply as ARC GOUGING PROCEDURES “trim”) can be adjusted between 0.500 and 1.500 on the control box’s Volts/Trim display. A Trim of 1.000 Arc gouging can be performed by choosing the arc means that no adjustments will be made to the preset gouging weld mode. Doing so automatically ener- arc lengths. A Trim greater than 1.000 increases the gizes the output terminals on the Power Wave, mak- preset arc lengths. A Trim setting less than
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C-1 C-1 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. K940-25 Voltage Sense Lead Kit- 25 foot voltage sense lead kit, if additional length is required. K940-50 Voltage Sense Lead Kit- 50 foot vol
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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 mac
