Lincoln Electric IM714 User Manual
IM714
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.
10833
™
February, 2005
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
IEC 60974-1
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
• 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.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.
POWER WAVE 455
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.
vapors
Mar ‘95
to
POWER WAVE 455
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
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.
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
zones où l’on pique le laitier.
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
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
vv
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 455 ....................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Lifting...............................................................................................................A-2
Stacking ..........................................................................................................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 Change Over Procedure..................................................................A-3
Electrode and Work Cable Connections................................................................A-3
Cable Inductance, and its Effects on Pulse Welding ............................................A-4
Negative Electrode Polarity ...................................................................................A-4
Voltage Sensing ................................................................................................... A-4
Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-5
System Description................................................................................................A-6
System Set-Up.........................................................................................A-7 thru A-9
Welding with Multiple Power Waves....................................................................A-10
Control Cable Specifications................................................................................A-10
I / O Receptacle Specifications............................................................................A-11
Dip Switch Settings and Locations...............................................................A-11
Control Board Dip Switch ..............................................................................A-11
Power Wave Water cooler (Field Installed) .........................................................A-11
Water Flow Sensor ..............................................................................................A-11
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................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
Nominal Procedures........................................................................................B-5
Fringe Procedures...........................................................................................B-5
Making a Weld ................................................................................................B-5
Welding Adjustment ........................................................................................B-5
Welding Mode .................................................................................................B-6
Arc Control ......................................................................................................B-6
Constant Voltage Welding...............................................................................B-7
Pulse Welding .................................................................................................B-8
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Equipment...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
Calibration Specification........................................................................................D-1
________________________________________________________________________
vi
vii
TABLE OF CONTENTS
Page
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-7
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagrams ..................................................................................Section F-2
Dimension Print............................................................................................Section F-3
________________________________________________________________________
Parts Lists ....................................................................................................P394 Series
________________________________________________________________________
vii
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455 (K1517-6)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
OUTPUT
CONDITIONS
INPUT
CURRENT
AMPS
IDLE
POWER
POWER FACTOR
@ RATED OUPUT
A-1
EFFICIENCY
@ RATED
OUPUT
208/230/460/575V - 60HZ.
200/220/440/575V - 50HZ.
450A@38V.100%
570A@43V. 60%
400A@36V.100%
500A@40V. 60%
58/53/25/22
82/78/37/31
49/45/23/18
67/61/31/25
400 Watts
Max.
.95 MIN.
OUTPUT
OPEN
CIRCUIT
VOLTAGE
75 VDC
PROCESS CURRENT RANGES (DC)
CURRENT
RANGE
Amps
5 - 570
PULSE
FREQUENCY
0.15 - 1000 Hz
MIG/MAG
FCAW
SMAW
Pulse
PULSE
VOLTAGE
RANGE
5 - 55 VDC
PULSE AND
BACKGROUND
TIME RANGE
100 MICRO SEC. -
3.3 SEC.
AUXILIARY POWER
(CIRCUIT BREAKER PROTECTED)
40 VDC AT
10 AMPS
115VAC AT
10 AMPS
CURRENT
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG[IEC]
SIZES (MM2)
GROUND WIRE IN CON-
TYPE 75°C
DUIT AWG[IEC] SIZES
(MM2)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
88%
208/50/60HZ
230/50/60HZ
460/50/60HZ
575/50/60HZ
4(25)
4(25)
8(10)
10(6)
PHYSICAL DIMENSIONS
HEIGHT
26.10 in
663 mm
WIDTH
19.86 in
505 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
6(16)
6(16)
10(6)
10(6)
POWER WAVE 455
110
100
50
40
DEPTH
32.88 in
835 mm
STORAGE TEMPERATURE RANGE
-40°C to +40°C
WEIGHT
286 lbs.
130 kg.
A-2
SAFETY PRECAUTIONS
INSTALLATION
LIFTING
A-2
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.
----------------------------------------------------------
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.
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.
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
Do not mount the Power Wave 455 over combustible
surfaces. Where there is a combustible surface directly
under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060"
(1.6mm) thick, which shall extend not less than 5.90"
(150mm) beyond the equipment on all sides.
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)
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
on the following page.
POWER WAVE 455
A-3
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
A-3
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
440-460V
550-575V
'A'
W / L 3
V / L2
U / L1
200-208V
220-230V
440-460V
550-575V
CR1
= 440-460V
VOLTAGE
VOLTAGEVOLTAGE
'A'
=
200-208V
200-208V
220-230V
440-460V
550-575V
= 550-575V
200-208V
220-230V
440-460V
550-575V
'A'
'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.
