Lincoln Power Wave 455, Power Wave 455R Operator's Manual

Page 1

IM690-A

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specications and availability of optional features may have changed.

POWER WAVE 455/R

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 thoughtful 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 careful.

™

10675; 10676

May, 2001

Date of Purchase: Serial Number: Code Number: Model: Where Purchased:

OPERATOR’S MANUAL

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• Sales and Service through Subsidiaries and Distributors Worldwide •

• World's Leader in Welding and Cutting Products •

IEC 60974-1

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

POWER WAVE 455/R

Page 3

SAFETY

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. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

POWER WAVE 455/R

Page 4

iii

SAFETY

iii

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.

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY 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 Code and the manufacturer’s recommendations.

Mar ‘95

POWER WAVE 455/R

Page 5

SAFETY

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 suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

POWER WAVE 455/R

Page 6

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• 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 is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Page 7

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications - Power Wave 455/R ..............................................A-1,A-2

Safety Precautions.................................................................................................A-3

Select Suitable Location ........................................................................................A-3

Lifting...............................................................................................................A-3

Stacking ..........................................................................................................A-3

Machine Grounding ...............................................................................................A-3

High Frequency Protection ....................................................................................A-3

Input Connection....................................................................................................A-3

Input Fuse and Supply Wire Considerations .........................................................A-4

Input Voltage Change Over Procedure..................................................................A-4

Welding with Multiple Power Waves......................................................................A-5

Electrode and Work Cable Connections................................................................A-6

Negative Electrode Polarity ..................................................................................A-6

Voltage Sensing at the Work Piece .......................................................................A-7

Power Wave / Power Feed Wire Feeder Interconnections....................................A-8

Control Cable Specifications ...........................................................................A-8

External I/O Connector....................................................................................A-8

High Speed Gear Box .....................................................................................A-9

Dip Switch Settings and Locations...............................................................A-10

Control Board Dip Switch ..............................................................................A-10

Feed Head Board Dip Switch........................................................................A-10

Devicenet/Gateway Board Dip Switch, Bank (S1) ........................................A-10

Bank (S2) ......................................................................................................A-11

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precuations.................................................................................................B-1

Graphic Symbols that appear on this machine or in this manual...........................B-2

General Description...............................................................................................B-3

Recommended Processes and Equipment ...........................................................B-3

Required Equipment..............................................................................................B-3

Limitations..............................................................................................................B-3

Duty Cycle and Time Period..................................................................................B-3

Case Front Controls ........................................................................................B-4

Constant Voltage Welding...............................................................................B-5

Pulse Welding .................................................................................................B-6

STT Welding ...................................................................................................B-7

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Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Factory Installed..............................................................................................C-1

Field Installed..................................................................................................C-1

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance, Periodic, Calibration Specification.....................................D-1

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Troubleshooting..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1

Using the Status LED to Troubleshoot System Problems .....................................E-2

Troubleshooting Guide.............................................................................E-3 thru E-6

Error Codes for the Power Wave ....................................................................E-7,E-8

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Wiring Diagram ....................................................................................Section F-1, F-2

Connector Pin Definitions ...........................................................................Section F-3

Connection Diagrams...........................................................................Section F-4, F-5

Dimension Print............................................................................................Section F-6

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Parts Lists .....................................................................................................P377Series

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Page 8

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

(K1761-1)

208/230/460V - 60HZ.

200/220/440V - 50HZ.

(K1761-2)

208/230/460/575V-60HZ.

208/230/460/575V-50HZ.

OPEN

CIRCUIT

VOLTAGE

CURRENT

RANGE

OUTPUT

CONDITIONS

450A@38V.100%

570A@43V. 60%

400A@36V.100%

500A@40V. 60%

450@38V.100%

570@43V.60%

400@36V.100%

500A@40V. 60%

PULSE

FREQUENCY

VOLTAGE

INPUT

CURRENT

AMPS

70/65/35 87/82/48

72/67/36 79/74/41

58/53/25/22 82/78/37/31

49/45/23/18 67/61/31/25

OUTPUT

PULSE

RANGE

IDLE

POWER

400 Watts

Max.

PULSE AND

BACKGROUND

TIME RANGE

POWER FACTOR

@ RATED OUPUT

.89 MIN.

.95 MIN.

STT PARAMETERS

EFFICIENCY

@ RATED OUPUT

88%

AUXILIARY POWER

(CIRCUIT BREAKER

PROTECTED)

A-1

75 VDC

5 - 570

PROCESS CURRENT RANGES (DC)

0.15 - 1000 Hz

MIG/MAG

FCAW

SMAW

Pulse

STT

5 - 55 VDC

100 MICRO SEC. -

3.3 SEC.

40-325 AMPS

CURRENT

50-570 Average Amps 40-570 Average Amps 30-570 Average Amps 5-750 Peak Amps 40-325 Average Amps

40 VDC @10 AMPS

115VAC @10 AMPS

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT

VOLTAGE /

FREQUENCY

(HZ)

(K1761-1)

208/50/60 230/50/60 460/50/60

(K1761-2)

208/50/60 230/50/60 460/50/60 575/50/60

TYPE 75°C

COPPER WIRE IN CON-

DUIT AWG[IEC] SIZES

(MM2)

4 (25) 4 (25) 8 (10)

4 (25) 4 (25) 8 (10) 10 (6)

GROUND WIRE IN CON-

TYPE 75°C

DUIT AWG[IEC] SIZES

(MM2)

6 (10) 6 (10) 10 (6)

6 (10) 6 (10) 10 (6) 10 (6)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

110 110

110 100

50 40

POWER WAVE 455/R

Page 9

A-2

HEIGHT

26.10 in 663 mm

INSTALLATION

PHYSICAL DIMENSIONS

WIDTH

19.86 in 505 mm

TEMPERATURE RANGES

DEPTH

32.88 in 835 mm

A-2

WEIGHT

(K1761-1) 247 lbs.

112 kg.

(K1761-2) 295lbs.

133 kg.

OPERATING TEMPERATURE RANGE

-20°C to +40°C

STORAGE TEMPERATURE RANGE

-40°C to +40°C

POWER WAVE 455/R

Page 10

A-3

INSTALLATION

SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

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. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

A-3

Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than

5.90”(150mm) beyond the equipment on all sides.

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.

STACKING

Power Wave machines can be stacked to a maximum of 3 high.

CAUTION

The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines toppling over if this precaution is not taken.

----------------------------------------------------------

SELECT SUITABLE LOCATION

Do not use Power Waves in outdoor environments. The Power Wave power source 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.

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

Machines above code 10500 are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled, to ensure all components are properly cooled.

If desired, the F.A.N. feature can be disabled (causing the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the output of the solid state fan control relay, located on the back of the Control PC board enclosure. (See Wiring Diagram)

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods.

HIGH FREQUENCY PROTECTION

Locate the Power Wave away from radio controlled machinery.

CAUTION

The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

INPUT CONNECTION

WARNING

Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death.

