Lincoln Electric POWER WAVE 455TM IM583-A manual

PO WER W A VE 455 ™ OPERA TOR’S MANUAL IM583-A December, 1999 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 READIN[...]

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 PRÉCA UTIONS 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 [...]

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. Pay par[...]

vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455..........................................................A-1 Safety Precautions............................................................................[...]

A-1 INST ALLA TION POWER WAVE 455 A-1 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455 OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 208V - 60HZ. 230V - 60HZ. 400V - 60HZ. 460V - 60HZ. 575V - 60HZ. 200V - 50HZ. 220V - 50HZ. 400V - 50HZ. 440V - 50HZ. 550V - 5[...]

A-2 INST ALLA TION POWER WAVE 455 A-2 ENVIRONMENT AL PRO TECTION The Power Wave power source is rated IP21S and should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area. LIFTING [...]

A-3 INST ALLA TION POWER WAVE 455 A-3 INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommend- ed super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circu[...]

A-4 INST ALLA TION POWER WAVE 455 A-4 V OL T A GE SENSING A T THE W ORKPIECE 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. To enable t[...]

A-5 INST ALLA TION POWER WAVE 455 A-5 PO WER FEED CONTROL BO X 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.) Co[...]

B-1 OPERA TION B-1 POWER WAVE 455 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS 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 wea[...]

B-2 OPERA TION B-2 POWER WAVE 455 INPUT PO WER ON OFF HIGH TEMPERA TURE MA CHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVER TER INPUT PO WER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT V O LTA G E INPUT V OL T A GE OUTPUT V OL T A GE INPUT CURRENT OUTPUT CURRENT PRO TECTIVE GROUND W ARNING GRA[...]

B-3 OPERA TION B-3 POWER WAVE 455 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 PR OCESSES AND EQUIPMENT RECOMMENDED PR OCESSES The [...]

B-4 OPERA TION POWER WAVE 455 B-4 WELDING CAP ABILITY 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. If the duty cycle is exceeded, a thermostat will shut off the output until[...]

B-5 OPERA TION B-5 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. It can be mounted directly on the wire f[...]

B-6 OPERA TION B-6 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. A Trim setting less than 1.000 decreases th[...]

C-1 A CCESSORIES C-1 OPTIONS / A CCESSORIES F A CT OR Y INST ALLED There are no factory installed options available for the Power Wave machines. FIELD INST ALLED 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[...]

D-1 MAINTENANCE D-1 POWER WAVE 455 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 periodically blo[...]

E-1 TR OUBLESHOO TING E-1 POWER WAVE 455 USING THE ST A TUS LED T O TR OUBLESHOO T SYSTEM PROBLEMS The Status LED on the pow er source case front can help diagnose problems do wn to the system component (pow er source, wire f eeder , wire drive, etc.) le vel. If , for an y reason, the system does not appear to be working properly , alwa ys check th[...]

E-2 TR OUBLESHOO TING E-2 POWER WAVE 455 HOW TO USE TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety[...]

E-3 TR OUBLESHOO TING E-3 POWER WAVE 455 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linco[...]

E-4 TR OUBLESHOO TING E-4 POWER WAVE 455 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linco[...]

E-5 TR OUBLESHOO TING E-5 POWER WAVE 455 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of 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 Linco[...]

F-1 DIA GRAMS F-1 POWER WAVE 455 3 1 L3A 18 TO AUX #1 TO CURRENT 32 33 4 POS X2 4 POWER BD RECTIFIER J24 NEG TO J32 NEG NEG NEG POWER BD RECT C3 + 32 TO J81 L1A A H1D 31 TO J61 612B S4 TO CB3 (TOP) 2 FRONT OF MACHINE 110V RECEPTACLE TO TP3 TO CONTACTOR TO CONTACTOR TO RECONNECT PANEL 11 TO SWITCH 11 16 BD #1 12 TRANSFORMER TO CURRENT BD #2 16 PRIMA[...]

F-2 DIA GRAMS F-2 POWER WAVE 455 N.B. 17A RECONNECT SWITCH N.C. 17B 18B + + P91 CURRENT TRANSDUCER 13 14B CR1 T3 TO AUX #1 T2 TO SW1 L3 L3A T1 W L2 TO SWITCH BD #1 TO TOP RIGHT PRI 13B THIS AREA VIEWED FROM REAR OF MACHINE L1 TO SW1 L1A TO BOTTOM RIGHT PRI 18A TO SWITCH BD #2 17 TO TOP LEFT PRI TO BOTTOM RIGHT PRI TO AUX #1 TO SWITCH BD #1 14 TO TO[...]

F-3 DIA GRAMS F-3 POWER WAVE 455 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 B M18241 DIMENSION PRINT - POWER WAVE 455[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO 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 •[...]