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 CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this con-
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 and wire feeder. Avoid
excessive lengths and do not coil excess cable.
Minimum work and electrode cables sizes are as follows:
TABLE A.1
(Current (60% Duty Cycle)
400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To-100 Ft. Length (30 m)
nection 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.
NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long cable lengths.
This is especially important when Pulse welding up to
350 amps.
S25198
XA
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.
POWER WAVE 455
CAUTION
When using inverter type power sources 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. 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.
------------------------------------------------------------------------
A-4
INSTALLATION
CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING
For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 feet, traditional
welding cables may be used without any effects on
welding performance. For the total welding loop length
greater than 50 feet, the K1796 Coaxial Welding
Cables are recommended. The welding loop length is
defined as the total of electrode cable length (A) +
work cable length (B) + work length (C) (See Figure
A.2).
FIGURE A.2
POWER
WAVE
A
C
A-4
For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the
Instruction Manuals.
CAUTION
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
------------------------------------------------------------------------
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).
WORK
B
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length
less than 50 feet. (See Figure A.3.)
POWER
WAVE
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
FIGURE A.3
A
WORK
C
B
SLIDING GROUND
A
B
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.
Most welding applications run with the electrode being
positive (+). For those applications, connect the electrode cable between the wire feeder and 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. 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.
When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed instruction
manual for further details.
VOLTAGE SENSING
C
The best arc performance occurs when the
PowerWaves 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.
Sense Lead Kits (K940 series) are available for this
purpose.
CAUTION
If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.
------------------------------------------------------------------------
The ELECTRODE sense lead (67) is built into the control cable, and is automatically enabled for all semiautomatic processes. The WORK sense lead (21) connects to the Power Wave at the four pin connector
located underneath the output stud cover. By default
the WORK voltage is monitored at the output stud in
the Power Wave 455. For more information on the
WORK sense lead (21), see"Work Voltage Sensing”
in the following paragraph.
All constant current processes sense the voltage at the
output studs of the POWER WAVE-455 by default.
POWER WAVE 455
A-5
INSTALLATION
A-5
Enable the voltage sense leads as follows:
TABLE A.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
GTAW
GMAW
SAW 67 lead required 21 lead optional
CAC-C
* The electrode voltage 67 sense lead is integral to
the control cable to the wire feeder.
In extremely sensitive applications requiring voltage
sense leads, it may be necessary to route the control
cable (67 lead) and the work voltage sense lead (21
lead) away from the electrode and work welding
cables. For more information regarding the placement
of voltage sense leads, see the section entitled
"Welding with Multiple Power Waves."
Work Voltage Sensing
The standard Power Wave 455’s default to the work
stud (work sense lead disabled)
67 lead required 21 lead optional
Voltage sense at studs Voltage sense at studs
Voltage sense at studs Voltage sense at studs
Voltage sense at studs Voltage sense at studs
4. Using a pencil or other small object, slide the switch
DOWN to the OFF position if the work sense lead is
NOT connected . Conversely, slide the switch UP to
the ON position if the work sense lead is present.
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 is internal to the control cable to
the wire feeder and always connected when a wire
feeder is present.
CAUTION
Important: The electrode polarity must be configured at the feed head for all semi-automatic
processes. Failure to do so may result in extremely high welding outputs.
------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMATIC POWER FEED WIRE FEEDER
INTERCONNECTIONS
For processes requiring work voltage sensing, connect the (21) work voltage sense lead (K940) from the
Power Wave work sense lead receptacle to the work
piece. Attach the sense lead to the work piece as
close to the weld as practical, but not in the return current path. Enable the work voltage sensing in the
Power Wave as follows:
WARNING
• 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.
The Power Wave 455 and semi-automatic POWER
FEED family communicate via a 5 conductor control
cable (K1543). The control cable consists of two
power leads, one twisted pair for digital communication, and one lead for voltage sensing. The cables are
designed to be connected end to end for ease of
extension. The output receptacle on the Power Wave
455 is located beneath the spring loaded output cover
at the bottom of the case front. The input receptacle
on the Power Feed is typically located at the back of
the feeder, or on the bottom of the user interface.
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.
Due to the flexibility of the platform the configuration
may vary. The following is a general description of the
system. For specific configuration information, consult
the semi-automatic Power Feed instruction manual.
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.
123456 78
O
N
POWER WAVE 455
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