-----------------------------------------------------------------------Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the upper left case back next to the input access door.

POWER WAVE 455/R

Page 11

A-4

INSTALLATION

(K1761-1) FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

A-4

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

Disconnect input power before inspecting or servicing machine.

Do not operate with covers removed.

ELECTRIC SHOCK CAN KILL

Do not touch electrically live parts.

Only qualified persons should install, use or service this equipment.

VOLTAGE=220-230V

200-208V

220-230V

380-415V

440-460V

’A’

W / L3

V / L2

U / L1

VOLTAGE=380-415V

200-208V

220-230V

380-415V

440-460V

CR1

’A’

VOLTAGE=200-208V

200-208V

220-230V

380-415V

440-460V

VOLTAGE=440-460V

200-208V

220-230V

380-415V

440-460V

(K1761-2) FIGURE B.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

Disconnect input power before inspecting or servicing machine.

Do not operate with covers

ELECTRIC

SHOCK

CAN KILL

removed. Do not touch electrically live parts. Only qualified persons should install,

use or service this equipment.

W / L3

V / L2

U / L1

CR1

VOLTAGE = 200-208V

200-208V

220-230V

440-460V

550-575V

'A'

S23847

’A’

11-14-97

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

S25198

VOLTAGE = 220-230V

200-208V

220-230V

440-460V

550-575V

'A'

VOLTAGE = 440-460V

200-208V

220-230V

440-460V

550-575V

'A'

VOLTAGE = 550-575V

200-208V

220-230V

440-460V

550-575V

'A'

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to

do so will result in damage to the machine.

Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A.1 on the following page.

INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY)

Welders are shipped connected for the highest input

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

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-

voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door. If the main reconnect switch or link position is placed in the wrong position, the welder will not produce output

power. ed super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose an input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents.

If the Auxiliary (A) lead is placed in the wrong position,

there are two possible results. If the lead is placed in a

position higher than the applied line voltage, the

welder may not come on at all. If the Auxiliary (A) lead

is placed in a position lower than the applied line volt-

age, the welder will not come on, and the two circuit

breakers in the reconnect area will open. If this

occurs, turn off the input voltage, properly connect the

(A) lead, reset the breakers, and try again.

POWER WAVE 455/R

Page 12

A-5

INSTALLATION

WELDING WITH MULTIPLE POWER WAVES

A-5

For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves.

CAUTION

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 work leads into one lead. The welding travel directions should be in the direction moving away from the work lead as shown below. Connect all of the work sense leads from each power source to the work piece at the end of the weld.

FIGURE A.2

TWO POWER WAVES

When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.

Every welding gun requires a seperate shielding gas regulator for proper flow rate and shielding gas coverage.

Do not attempt to supply shielding gas for two or more guns from only one regulator.

If an anti-spatter system is in use then each gun must have its own anti-spatter system. (See Figure A.2.)

POWERWAVE

Travel

Direction

Connect All Work Sense Leads at the End of the Joint

Connect All Welding Work Leads at the Beginning of the Joint

POWER WAVE 455/R

Page 13

A-6

INSTALLATION

ELECTRODE AND WORK CABLE CONNECTIONS

Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. Avoid excessive lengths and do not coil excess cable. Do not tightly bundle the electrode and work cables together. Use K1796 Coaxial welding cables wherever possible. (See Section F-5 Connection Diagram). Minimum work and electrode cables sizes are as follows:

TABLE 1

(Current (60% Duty Cycle)

400 Amps 2/0 (67 mm2) 500 Amps 3/0 (85 mm2) 600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommended to reduce the cable inductance in long distance Pulse and STT applications up to 300 amps.

When using an inverter type power source like the Power Waves, use the largest welding (electrode and ground) cables that are practical. At least 2/0 copper wire - even if the average output current would not normally require it.

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)

CAUTION

When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.

-----------------------------------------------------------------------Most welding applications run with the electrode being positive (+). For those applications, connect one end of the electrode cable to the positive (+) output stud on the power source (located beneath the spring loaded output cover near the bottom of the case front). Connect the other end of the electrode cable to the wire drive feed plate using the stud, lockwasher, and nut provided on the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the work cable connections section. Connect a work lead from the negative (-) power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

A-6

CAUTION

Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance.

-------------------------------------------------------------------------

When welding with the STT process, use the positive output connection labeled (STT) for STT welding. (If desired, other welding modes can be used on this stud; however, their average output current will be limited to 325 amps.) For non-STT processes, use the positive output connection labeled (Power Wave), so that the full output range of the machine is available.

CAUTION

Do not connect the STT and Power Wave stud together. Paralleling the studs will bypass STT circuitry and severely deteriorate STT welding performance. (See Section F-3 Connection Diagram)

-------------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud). When operating with electrode polarity negative the switch 7 must be set to ON on the Wire Feed Head PC Board. The default setting of the switch is OFF to represent positive electrode polarity. Set the Negative Polarity switch on Wire Feed Head PC board as follows:

WARNING

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.

------------------------------------------------------------------

1. Turn off power to the power source at the disconnect switch.

2. Remove the front cover from the power source.

3. The wire feed head board is on the right side of the power source. Locate the 8-position DIP switch and look for switch 7 of the DIP switch.

4. Using a pencil or other small object, slide the switch right to the OFF position for positive electrode polarity. Conversely, slide the switch left to the ON position for negative electrode polarity.

123456 78

POWER WAVE 455/R

Page 14

A-7

5. Replace the cover and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.

INSTALLATION

A-7

Work Voltage Sensing

The Power Waves are shipped from the factory with the work sense lead enabled.

VOLTAGE SENSING

The best arc performance occurs when the Power Waves have accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance.

CAUTION

If the voltage sensing is enabled but the sense leads are missing or improperly connected, extremely high welding outputs may occur.

------------------------------------------------------------------------

Do not tightly bundle the work sense lead to the work lead. The ELECTRODE sense lead (67) is built into the K1795 control cable. The WORK sense lead (21) connects to the Power Wave at the four-pin connector located underneath the output stud cover. Enable the voltage sense leads as follows:

TABLE 2

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional** GMAW-P FCAW 67 lead required 21 lead optional** STT 67 lead required 21 lead required** GTAW SAW 67 lead required 21 lead optional** * The electrode voltage 67 sense lead is part of to the

control cable to the wire feeder.

67 lead required 21 lead optional**

Voltage sense at studs Voltage sense at studs

For processes requiring work voltage sensing, connect the (21) work voltage sense lead from the Power Wave to the work. Attach the sense lead to the work as close to the weld as practical. Enable the work voltage sensing in the Power Wave as follows:

WARNING

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.

-----------------------------------------------------------

1. Turn off power to the power source at the disconnect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side of the power source. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.

4. Using a pencil or other small object, slide the switch right to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch left to the ON position if the work sense lead is present.

123456 78

** For consitent weld quality work voltage sensing is

recommended.

