Lincoln Electric 455 M manual

PO WER W A VE 455 M ™ OPERA TOR’S MANUAL IM807-A June, 2004 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 [...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv 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. Les circuits ?[...]

v SAFETY v[...]

vi SAFETY vi[...]

vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference.[...]

ix ix T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455M .................................................A-1 Safety Precautions................................................................................[...]

x x T ABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems .....................................E-2 [...]

A-1 INST ALLA TION POWER WAVE 455M (CE) A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 455M (CE) (K2202-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS PROCESS CURRENT RANGE (DC) CURRENT TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 380V - 60HZ. 380V - 50HZ. 415V - 60HZ. 415V - 50HZ. OPEN CIRCUIT VOLT[...]

LIFTING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it. ST ACKING Power Wave machines can be stacked to a maximum of 3 high. The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines [...]

A-3 INST ALLA TION A-3 INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power Wave 455M (CE). Connections should be made in accordance with all local and national electrical codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bo[...]

A-4 INST ALLA TION POWER WAVE 455M (CE) A-4 CABLE INDUCT ANCE, AND ITS AFFECT ON PULSE WELDING For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than 15.24m (50 ft.), tra- ditional welding cables may be used without any effects on welding performance. For the total we[...]

A-5 INST ALLA TION POWER WAVE 455M (CE) A-5 Electrode Voltage Sensing Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present. Important: The electrode polarity must be config- ured at the [...]

A-6 INST ALLA TION POWER WAVE 455M (CE) A-6 CONFIGURING THE SYSTEM For codes below 11100, consult the semi-automatic Power Feed instruction manual for configuration infor- mation about DIP switch settings. For codes above 11100 the power source will “ Auto Map ” the system eliminating most of the need to set DIP switches to configure the system[...]

A-7 INST ALLA TION POWER WAVE 455M (CE) A-7 In this case the individual feed heads need to be assigned to the dual head control and the PW455M auto map- ping disabled and the Equipment Groups set. (See the Feeder documentation for information on setting the feeder DIP switches) System that is NOT "Auto Mappable" POWER WAVE 455M (CE) POWER[...]

A-8 INST ALLA TION POWER WAVE 455M (CE) A-8 WELDING WITH MUL TIPLE POWER W A VES Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the wor[...]

A-9 INST ALLA TION POWER WAVE 455M (CE) A-9 MUL TIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES[...]

A-10 INST ALLA TION POWER WAVE 455M (CE) A-10 I / O RECEPT ACLE SPECIFICA TIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc E 51 +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 PIN LEA[...]

B-1 OPERA TION B-1 POWER WAVE 455M (CE) SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. 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. • Always wear dry insulating gloves. • Do not [...]

B-2 OPERA TION B-2 POWER WAVE 455M (CE) INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING OR CAUTI[...]

B-3 OPERA TION B-3 POWER WAVE 455M (CE) DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage b[...]

DeviceNet Interface Module This module can be used for DeviceNet capability. It will be a 5 pin sealed mini connector per ANSI B93.55M-1981. EtherNet/DeviceNet Module This module includes the DeviceNet and EtherNet capability. The DeviceNet uses a 5 pin sealed mini connector per ANSI B93.55M-1981. The EtherNet uses a RJ5 connector. RECOMMENDED EQUI[...]

B-5 OPERA TION POWER WAVE 455M (CE) B-5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave 455m (CE). (See Figure B.1) 1 . POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light. Error condi[...]

B-6 OPERA TION B-6 NOMINAL PROCEDURES The Power Wave 455M (CE) is designed to operate with 19.1mm (3/4") electrode stick-out for CV and Pulse processes. FRINGE PROCEDURES Excessively short or long electrode stick-outs may function only on a limited basis, if at all. MAKING A WELD The serviceability of a product or structure utiliz- ing the wel[...]

W a v e Con tr ol 0. 0 0 W a ve C o n trol + 10 . 0 W a ve C o n trol - 10.0 Current T ime CURRENT W A VE FORM (CV) B-7 OPERA TION B-7 • WELDING MODE May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characterist[...]

B-8 OPERA TION B-8 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed [...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED Work Voltage Sense Lead Kit, K940 Dual Cylinder Undercarriage, K1570-1. Gas Guard Regulator, K659-1 Coaxial welding Cable, K1796 Cool-Arc 40 K2187-1 (230V AC) Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet interface Module, K2206-[...]

D-1 MAINTENANCE D-1 POWER WAVE 455M (CE) SAFETY PRECAUTIONS 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 periodical[...]

E-1 TROUBLESHOOTING E-1 POWER WAVE 455M (CE) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and re[...]

E-2 TROUBLESHOOTING E-2 POWER WAVE 455M (CE) USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on t[...]

E-3 TROUBLESHOOTING E-3 POWER WAVE 455M (CE) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ER[...]

E-4 TROUBLESHOOTING E-4 POWER WAVE 455M (CE) Observe all Safety Guidelines detailed throughout this manual CAUTION 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. PROBLEMS (SYMPTOMS) POSSIB[...]

E-5 TROUBLESHOOTING E-5 POWER WAVE 455M (CE) Observe all Safety Guidelines detailed throughout this manual CAUTION 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. PROBLEMS (SYMPTOMS) POSSIB[...]

E-6 TROUBLESHOOTING E-6 POWER WAVE 455M (CE) Observe all Safety Guidelines detailed throughout this manual CAUTION 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. PROBLEMS (SYMPTOMS) POSSIB[...]

F-1 DIAGRAMS F-1 POWER WAVE 455M (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment cod[...]

F-2 CONNECTION DIAGRAM F-2 POWER WAVE 455M (CE) Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK[...]

F-3 DIAGRAMS F-3 POWER WAVE 455M (CE) 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 1 1-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455M[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND 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 F ABRICANTE P ARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• 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 • World's Leader in Welding and Cutting Products •[...]