Lincoln Electric IM762-C User Manual

IM762-C

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POWER WAVE 455 M

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.

™

10942, 11057, 11152, 11311

October, 2006

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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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.d. Keep

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 case s it m ay be neces sary to remove 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.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel 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.

all equipment safety guards, covers and devices in

1.f. Do not put your hands near the engine fan.

not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

near an open flame

safety

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. EM F 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

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.

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.

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.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

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.

vapors

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

5.d. 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.e. 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.f. Also see item 1.b.

AUG 06

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. Us e 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

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.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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_________________________________________________________________________

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.

TABLE OF CONTENTS

Page

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

Technical Specifications - POWER WAVE 455M .................................................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-5

Welding with Multiple Power Waves......................................................................A-6

Control Cable Specifications..................................................................................A-6

Multiple Arc Unsynchronized .................................................................................A-7

I / O Receptacle Specifications..............................................................................A-8

Dip Switch Settings and Locations.................................................................A-8

Control Board Dip Switch ................................................................................A-8

Water Flow Sensor..........................................................................................A-8

________________________________________________________________________

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

Safety Precautions.................................................................................................B-1

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

Definition of Welding Terms...................................................................................B-3

General Description...............................................................................................B-4

Recommended Processes and Equipment ...........................................................B-4

Required Equipment..............................................................................................B-4

Limitations..............................................................................................................B-4

Duty Cycle and Time Period..................................................................................B-4

Case Front Controls ........................................................................................B-5

Nominal Procedures........................................................................................B-6

Fringe Procedures...........................................................................................B-6

Making a Weld ................................................................................................B-6

Welding Adjustment ........................................................................................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

Compatible Lincoln Equipment .......................................................................C-1

________________________________________________________________________

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

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

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Calibration Specification........................................................................................D-1

________________________________________________________________________

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

Error Codes For Power Waves..............................................................................E-3

Troubleshooting Guide.............................................................................E-4 thru E-6

________________________________________________________________________

Wiring Diagram ............................................................................................Section F-1

Connection Diagrams ..................................................................................Section F-2

Dimension Print............................................................................................Section F-3

________________________________________________________________________

Parts Lists ....................................................................................................P438 Series

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vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS-

FREQUENCY

OUTPUT

CONDITIONS

AMPS / VOLTS / DUTY CYCLE

INPUT

CURRENT

AMPS

IDLE

POWER

POWER FACTOR

@ RATED OUTPUT

EFFICIENCY

@ RATED

OUTPUT

A-1

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

CURRENT

RANGE

AMPS

5 - 570A

PULSE

FREQUENCY

0.15 - 1000 Hz

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

15* AMPS

PROCESS CURRENT RANGE (DC) CURRENT

MIG/MAG

FCAW

SMAW

GTAW

Pulse

50-570 Average Amps 40-570 Average Amps 30-570 Average Amps 15-500 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

* Earlier models used 10 amps circuit breaker.

6(16) 6(16) 10(6) 10(6)

POWER WAVE 455M

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

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.

A-2

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.

• 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.

Do not mount the Power Wave 455M 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 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)

POWER WAVE 455M

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. 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.

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 / L 2

U / L1

200-208V

220-230V

440-460V

550-575V

CR1

= 440-460V

VOLTAGE

VOLTAGEVOLTAGE

'A'

200-208V

220-230V

440-460V

550-575V

= 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.

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

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.

“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 connection to a different input voltage, see the diagram

Minimum work and electrode cable sizes are as follows:

TABLE A.1

(Current (60% Duty Cycle)

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m) 400 Amps 2/0 (67 mm2) 500 Amps 3/0 (85 mm2) 600 Amps 3/0 (85 mm2)

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.

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 or fuses 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. For machines equipped with a fuse in the reconnect area, turn off the input voltage and replace the fuse with the spare fuse that is attached to the reconnect switch pin.

When using inverter type power sources like the Power Waves, use the largest welding (electrode and work) cables that are practical. At least 2/0 (67 mm2) 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.

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CAUTION

POWER WAVE 455M

S25198

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 tional welding cables may be used without any effects on welding performance. For the total welding loop length greater than

50 ft.(15.24m)), 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.3).

FIGURE A.3

POWER WAVE

50 ft.(15.24m), tradi-

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.

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NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as in some Innershield applications, switch the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).

WORK

For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less than

K1796 COAXIAL CABLE

50 ft.(15.24m). (See Figure A.4.)

FIGURE A.4

POWER WAVE

MEASURE FROM END OF OUTER JACKET OF CABLE

FIGURE A.4

SLIDING

WORK

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

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 apparent voltage 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 (K940-10, -25 or -50) 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.

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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 455M. 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-455M by default.

POWER WAVE 455M

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

* The electrode voltage 67 sense lead is integral to

the control cable to the wire feeder.

Work Voltage Sensing

The standard Power Wave 455M’s default to the work stud (work sense lead disabled)

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:

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

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.

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present.

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.

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POWER WAVE TO SEMI-AUTOMATIC POWER FEED WIRE FEEDER INTERCONNECTIONS

The Power Wave 455M 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 455M 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.

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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 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.

12 3456 78

POWER WAVE 455M

Due to the flexibility of the platform the configuration may vary. The following is a general description of the system.

SYSTEM DESCRIPTION

The Power Wave 455M and Power Feed M family of products utilize a digital communication system called ArcLink. Simply put, ArcLink allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communication, and because of its bus-like structure, the components may be connected to the network in any order, thus simplifying the system setup.

Each "system" must contain only one power source. The number of wire feeders is determined by the type of wire feeder. Refer to the wire feeder instruction manual for details

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