5. Replace the cover and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead must be connected at the wire feeder.

POWER WAVE 455/R

Page 15

A-8

INSTALLATION

POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS

Connect the control cable between the power source and wire feeder. The wire feeder connection on the robotic Power Waves is located under the spring loaded output cover, near the bottom of the case front. The control cable is keyed and polarized to prevent improper connection.

A-8

EXTERNAL I/O CONNECTOR

The Power Wave is equipped with a port for making simple input signal connections. The port is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group. Because the Power Wave is a ‘slave’ on the DeviceNet network, the Trigger and Cold Inch Groups are disabled when the DeviceNet/Gateway is active.

For convenience sake, the electrode and control cables can be routed behind the left or right strain reliefs (under the spring loaded output cover), and along the channels formed into the base of the Power Wave, out the back of the channels, and then to the wire feeder.

Output connections on some Power Waves are made via 1/2-13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles, that are also located beneath the spring loaded output cover at the bottom of the case front.

A work lead must be run from the negative (-) power source output connection to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

CAUTION

Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding performance.

------------------------------------------------------------------------

CONTROL CABLE SPECIFICATIONS

It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system.

The shutdown group is always enabled. Shutdown 2 is used for signaling low flow in the water cooler. Unused shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See Figure A.3)

FIGURE A.3

Shutdown2 input (Water Fault)

Reserved for future use

Trigger Input

+15 VDC for Trigger Group

4 Step Input

Dual Procedure Input

Cold Inch Forward

+15 VDC for Cold Inch Group

Gas Purge Input

Cold Inch Reverse

+15 for shutdown group

910

Shutdown1 input

CAUTION

The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).

-----------------------------------------------------------------------Lincoln control cables are copper 22 conductor cable in a SO-type rubber jacket.

POWER WAVE 455/R

Page 16

A-9

INSTALLATION

HIGH SPEED GEAR BOX

Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. To change Gear ratio see Power Feed 10/R Instruction Manual.

WARNING

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.

-----------------------------------------------------------

A-9

1. Set the High/Low switch code on Wire Drive PC board as follows:

• Turn off power to the power source at the disconnect switch.

• Remove the front cover from the power source.

• The wire feed head board is on the right

side of the power source. Locate the 8position DIP switch and look for position 8 of the DIP switch.

• Using a pencil or other small object, slide the switch right to the OFF position, when the low speed gear is installed. Conversely, slide the switch left to the ON position when the high speed gear is installed.

• Replace the cover and screws. The PC board will “read” the switch at power up, automatically

adjusting all control parameters for the speed range selected.

123456 78

POWER WAVE 455/R

Page 17

A-10

Left

Right

INSTALLATION

DIP Switch Settings and Locations

DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches:

WARNING

• Turn off power at the disconnect switch.

------------------------------------------------------------------------

• Remove the top four screws securing the front access panel.

• Loosen, but do not completely remove, the bottom two screws holding the access panel.

• Open the access panel, allowing the weight of the panel to be carried by the bottom two screws. Make sure to prevent the weight of the access panel from hanging on the harness.

• Adjust the DIP switches as necessary.

• Replace the panel and screws, and restore power.

Feed Head Board DIP Switch:

switch 1 = Object Instance LSB (see table 1) switch 2 = Object Instance MSB (see table 1) switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select

switch 7 = negative polarity switch

switch 7

off positive (default) on negative

switch 8 = high speed gear

switch 8

off low speed gear (default) on high speed gear

electrode polarity

wire drive gear

DeviceNET/Gateway Board DIP Switch:

A-10

Control Board

DeviceNET/Gateway Board

Feed Head Board

Control Board DIP Switch:

switch 1 = Object Instance LSB1(see table 1) switch 2 = Object Instance

switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = reserved for future use switch 8 = work sense lead

LEASE SIGNIFICANT BIT

MOST SIGNIFICANT BIT

MSB2(see table 1)

Bank (S1)

switch 1 = Object Instance LSB (see table1) switch 2 = switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = Reserved for future use switch 8 = Reserved for future use

Object Instance MSB (see table 1)

TABLE 1 Object Instance switch 2 switch 1 Instance

off off 0 (default) off on 1 on off 2 on on 3

switch 8

off work sense lead not connected on work sense lead connected

work sense lead

POWER WAVE 455/R

Page 18

A-11 Bank (S2)

INSTALLATION

switch Description

1 Devicenet Baud Rate 2(see table 2)

TABLE 2

Prior to S24958-6 software switch 1 switch 2 baud rate

off off Programmable value on off 125K off on 250K on on 500K

S24958-6 and later software switch 1 switch 2 baud rate

off off 125K off on 250K on off 500K on on Programmable value

Bank (S2)

switch Description

3 Devicenet Mac ID

thru (see table 3)

TABLE 3

SWITCH 8

SWITCH 7

SWITCH 6

SWITCH 5

SWITCH 4

SWITCH 3

0000000 1000001 2000010 3000011 4000100 5000101 6000110 7000111 8001000 9001001 10001010 11001011 12001100 13001101 14001110 15001111 16010000 17010001

SWITCH 8

SWITCH 7

SWITCH 6

SWITCH 5

SWITCH 4

SWITCH 3

18010010 19010011 20010100 21010101 22010110 23010111 24011000 25011001 26011010 27011011 28011100 29011101 30011110 31011111 32100000 33100001 34100010 35100011 36100100 37100101 38100110 39100111 40101000 41101001 42101010 43101011 44101100 45101101 46101110

47101111 48110000 49110001 50110010 51110011 52110100 53110101 54110110 55110111 56111000 57111001 58111010 59111011 60111100 61111101 62111110 *Software Selectable (Line 0) **Default Setting (Line 62)

A-11

POWER WAVE 455/R

Page 19

B-1

OPERATION

SAFETY PRECUATIONS

Read this entire section of operating instructions before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the

welding ceases.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

B-1

• 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 SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning of this manual.

POWER WAVE 455/R

Page 20

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

B-2

INPUT POWER

OFF

HIGH TEMPERA TURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

SMAW

GMAW

FCAW

GTAW

OPEN CIRCUIT

VOLTAGE

INPUT VOLTA GE

OUTPUT VOLTA GE

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING OR CAUTION

POWER WAVE 455/R

Page 21

B-3

OPERATION

B-3

GENERAL DESCRIPTION

The Power Wave power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, Surface Tension Transfer and pulse welding modes.

The Power Wave power source is designed to be used with the family of Power Feed wire feeders, operating as a system. Each component in the system has special circuitry to "talk with" the other system components, so each component (power source, wire feeder, electrical accessories) knows what the other is doing at all times. The components communicate using Arc-Link protocol.

Robotic systems can communicate with other industrial machines via DeviceNET protocol. The result is a highly intrigated and flexible welding cell.

