Lincoln Electric IM924 User Manual
IM924
RETURN TO MAIN MENU
POWER WAVE 455M/STT
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.
11376
™
January, 2007
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
IEC 60974-1
NRTL/C
OPERATOR’S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
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
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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.
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.
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.
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.
vapors
to
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 and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
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.
the welding sparks from starting a fire.
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.
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan, 07
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
v
SAFETY
v
vi
SAFETY
vi
Thank You
viivii
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!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that
time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or
advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect
to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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.
viii
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 455M/STT .........................................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
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
Configuring the System...................................................................................................A-6
Alternate Hard Automatic Application ....................................................................A-7
Combination Hard Automation Application ............................................................A-7
Dual Head Boom Feeder.......................................................................................A-7
Welding with Multiple Power Waves......................................................................A-8
Control Cable Specifications .................................................................................A-8
Multiple Arc Unsynchronized .................................................................................A-9
I / O Receptacle Specifications ...........................................................................A-10
Dip Switch Settings and Locations ..............................................................A-10
Control Board Dip Switch..............................................................................A-10
Water Flow Sensor........................................................................................A-10
________________________________________________________________________
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
STT Welding ...................................................................................................B-9
________________________________________________________________________
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
________________________________________________________________________
viii
ix
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-7
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagrams...........................................................................Section F-2, F-3
Dimension Print............................................................................................Section F-4
________________________________________________________________________
Parts Lists...................................................................................................P-548 Series
________________________________________________________________________
ix
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-4)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT
VOLTS
OUTPUT CONDITIONS
AMPS / VOLTS / DUTY CYCLE
EXCEPT STT PROCESS
INPUT
CURRENT
AMPS
OUTPUT CONDITIONS
AMPS / VOLTS / DUTY CYCLE
EXCEPT STT PROCESS
INPUT
CURRENT
AMPS
A-1
380V - 60Hz.
380V - 50Hz.
415V - 60Hz.
415V - 50Hz.
OPEN
CIRCUIT
VOLTAGE
75 VDC
PROCESS CURRENT RANGE (DC) CURRENT AMPS
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
STT PROCESS ALL VOLTAGES
325A@33V. 100%
CURRENT
RANGE
AMPS
5 - 570 A
PULSE
FREQUENCY
0.15 - 1000 Hz
MIG/MAG
FCAW
SMAW
Pulse
STT
VOLTAGE
5 - 55 VDC
PULSE
RANGE
36 A
36 A
33 A
33 A
OUTPUT
PULSE AND
BACKGROUND
TIME RANGE
100 MICRO SEC.
3.3 SEC.
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
STT PROCESS ALL VOLTAGES
325A@33V. 100%
STT PARAMETERS
PEAK & BACK-
GROUND CURRENT
15-450 AMPS
-
50-500 A
40-500 A
30-500 A
5-750 A
40-325 A
48 A
48 A
44 A
44 A
AUXILIARY
POWER
40 VDC AT
10 AMPS
220 VAC AT
5 AMPS
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE /
FREQUENCY
380V Hz.
415V Hz.
HEIGHT
663 mm
(26.10 in)
OPERATING TEMPERATURE RANGE
DUTY
CYCLE
100%
100%
-20°C to 40°C
INPUT AMPERE
RATING ON
NAMEPLATE
36 A
33 A
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG[IEC] SIZES
(mm
8 (10)
8 (10)
PHYSICAL DIMENSIONS
WIDTH
505 mm
(19.86 in)
(32.88 in)
TEMPERATURE RANGES
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG[IEC] SIZES
2
)
DEPTH
835 mm
STORAGE TEMPERATURE RANGE
-40°C to 40°C
(mm
10 (6)
10 (6)
2
)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
40 A
40 A
WEIGHT
121 kg.
(267 lbs.)
POWER WAVE 455M/STT (CE)
A-2
INSTALLATION
SAFETY PRECAUTIONS Read this
entire installation section before you start installation.
WARNING
ELECTRIC SHOCK can kill.
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
• 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 455M/STT (CE)
grounding lug (located inside the reconnect input
access door) to a proper safety (Earth) ground.
----------------------------------------------------------
SELECT SUITABLE LOCATION
Do not use Power Wave 455M/STT (CE) in outdoor
environments. The Power Wave 455M/STT (CE) 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/STT (CE) 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 1.6mm (.060") thick, which shall extend
not less than 150mm (5.90") 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/STT (CE)
Power Wave machines can be stacked to a maximum
of 3 high.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trailer or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
Do not stack the Power Wave 455M/STT (CE) on
top of any other machine.
------------------------------------------------------------------------
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.
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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.
A-3
W / L3
V / L2
U / L1
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
XA
S24190
use or service this equipment.
Do not touch electrically live parts.
removed.
Only qualified persons should install,
Do not operate with covers
inspecting or servicing machine.
Disconnect input power before
.
.
.
.
CR1
INPUT SUPPLY CONNECTION DIAGRAM
INSTALLATION
A-3
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
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 CONNECTION
WARNING
Only a qualified electrician should connect the
input leads to the Power Wave 455M/STT (CE).
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 45 mm (1.75 inch)
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.
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.
POWER WAVE 455M/STT (CE)
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) MINIMUM COPPER
WORK CABLE SIZE AWG
Up To-30 m Length (100 Ft.)
400 Amps 67 mm
2
(2/0)
500 Amps 85 mm2(3/0)
600 Amps 85 mm2(3/0)
NOTE: K1796 coaxial welding cable is recommended to
reduce the cable inductance in long cable lengths. This is
especially important in Pulse and STT applications.
CAUTION
When using inverter type power sources like the
Power Waves, use the largest welding (electrode and
ground) cables that are practical. At least 67 mm
(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.
------------------------------------------------------------------------
2
A-4
B
A
C
FIGURE A.3
POWER
WAVE
WORK
A
C
B
POWER
WAVE
FIGURE A.4
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
C
A
B
WORK
SLIDING WORK CONNECTION
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
may be used without any effects on welding performance. For
the total welding loop length greater than
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).
For long work piece lengths, a sliding work connection should
be considered to keep the total welding loop length less than
50 feet. (See Figure A.4.)
15.24m (50 ft.), traditional welding cables
15.24m (50 ft.), the
FIGURE A.4
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).
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 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 (K940-10, -25 or
-50) are available for this purpose.
Output connections on some Power Waves are made via 1/213 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 welding with the STT process, use the positive output
connection labeled “STT” for STT welding. (If desired ,other
welding modes can be used on this stud; however, the average output current will be limited to 325 amps.) For non-STT
processes, use the positive output connection labeled “Power
Wave”, so that the full output range of the machine is available.
Do Not connect the STT and Power Wave stud together.
Paralleling the connection will bypass the STT circuitry and
severely deteriorate STT welding performance.
POWER WAVE 455M/STT (CE)
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 semi-automatic
processes. The WORK sense lead (21) connects to the
Power Wave 455M/STT (CE) 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/STT (CE). For more information on the WORK sense
lead (21), see "Work V oltage Sensing” in the following paragraph.
All constant current processes sense the voltage at the output studs of the POWER WAVE 455M/STT (CE) by default.
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