Lincoln Electric IM583 User Manual
IM583-A
R
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POWER WAVE 455
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.
™
10372, 10553, 10555
December, 1999
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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.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.
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.
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
ii
SAFETY
ii
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.
Mar ‘95
vapors
to
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
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales 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
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.
vv
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.
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - Power Wave 455..........................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Stacking ..........................................................................................................A-2
Environmental Protection ................................................................................A-2
Lifting...............................................................................................................A-2
Machine Grounding ...............................................................................................A-2
High Frequency Protection ....................................................................................A-2
Input Connection....................................................................................................A-2
Input Fuse and Supply Wire Considerations .........................................................A-3
Input Voltage Reconnect Procedure......................................................................A-3
Output Connections...............................................................................................A-3
Voltage Sensing at the Work Piece .......................................................................A-4
Power Wave / Power Feed Wire Feeder Interconnections....................................A-4
Electrode and Work Leads - Electrode Positive Applications .........................A-4
Electrode and Work Leads - Electrode Negative Applications........................A-4
Control Cable Connections .............................................................................A-4
Power Feed Control Box Mounting .................................................................A-4
Operation .........................................................................................................Section B
Safety Instructions .................................................................................................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
Design Features and Advantages .........................................................................B-3
Additional Features................................................................................................B-3
Welding Capability.................................................................................................B-4
Limitations..............................................................................................................B-4
Compatible Lincoln Equipment..............................................................................B-4
Power Source Operation .......................................................................................B-4
Duty Cycle and Time Period ...........................................................................B-4
Case Front Controls ........................................................................................B-4
Welding Adjustments ......................................................................................B-5
Detailed Weld Mode Descriptions ...................................................................B-5
vi
Accessories.....................................................................................................Section C
Options / Accessories............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Troubleshooting..............................................................................................Section E
Troubleshooting the Power Wave / Power Feed System using the Status LED ...E-1
Safety Precautions.................................................................................................E-2
How to Use Troubleshooting Guide.......................................................................E-2
Troubleshooting Guide ..........................................................................................E-3
Wiring Diagram and Dimension Print............................................................Section F
Parts Lists ....................................................................................................P291 Series
Nov97
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
OUTPUT
CONDITIONS
INPUT
CURRENT
OUTPUT
CONDITIONS
A-1
INPUT
CURRENT
208V - 60HZ.
230V - 60HZ.
400V - 60HZ.
460V - 60HZ.
575V - 60HZ.
200V - 50HZ.
220V - 50HZ.
400V - 50HZ.
440V - 50HZ.
550V - 50HZ.
OPEN
CIRCUIT
VOLTAGE
75 VDC
PROCESS CURRENT RANGES (DC)
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
CURRENT
RANGE
5 - 570
MIG/MAG
FCAW
SMAW
Pulse
PULSE
FREQUENCY
0.15 - 1000 Hz
70
65
39
35
29
72
67
40
36
29
OUTPUT
PULSE
VOLTAGE
RANGE
5 - 55 VDC
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
PULSE AND
BACKGROUND
TIME RANGE
100 MICRO SEC. -
3.3 SEC.
CURRENT
50-570 Amps
40-570 Amps
30-570 Amps
5-750 Amps
87
82
50
48
38
79
74
45
41
33
AUXILIARY
POWER
40 VDC AT
10 AMPS
115 VAC AT
10 AMPS
INPUT
VOLTAGE /
FREQUENCY
208/60
230/60
400/60
460/60
575/60
200/50
220/50
400/50
440/50
550/50
HEIGHT
26.10 in
663 mm
RECOMMENDED INPUT WIRE AND FUSE SIZES
OUTPUT AMPS/
DUTY
CYCLE
450/100%
450/100%
450/100%
450/100%
450/100%
400/100%
400/100%
400/100%
400/100%
400/100%
INPUT AMPERE
RATING ON
NAMEPLATE
70
65
39
35
29
72
67
35
31
29
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG[IEC] SIZES
(MM2)
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
PHYSICAL DIMENSIONS
WIDTH
19.86 in
505 mm
DEPTH
32.88 in
835 mm
TEMPERATURE RANGES
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG[IEC] SIZES
(MM2)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
80 AMP
70 AMP
50 AMP
40 AMP
40 AMP
80 AMP
80 AMP
50 AMP
40 AMP
40 AMP
WEIGHT
250 lbs.
114 kg.
OPERATING TEMPERATURE RANGE
0°C to 40°C
POWER WAVE 455
STORAGE TEMPERATURE RANGE
-50°C to 85°C
A-2
Read this entire installation section before you
start installation.
INSTALLATION
SAFETY PRECAUTIONS
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.
• 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-2
ENVIRONMENTAL PROTECTION
The Power Wave power source is rated IP21S and
should not be subjected to falling water, nor should
any parts of it be submerged in water. Doing so may
cause improper operation as well as pose a safety
hazard. The best practice is to keep the machine in a
dry, sheltered area.
LIFTING
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.
MACHINE GROUNDING
-------------------------------------------------------------
SELECT SUITABLE LOCATION
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. Using filters on the air intake to
prevent dirt from building up restricts air flow. Do
not use such filters. Failure to observe these precautions can result in excessive operating temperatures
and nuisance shutdowns.
This machine (above code 10500 only) is 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.
STACKING
Power Wave machines can be stacked to a maximum
of 3 high. The bottom machine must always be
placed on a firm, secure, level surface. There is a
danger of machines toppling over if this precaution is
not taken.
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
If possible, locate the Power Wave away from radio
controlled machinery. 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.
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
following.
POWER WAVE 455
A-3
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
VOLTAGE=220-230V
220-230V
200-208V
220-230V
380-415V
440-460V
200-208V
U / L1
440-460V
380-415V
.
inspecting or servicing machine.
Do not operate with covers
.
removed.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
.
’A’
’A’
VOLTAGE=380-415V
’A’
S23847
VOLTAGE=200-208V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
A
’A’
VOLTAGE=440-460V
CR1
W / L3
V / L2
380-415V
440-460V
Disconnect input power before
INPUT SUPPLY CONNECTION DIAGRAM
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
.
Disconnect input power before
inspecting or servicing machine.
.
Do not operate with covers
removed.
.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=440-460V VOLTAGE=550-575V
W / L3
V / L2
U / L1
A-3
CR1
S24196
NOTE: Turn main input power to the machine OFF before performing reconnect procedure. Failure to do
so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON.
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-
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.
INPUT VOLTAGE RECONNECT
PROCEDURE
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.
------------------------------------------------------------------------
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this connection to a different input voltage, refer to reconnect
WARNING
POWER WAVE 455
instructions located on the inside of the input access
door or in Figure A.1. If the main reconnect switch is
placed in the wrong position, the welder will not produce output power. 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 voltage, 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.
OUTPUT CONNECTIONS
Use the largest welding (electrode and ground) cables
possible — at least 2/0, 4/0 preferred, copper wire —
even if the average output current would not normally
require it. When pulsing, the pulse current can
exceeds 650 amps. Voltage drops can become
excessive, leading to poor welding characteristics, if
undersized welding cables are used.
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, bundle the electrode and ground
cables together where practical, and do not coil
excess cable.
440-460V
550-575V
’A’ ’A’
440-460V
550-575V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
A
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