GENERAL DESCRIPTION - POWER WAVE 455/R

The Power Wave 455/R 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, GTAW and STT processes. It carries an output rating of either 450 amps, 38 volts; or 400 amps, 36 volts (both at 100% duty cycle), depending on input voltage and frequency. The Surface Tension transfer process (STT) is supported at currents up to 325 amps, at 100% duty cycle.

If the duty cycle is exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature.

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED EQUIPMENT

• Automatic Operation

All welding programs and procedures are set through software for the robotic Power Waves. FANUC robots equipped with RJ-3 controllers may communicate directly to the Power Wave. Other pieces of equipment such as PLC’s or computers can communicate to the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.

REQUIRED EQUIPMENT

• PF-10/R Wire Feeder, K1780-1

• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100

• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 10 ft), K1804-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 18 in), K1805-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 18 in), K1804-2

LIMITATIONS

• The Power Wave 455/R is not suitable for SMAW,

CAC-A or other processes not listed.

• Power Waves are not to be used in outdoor environ-

ments.

• Only Arc-Link Power Feed wire feeders and user

interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIOD

The Power Feed wire feeders are capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. Note that the duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.

RECOMMENDED PROCESSES

The Power Wave 455/R can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, GTAW and STT for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum. The STT process supports mild steel and stainless steel welding.

The Power Wave 455/R is recommended only for automatic or mechanized applications such as robotic welding.

POWER WAVE 455/R

Page 22

B-4

OPERATION

CASE FRONT CONTROLS

All operator controls and adjustments are located on the case front of the Power Wave. (See Figure A.4)

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 conditions are indicated, per table 4.

NOTE: The robotic Power Waves’ status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

TABLE 4

Light

Condition

Steady Green

Blinking Green

Alternating Green and Red

System OK. Power source communicating normally with wire feeder and its components.

Occurs during a reset, and indicates the PW455/R is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.

Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the PW455/R. Read the error code before the

machine is turned off.

Meaning

B-4

3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.

10 AMP AUXILIARY POWER CIRCUIT BREAKER:

5. Protects 115 volt AC case front receptacle auxiliary supply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. 5-PIN ARC LINK S1

8. 5-PIN DEVICENET CONNECTOR S5

9. I / O CONNECTOR

10. NEGATIVE STUD

11. INTERFACE CONNECTOR S6

12. STT STUD

13. POSITIVE STUD

14. AUXILIARY OUTPUT

FIGURE A.4

Steady Red Blinking Red

Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light.

To clear the error, turn power source off, and back on to reset. See Troubleshooting Section.

Not applicable. Not applicable.

POWERWAVE

Case Front Layout

Power Wave 455/R (Domestic/Canadian Version)

POWER WAVE 455/R

Page 23

B-5

OPERATION

CONST ANT V OL T AGE WELDING

For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the best average voltage for a given wire feed speed. With synergic programs, when the wire feed speed changes the Power Wave will automatically adjust the voltage correspondingly.

Wave control adjusts the inductance of the waveshape. (This adjustment is often referred to as "pinch". Inductance is inversely proportional pinch.) Increasing wave control greater than 0 results in a harsher, colder arc while decreasing the wave control to less than 0 provides a softer, hotter arc. (See Figure A.5)

FIGURE A.5

B-5

Current

Time

Wav

Control +10.0

ave Control 0.00

ave Control -10.0

POWER WAVE 455/R

Page 24

B-6

PULSE WELDING

OPERATION

B-6

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 can only be predicted when all the pulsing waveform parameters are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting "trim".

Trim adjusts the arc length and ranges from 0.50 to

1.50, with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length.

Most pulse welding programs are syngeric. As the wire feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain similar arc properties.

FIGURE A.6

The Power Wave utilizes "adaptive control" to compensate for changes in electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The Power Wave waveforms are optimized for a 0.75" (19mm) stick-out. The adaptive behavior supports a range of stickouts from 0.50" (13mm) to 1.25" (32mm). At very low or high wire feed speeds, the adaptive range may be less due to reaching physical limitations of the welding process.

Wave control in pulse programs usually adjusts the focus or shape of the arc. Wave control values greater than 0 increase the pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed sheet metal welding. Wave control values less than 0 decrease the pulse frequency while increasing the background current, for a soft arc good for out-of-position welding. (See Figure A.6)

Wave Control -10.0

Current

Wave Control 0.0

Wave Control +10.0

Time

POWER WAVE 455/R

Page 25

B-7

STT WELDING

OPERATION

B-7

The pictures illustrate the waveshape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the variables effect the waveform.

FIGURE A.7

Current

Time

Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater than 1.0 add more energy to the weld and make the weld puddle hotter; trim values less than 1.0 reduce energy to weld A nominal value of 1.0 will work for most applications. (See Figure A.7)

rim 1.50

rim 1.00

Trim 0.50

For most programs, peak current is adjusted by wave control values. A value of +10.0 maximizes the peak current, while a wave control of -10.0 minimizes peak current. In general, the peak current is proportional torch arc length. (See Figure A.8)

FIGURE A.8

Current

NOTE: The ranges on Wave Control and Trim are

dependent on the weld programs. The values shown are typical ranges.

Wave Control +10.0

Wave Control 0.0

ave Control -10.0

Time

POWER WAVE 455/R

Page 26

C-1

ACCESSORIES

OPTIONAL EQUIPMENT

FACTORY INSTALLED

There are no factory installed options available for the Power Wave 455R.

FIELD INSTALLED

• Gas Guard Regulator (K659-1)

The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive unit. Install the 5/8-18 male outlet on the regulator to the proper 5/8-18 female gas inlet on the back panel of the wire drive. Secure fitting with flow

adjuster key at top.

* Voltage Sense Leads (K940-10, -25 or -50)

The voltage sense leads connect at the front of the machine. (See Section A-6)

C-1

The water coolers are designed to cool only one welding gun and should be not used to cool multiple guns or other devices.

Water cooler manufacturers often specify additives to the coolant such as fungicides or alkalides. Follow manufacturers recommendations to achieve proper operation and long lifetimes without clogging.

* Water Flow Sensor (K1536-1)

Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing. Recommend practice is to install a water flow sensor such as on the water return line of the torch. When fully integrated into the welding system, the sensor will prevent welding if no water flow is present.

• Dual Cylinder Undercarriage, K1570-1*

• Power Wave Water Cooler (K1767-1)*

(See Section F-4 Connection Diagram) The K1767-1 is the recommended water cooler for the Power Waves. Incorporated into the cooler is an automatic flow sensor to detect low coolant flow. In the event of a low flow condition, a fault signal is sent to the Power Wave and welding output automatically stops to protect the torch.

• Coaxial welding Cable, K1796

(See Section F-5 Connection Diagram)

*The Dual Cylinder Undercarriage, K1570-1 is not

compatible in combination with the Power Wave Water Cooler K1767-1.

POWER WAVE 455/R

Page 27

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 machine.

D-1

PERIODIC MAINTENANCE

Calibration of the Power Wave-455/R is critical to its operation. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and Current should be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the factory. Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility.

The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. Detailed instructions are available with the utility.

POWER WAVE 455/R

Page 28

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOO TING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

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

POWER WAVE 455/R

Page 29

E-2

TROUBLESHOOTING

E-2

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Status LED on the power source case front can help diagnose problems down to the system component (power source, wire feeder, wire drive, etc.) level. If, for any reason, the system does not appear to be working properly,

Steady Green

Blinking Green

Alternating Green and Red

always check the color of the Status LED, and refer to the following chart to help you determine which system component (power source, wire feeder, wire drive, etc.) may be faulty. Replace the components identified as potentially faulty with known good components, and the system should operate normally.

System OK. Power source communicating normally with wire feeder and its components.

Occurs during a reset, and indicates the Power Wave is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation

Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the Power Wave. Read the error code

before the machine is turned off.

Steady Red Blinking Red

To clear the error, turn power source off, and back on to reset.

Not applicable. Not applicable.

POWER WAVE 455/R

Page 30

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal covers are removed.

Input fuses keep blowing, or input breaker keeps tripping.

Machine will not power up (no lights, no fan, etc.)

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. Make certain that fuses or breakers are properly sized. See Installation section of this manual for recommended fuse and breaker sizes.

2. Welding procedure is drawing too much output current, or duty cycle is too high. Reduce output current, duty cycle, or both.

3. There is internal damage to the power source. Contact an authorized Lincoln Electric Service facility.

1. Make certain that the Power Switch (SW1) is in the “ON” position.

2. Circuit breaker CB4 (in reconnect area) may have opened. Reset. Also, check input voltage selection, below.

3. Input voltage selection made improperly. Power down, check input voltage reconnect according to diagram on reconnect cover.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

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.

CAUTION

POWER WAVE 455/R

Page 31

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Thermal LED is lit.

Machine won’t weld, can’t get any output. (CR1 will not pull in.)

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Fan thermostat has opened.

Check for proper fan operation. (Fan should run whenever main power is on.) Check for material blocking intake or exhaust louvers, or for excessive dirt clogging cooling channels in machine.

2. Secondary rectifier thermostat

has opened. After machine has cooled, reduce load, duty cycle, or both. Check for material blocking intake or exhaust louvers.

1. Input voltage is too low or too

high. Make certain that input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. If the Thermal LED is also lit,

see “Yellow Thermal LED is Lit” section.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

CAUTION

POWER WAVE 455/R

Page 32

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Machine often “noodle welds” (output is limited to approximately 100 amps) when running a particular procedure

Machine won’t produce full output.

For no apparent reason, the weld-

ing characteristics have changed.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Secondary current limit has been exceeded, and the machine has phased back to protect itself. Adjust procedure or reduce load to lower current draw from the machine.

1. Input voltage may be too low,

limiting output capability of the power source. Make certain that the input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. Input may be “single phased”.

Make certain the input voltage is proper on all three input lines.

1. Check for proper Wire Feed

Speed setting. In CV MIG and FCAW modes, check for proper Voltage setting. In the MIG/MAG pulse modes, check the Trim setting. These controls are on the wire feeder.

2. Check for proper shielding

gas mix and flow.

3. Check for loose or faulty weld

cables and cable connections.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

Auxiliary receptacle is “dead”— no auxiliary voltage .

1. Circuit breaker CB2 (on case

front) may have opened. Reset.

2. Circuit breaker CB4 (in recon-

nect area) may have opened. Reset.

CAUTION

POWER WAVE 455/R

Page 33

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

The PowerWave is triggered to weld, but there is no output.

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

WELDING PROBLEMS

1. Check for fault signals from the I/O connector. Possible faults are lack of water flow/ water flow turned off.

E-6

RECOMMENDED

COURSE OF ACTION

In the STT mode, the arc is excessively long and erratic.

In the STT mode, the spatter is higher than normal and the arc is inconsistent.

The feeder will not cold inch wire

Arc loss fault on robot

1. Check that the (21) work sense lead is connected.

2. Verify that the electrode lead is connected to the STT stud and not the "POWERWAVE" stud.

3. Check that the "POWERWAVE" stud is not electrically connected to the STT stud.

1. Check for fault signals from the I/O connector. Possible faults are lack of water flow/ water cooler turned off.

1. Possibly caused by wire feeding problem.

2 Problem - Conduit leading to the

wire feeder has bends or twists, which can reduce the wire feed speed. Solution - Remove bends and twists from conduit.

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

3. Problem – Conduit leading up to the wire feeder from the wire reel is too long.

Solution – Use a shorter length of conduit.

CAUTION

POWER WAVE 455/R

Page 34

E-7

Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWERWAVE

The following is a list of possible error codes that the PW-455 can output via the status light (see "Troubleshooting the PowerWave / Power Feed System Using the Status LED").

TROUBLESHOOTING

E-7

Error Code #

11 CAN communication bus off. 12 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage

(Left side facing machine)

33 Capacitor "B" under voltage

(Right side facing machine)

Indication

Probably due to excessive number of communication errors. User Interface is no longer responding to the Power Source. The most

likely cause is a fault/bad connection in the communication leads or control cable. Contact the Service Department for instructions on reloading the Welding Software.

Contact the Service Department for instructions on reloading the Welding Software.

Excessive Primary current present. May be related to a switch board or output rectifier failure.

Low voltage on the main capacitors. May be caused by improper input configuration. When accompanied by an overvoltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.

34 Capacitor "A" over voltage

(Left side facing machine)

35 Capacitor "B" over voltage

(Right side facing machine)

36 Thermal error

37 Softstart error

Excess voltage on the main capacitors. May be caused by improper input configuration. When accompanied by an undervoltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.

CAUTION

POWER WAVE 455/R

Page 35

E-8

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-8

Error Code #

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indication

The secondary (weld) current limit has been exceeded. When this occurs the machine output will phase back to 100 amps, typically resulting in a condition referred to as "noodle welding" NOTE: For the Power Wave 455/R the secondary limit is 570 amps for the standard stud, and 325 amps for the STT stud and all single phase operation.

The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors 32-35.

Indicates machine is running on single phase input power. Usually caused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal errors. These codes generally indicate internal errors on the PS Control Board. If cycling the input power on the machine does not clear the error, try reloading the operating system. If this fails, replace the control board.

CAUTION

POWER WAVE 455/R

Page 36

F-1

POWER WAVE 455 / R WIRING DIAGRAM

W=WHITE

U=BLUE

F-1

11-2000A

G3792

(VIEWED FROM COMP ONENT SIDE OF BOARD)

CONNECTOR CAVITY NUMBERING SEQ UENCE

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 code number..

DIAGRAMS

AUXILIARY TRANSFORMER #2

(TOP)

J87

J1,J6,J7

J10,J70,J85

J4,J13,

J43,J71

J3,

J61,J86

J8,

J84

J47,J60

J14,J40J42,

J50,J75,J83

J1VS,J9,J10CH,

J82

3 4

J2,J5,J11,

J41,J46,J72

J73,J76,J81

J10,J2VS

J74

RESISTORS=OHMS/WATTS

COMPONENT VALUES:

CAPACITORS=MFD/V OLTS

CB2

R=RED

N=BROWN

G=GREEN

B=BLACK

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537

RIGHT SIDE OF MACHINE

C10

20uF

400V

288E

289E

289D

288D

288C

288B

289C

289B

289F

2Ω

RESISTOR BANK

STT SNUBBER

288F

L1A

L3A

TO CONTACTOR

LOAD LINE

612B

H1D

TO J61

TO CB3

SW1

POWER

WATER

352

LEFT)

TO D5

287

345

503

COOLER

33A

AUX #2

MAIN TRANSFORMER

19C

20C

TO C8

J10

J50

J40

405

406

RECEPTACLE

TO RECONNECT SWITCH

289A

289B

346

238

5054506

ELECTRODE

WORK

TP3

TO C10

604

REAR OF MACHINE

SWITCH

RECONNECT

CR1

AUX #1

231

238

232

601

604

765

J60

INPUT BOARD

TO J6, J10B

SWITCH

BD #2

PRI

RIGHT)

(BOTTOM

SEC

RIGHT)

(BOTTOM

.022

800V

2.7 10W

268

268A

POS

POWER BD

RECTIFIER

IFACE

ROBOT

1112131415

J87

SSR

J10CH

404

56789

SELECT

VOLTAGE SENSE

CB2

AUX 2

STT

WORK

TP6

RECEPTACLE

J85

852

853

854

855

856

857

858

859

860

861

862

EMITTER

141112

12 PIN

CONNECTOR

TOJ4J43

262

403

115V

851

POS

INPUT

RECTIFIER

NEG

T1T2612

506 505 504 503 518 514

SWITCH

PRI

(TOP

SEC

(TOP

2.7 10W

TP7

AUX. #1

NEG

D6TOJ11

J47

SSR, J10 CHOPPER BD.

3R3R

151112

J85

511

512

BOARD

202A

GND-A

GND-B

FRONT OF MACHINE

POS

NEG

TO J61

CR1

SW1

CB4

H1D

J61

5 4 3 2

J50

SWITCH B OARD

BD #1

RIGHT)

RIGHT SIDE

RIGHT)

.022

800V

287

TO J46

POS

POWER BD RECT

NEG

μF

100V

2400

J73

WORK

ELECTRODE

P90

P91

TO J1 VOLTAGE SENSE

212

213

813

811

216

202

206

211

812

816

456

67A

67B

216

+40VDC

AUX 2

ELECTRODE

WORK

206A

50Ω

CB2

BREAKER

10A CIRCUIT

μF

3500

STT SNUBBER

DIODE

500V

DIODE D5

STT CURRENT

880

TO J60

288B

21A

621

N.A.

288A

TRANSDUCER

414

J83

STATUS LED (R/G)

601

19D

20D

1516

TO C10

TO C8

P90

TO J8

J40,J50

418

5141273

J10A

J10B

886

AC AC

TO J7

L1A

TO SW1

TO SUPPLY LINES

TO A SYSTEM GROUND PER

H5A

H5H4H3

(440-460)

P52

350

N.B. PLACE SWITC H IN APPROPRIATE POSITIO N FOR INPUT

VOLTAGE. CONNECTION SH OWN IS FOR 380-460V

NATIONAL ELECTRICAL CODE.

AUX #1

CB3

H4A

H2A

H3A

H1A

(220-230)

(380-415)

(200-208)

(115V)

(230V)

352

33A

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V

OPERATION.

N.C. PLACE "A" LEA D ON APPROPRIATE CONN ECTION FOR

OPERATION.

L3A

TO SW1

CR1

TO AUX #1

H6A

P50

(550-575)

SWITCH

RECONNECT

MAIN

TRANSFORMER

NOTES:

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

ALIGNS WITH BLAC K LEAD OF LED SOCKET.

813

812

811

816

STT SNUBBER

CAPACITOR BANK

20uF

400V

TO D5

288C

289C

288A

289A

J43

J88

274

154

153

518

J11

THERMAL LED (Y)

TO J7

N.A.

206

TO J9

289E288E

289D

2Ω

288D

TO TP6

STT

.05/600V

TP5

TO TP3

.05/600V

TP2

TO RECONNECT PANEL

206A

TO R1

ELECTRODE

200-208V

220-230V

380-415V

10A

CB3

CIRCUIT

BREAKER

CB4

CB3

TO J61

H1A

612B

612A

TO CB4

TO SW1

TO AUX #2

FAN

CIRCUIT

BREAKER

444

TO AUX#1

612

612A

TO SOLID STATE RELAY

TO AUX #1

N.B.

REAR OF MACHINE

THIS AREA VIEWED FROM

RECONNECT SW ITCH

CB4

TOX3AUX #2X5RECONNECT PANEL

H3A

H2A

H4A

H5A

H6A

TO FAN

(380-415)

(440-460)

(550-575)

(200-208)H2(220-230)

(51V)

AUXILIARY TRANSFORMER #1

TO POWER BD.

RECTIFIER

X3A

TP4

444

SOLID

STATE

RELAY

J47

475

223

221

225

477

476

478

222

227

65432

J42

J41

J11

J47

J72

741

743

154

153

500

540

539

800

840

J81

J82

9137

J70

LEFT SIDE OF MACHINE

TO3WJ7

SUPPLY BOARD

DIGITAL POWER

BOARD

FEED HEAD

CONTROL BOARD

BOARD

GATEWAY

DEVICE NET

CB1

J47

TO J9

TO TP3

TO TP6

202

.05/600V

202A

TO R1

TP1

WORK

DEVICENET

X3A

(24V)

(115V)

J60

CR1

CHOKE

THERMTO RECT

291

224A

THERM

P91

TO AUX#1

211

216

TO FAN

MAIN CHOKE

TO J8

TOJ4J11

346

345

274

226

266

268A

765

J43

844

843

842

841

880

886

522

521

541

J83

251

253

254

234

J47

P73

CB1

J2VS

67A

54E53

WIRE

FEEDER

RECEPTACLE

J75

892

891

893

894

CONNECTOR

CAN_H

CAN_L

+24V

+24V GND

TO J6,J10B

TO SOLID STATE RELAY

MAIN

LEFT SIDE

CURRENT

TRANSFORMER

TRANSDUCER

OUTPUT

RECT

213

212

220A

220

TO J5

224

224A

2733228

267

262

POS

TO C3

BOARD

DC BUS

J46

846

845

847

854

853

852

851

J84

267

266

268

J81

800

840

743

741

123

987

654

J71

J72

2513

VOLTAGE

841

844

ROBOTIC/

WIREDRIVE

INTERFACE

RECEPTACLE

440-460V

20C

SWITCH BD #1

20D

J40

SWITCH B OARD

TO RECT

4777

4788

220A

DC BUS

511

151216

RECT

THERM

THERMTOJ20

225

224

220

891

894

J75

251

CONNECTOR

521

522

NPRSTUV

SWITCH BD #2

THERM

350

NEG

INPUT RECT

μF

500V

3500

BD #1

SWITCH

PRI

LEFT)

(BOTTOM

SEC

(BOTTOM

.022

800V

2.7 10W

292

COLLECTOR

CHOPPER

J86

504

231

232

56879

830

J76

BUSS BD

CB1

BREAKER

10A CIRCUIT

GND-A

TO SW1

N.C.

TO AUX #1

PANEL

RECONNECT

19C

SWITCH BD #1

POS

19D

INPUT RECT

SWITCH BD #2

406

405 404

403

418 414

BD #2

SWITCH

PRI

(TOP

LEFT)

SEC

(TOP

LEFT)

291

292

THERM

RECT

THERM

CHOKE

J41

J82

CB1

500251

54044755

4766

NEG

1503

J47

J1VS

858

856

855

857

512

862

861

860

859

131110

J85

J42

J43

223

222

228

226

221

227

892

893

J74

J73

253

254

21A

RS232

SENSE

RECEPTACLE

J83

J84

J2VS

3 CONDUCTOR

TWISTED/SHIELDED

SHIELD GROUND TO CASE

842

843

845

846

847

539

541

67B

JKL

POWER WAVE 455/R

Page 37

F-2

10A

CB3

CIRCUIT

BREAKER

CB4

TO J61

H1A

612B

612A

TO CB4

TO SW1

TO AUX #2

TOX3AUX #2X5RECONNECT PANEL

H4A

H5A

H6A

(380-415)

(440-460)

(550-575)

(51V)

AUXILIARY TRANSFORMER #1

TO POWER BD.

SUPPLY BOARD

BOARD

RECTIFIER

SOLID

STATE

RELAY

223

221

225

222

227

475

65432

J42

J11

J47

J72

741

743

154

153

500

800

840

J81

J82

LEFT SIDE OF MACHINE

TO3WJ7

DIGITAL POWER

FEED HEAD

9137

CONTROL BOARD

BOARD

GATEWAY

DEVICE NET

CB1

POWER WAVE 455 / R WIRING DIAGRAM (NORTH AMERICAN)

TO J9

TO TP3

TO TP6

202

J70

J47

.05/600V

202A

TO R1

TP1

WORK

FAN

CIRCUIT

BREAKER

444

CB3

612

612A

TO AUX#1

TO SOLID STATE RELAY

TO AUX #1

THIS AREA VIEWED FROM

CB4

H3A

H2A

TO FAN

(200-208)H2(220-230)

X3A

TO SOLID STATE RELAY

(24V)

(115V)

J60

CR1

CHOKE

THERMTO RECT

291

224A

CURRENT

TRANSDUCER

THERM

X3A

TO AUX#1

TP4

444

TO FAN

J47

346

477

476

478

J41

540

521

541

539

DEVICENET

CONNECTOR

P91

211

216

213

212

MAIN CHOKE

TO J8

TO J5

TOJ4J11

345

2733228

274

226

267

266

262

268A

765

J43

846

845

844

843

842

841

847

880

886

522

J84

J83

251

253

254

234

654

J71

J47

P73

CB1

J2VS

54E53

WIRE

J75

893

894

+24V

+24V GND

67A

FEEDER

RECEPTACLE

892

891

ROBOTIC/

WIREDRIVE

INTERFACE

CAN_H

CAN_L

DIAGRAMS

J87

J1,J6,J7

J10,J70,J85

NATIONAL ELECTRICAL CODE.

J4,J13,

J43,J71

J3,

J61,J86

(VIEWED FROM COMP ONENT SIDE OF BOARD)

J8,

J84

J47,J60

J14,J40J42,

J50,J75,J83

J1VS,J9,J10CH,

J82

3 4

J2,J5,J11,

J41,J46,J72

J73,J76,J81

CONNECTOR CAVITY NUMBERING SEQ UENCE

J10,J2VS

J74

AUXILIARY TRANSFORMER #2

RESISTORS=OHMS/WATTS

COMPONENT VALUES:

CAPACITORS=MFD/V OLTS

CB2

W=WHITE

U=BLUE

R=RED

N=BROWN

G=GREEN

B=BLACK

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537

RIGHT SI DE OF MACHINE

C10

20uF

400V

288E

289E

289D

288D

288C

288B

289C

289B

289F

2Ω

RESISTOR BANK

STT SNUBBER

288F

STT

L1A

L3A

TO CONTACTOR

(TOP)

LOAD LINE

612B

H1D

TO J61

TO CB3

SW1

POWER

WATER

352

LEFT)

TO D5

MAIN TRANSFORMER

19C

20C

287

345

J40

503

406

COOLER

RECEPTACLE

33A

AUX #2

TO C8

289A

J10

346

J50

238

405

WORK

TP3

TO RECONNECT SWITCH

289B

5054506

ELECTRODE

REAR OF MACHINE

FILTER

SWITCH

HARMONIC

RECONNECT

CR1

AUX #1

238

232

601

604

J60

INPUT BOARD

SWITCH

BD #2

PRI

RIGHT)

(BOTTOM

SEC

RIGHT)

(BOTTOM

.022

800V

2.7 10W

TO C10

TOJ4J43

268

268A

POS

262

EMITTER

POWER BD

RECTIFIER

IFACE

ROBOT

1112131415

J87

SSR

J10CH

404

403

604

56789

141112

STT

WORK

TP6

115V

RECEPTACLE

J85

851

852

853

854

855

856

857

858

12 PIN

CONNECTOR

859

231

765

TO J6, J10B

AUX. #1

D6TOJ11

J47

SELECT

BOARD

VOLTAGE SENSE

CB2

AUX 2

860

861

862

POS

INPUT

NEG

RECTIFIER

NEG

CR1

T1T2612

J61

506

505

5 4

504 503

3 2

518

514

BD #1

SWITCH

PRI

(TOP

RIGHT)

SEC

(TOP

RIGHT)

.022

800V

2.7 10W

TP7

NEG

POS

NEG

J73

SSR, J10 CHOPPER BD.

P90

P91

3R3R

212

213

813

211

456

151112

J85

67A

67B

511

512

216

ELECTRODE

WORK

206A

202A

50Ω

GND-A

GND-B

FRONT OF MACHINE

601

TO J61

TO J60

SW1

CB4

H1D

μF

500V

3500

19D

J50

20D

15 16

SWITCH BOA RD

L1A

TO SW1

TO SUPPLY LINES

H6A

(550-575)

H5A

H5H4H3

(440-460)

P52

350

TO A SYSTEM GROUND PER

AUX #1

CB3

H4A

H2A

H3A

H1A

(220-230)

(380-415)

(200-208)

(115V)

(230V)

352

33A

L3A

TO SW1

CR1

TO AUX #1

P50

SWITCH

RECONNECT

MAIN

TRANSFORMER

RIGHT SIDE

DIODE D5

STT SNUBBER

TO C10

288B

287

TO J46

POS

POWER BD RECT

STT CURRENT

μF

100V

2400

WORK

ELECTRODE

TO J1 VOLTAGE SENSE

816

811

216

202

206

812

DIODE

+40VDC

AUX 2

CB2

BREAKER

10A CIRCUIT

880

N.A.

TRANSDUCER

21A

621

J83

STATUS LED (R/G)

288A

414

418

J10A

886

AC AC

TO J7

TO C8

P90

812

TO J8

J40,J50

5141273

518

J10B

N.A.

NOTES:

813

811

816

J43

J88

274

154

153

J11

THERMAL LED (Y)

TO J7

TO J9

INPUT VOLTAGE. CONNECTION SH OWN IS FOR 550-575V

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

ALIGNS WITH BLACK L EAD OF LED SOCKET.

N.B. PLACE SWI TCH IN APPROPRIATE POSIT ION FOR INPUT

OPERATION.

N.C. PLACE "A" LEA D ON APPROPRIATE CONNEC TION FOR

OPERATION.

VOLTAGE. CONNECTION SH OWN IS FOR 440-575V

STT SNUBBER

CAPACITOR BANK

20uF

400V

TO D5

288C

289C

288A

289A

289E288E

289D

2Ω

288D

TO TP6

.05/600V

TP5

TO TP3

.05/600V

TP2

TO RECONNECT PANEL

206A

TO R1

206

ELECTRODE

200-208V

220-230V

440-460V

550-575V

TO SW1

N.C.

TO AUX #1

PANEL

RECONNECT

350

N.B.

19C

SWITCH BD #1

20C

SWITCH BD #1

FILTER

HARMONIC

REAR OF MACHINE

20D

19D

987

TO J6,J10B

MAIN

224

DC BUS

RECEPTACLE

TRANSFORMER

220

BOARD

851

224A

743

123

RECONNECT SW ITCH

LEFT SIDE

OUTPUT

RECT

220A

TO C3

853

852

267

741

841

FILTER

HARMONIC

SWITCH BD #2

406 405 404 403 418 414

SWITCH BD #2

μF

500V

6 5 4 3 2

3500

J40

SWITCH BOA RD

PRI

SEC

291

292

THERM

RECT

THERM

CHOKE

500251

NEG

POS

1503

J46

856

855

854

857

858

J85

228

226

266

268

227

J81

800

840

J72

J73

21A

2513

SENSE

VOLTAGE

RECEPTACLE

3 CONDUCTOR

TWISTED/SHIELDED

844

842

843

845

846

BD #2

SWITCH

(TOP

LEFT)

(TOP

LEFT)

J41

J82

CB1

54044755

4766

4777

J47

J1VS

511

512

862

861

860

859

131110

J42

J43

225

223

222

221

892

893

J74

253

254

RS232

J83

J84

J2VS

SHIELD GROUND TO CASE

847

539

541

67B

JKL

THERM

TO RECT

4788

220A

THERM

DC BUS

151216

RECT

THERM

THERMTOJ20

224

220

891

894

J75

251

CONNECTOR

521

522

NPRSTUV

BD #1

SWITCH

PRI

LEFT)

(BOTTOM

SEC

(BOTTOM

.022

800V

2.7 10W

292

COLLECTOR

CHOPPER

J86

504

231

232

56879

830

J76

BUSS BD

CB1

BREAKER

10A CIRCUIT

GND-A

F-2

G4010

POWER WAVE 455/R

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 code number..

Page 38

F-3

CONNECTOR PIN DEFINITIONS

F-3

TABLE 1 INTERFACE CONNECTOR S6

Pin Lead # Function

A 841 +15vdc Tach v oltage B 844 Tach common C 842 Tach 1A differential signal D 843 Tach 1B differential signal E 845 Tach 2A differential signal F 846 Tach 2B differential signal G 847 Single Tach Input H Reserved for future use I 67B Voltage sense lead J 539 Motor "+" K 541 Motor "-" L Reserved for future use M Reserved for future use N 521 +40vdc for solenoid P 522 Solenoid input R Reserved for future use S Reserved for future use T 855A Shield ground to case U Reserved for future use V Reserved for future use W Reserved for future use X Reserved for future use

TABLE 2 WIRE FEEDER RECEPTACLE S1

Pin Lead # Function

A 53 Arclink L B 54 Arclink H C 67A Electrode V oltage Sense D 52 Ground(0v) E 51 +40vdc

TABLE 3 VOLTAGE SENSE RECEPTACLE S2

TABLE 4 RS232 CONNECTOR S3

Pin Lead # Function

2 253 RS232 Receive 3 254 RS232 Transmit 4 # S3 Pin5 5 # S3 Pin4 6 ## S3 Pin20 20 ## S3 Pin6 7 251 RS232 Common

TABLE 5 DEVICENET CONNECTOR S5

Pin Lead # Function

2 894 +24vdc Devicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L

TABLE 6 EXTERNAL I/O S7

Pin Lead # Function

1 851 +15vdc for Trigger group 2 852 Trigger input 3 853 Dual procedure input 4 854 4 Step input 5 855 +15vdc for cold inch group 6 856 cold inch forward 7 857 cold inch reverse 8 858 gas purge input 9 859 +15vdc for shutdown group 10 860 shutdown1 input 11 861 shutdown2 input 12 862 input B

Pin Lead # Function

3 21A Work Voltage Sense

POWER WAVE 455/R

Page 39

F-4

- +

WORK SENSE LEAD K940

WATERCOOLED TORCH

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLER POWER CONNECTION

SHIELDING GA S

TO SHIELDING GAS DEVICENET CA BLE

TO PLC/CONTROLLER

CONNECTION DIAGRAM

Hard Automation, Electrode Positive, STT Configuration

DEVICENET CABLE TO PLC/CONTROLLER

CONTROL CABLE K1795

F-4

ELECTRODE LEAD

WATER LINES

WATER COOLER POWER CONNECTION

POWER WAVE 455/R

Page 40

F-5

K1796 COAXIAL WELD CABLE

User supplied work lead

User supplied electrode lead

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE

User supplied work lead

User s uppl ied elect rod e lea d

CONTROL CABLE K1805- 1

CONNECTION DIAGRAM

Robotic Set Up, Electrode Positive, CV/Pulse Configuration

F-5

POWER WAVE 455/R

Page 41

F-6

DIAGRAMS

32.88

11-14-97

M18241

F-6

DIMENSION PRINT - POWER WAVE 455

19.90

19.16

9.48 14.62

22.63

26.10

23.51

23.12

12.35

19.00

POWER WAVE 455/R

Page 42

NOTES

POWER WAVE 455/R

Page 43

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 44

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 45

• 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

Lincoln Power Wave 455, Power Wave 455R Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual