Lincoln Electric Power Wave 455M Robotic, 455M-STT, POWER WAVE 455 M User Manual
Description
Output Input
MIG Pulsed STT Flux-Cored
Power Wave® 455M Robotic &
Power Wave
®
455M/STT Robotic
The Next Generation . . .
AUTOMATED SOLUTIONS
The Power Wave 455M Robotic is a high performance, digitally controlled inverter power
source designed for robotic, hard automation and semiautomatic applications. It is designed
to be part of a modular, multi-process welding system that can be arranged in a variety of
ways for optimum, customized performance and easy maintenance. Optional DeviceNet™
and Ethernet communication modules provide networking capabilities and allow the
power sources to communicate with other industrial machines to create a highly integrated
and flexible welding cell. Available as a standard model or with Lincoln’s STT® process
for applications in which heat input control, minimal distortion, reduced spatter and low
fumes are essential.
Publication E10.90 4/03
www.lincolnelectric.com
Processes
Advantage Lincoln
Recommended Wire Feeder
Order
TECHNICAL SPECIFICATIONS
Recommended General Options
• Program your own waveform or choose from over 60 standard
welding waveform programs that offer a broad range of electrode
size, type and shielding gas combinations to give you optimal
appearance, penetration, beadshape and travel speed for each
application.
• Modular design enables robotic, hard automation and semiautomatic applications using a single machine platform.
• Optional communication modules provide networking capabilities
via DeviceNet or Ethernet.
• Utilizes ArcLink™ - the leading digital communication protocol
for welding, making it the best choice for seamless, time critical
integration to the power source and networked equipment.
• Software based controls can be upgraded as new features
become available.
• Process and production monitoring with access to real time
(500Hz) feedback such as arc current, voltage and wire feed
speed. Access to internal data acquisition (10KHz) and access
to real time machine status such as fault/alarm conditions and
arc time.
• A Power Wave inverter operates at a high efficiency (88-90%)
with a 95% minimum power factor
(
1)
and is capable of operat-
ing from a universal input voltage (208 to 575 volts).
• Power Wave 455M/STT features Lincoln’s Surface Tension
Transfer® Process, which controls heat input for great penetration and reduced spatter and fumes.
Power Feed 10R
DeviceNet Interface Module, Ethernet Interface Module, Analog
Interface Module, Wave Designer™ Software, Dual Cylinder
Platform Undercarriage, CoolArc® 40 Water Cooler
K2262-1 Power Wave 455M Robotic
K2263-1 Power Wave 455M/STT Robotic
Call the Lincoln Electric Automation Division at 216.383.2667 for
more information.
Product Product Input Rated Output Input current Output Dimensions Net
Name Number Voltage Current/Voltage/Duty Cycle @Rated Output Range H x W x D Weight
in. (mm) lbs. (kg)
Power Wave 455M Robotic K2262-1 208/230/460/575/3/50/60 60Hz: 60Hz: 5-570A 26.1 x 19.9 x 32.9 286
450A/38V/100% 58/53/25/22A (663 x 505 x 835) (130)
(570A/43V/60%) (82/78/37/31A)
Power Wave 455M/STT Robotic K2263-1 50Hz: 50Hz: 293
400A/36V/100% 49/45/23/18A (133)
(500A/40V/60%) (67/61/31/25A)
(1) At rated output.
CV
CC
3
PHASE
60
50
Hz
DC
Robot Teach Pendant
• Select from over 60 standard welding procedures in the power
source library from the robot’s Teach Pendant.
• Search by process and wire type.
• Full access to all power source details, including: control loop
gains, machine calibration, arc statistics, unfiltered feedback signals.
• Access to power source diagnostic such as fault/alarm
status/details.
• ArcLink is a leading digital communications protocol for sharing
information between intelligent components in an arc welding system.
• Individual status light for each system component.
Nextweld
Lincoln's Power Wave power sources are equipped with Nextweld
innovations that offer seamless system integration, high efficiency
and reliability, and outstanding arc control. Here are just a few of
Nextweld's technologies and processes that are standard with this
machine.
• Waveform Control Technology™ controls and shapes the output
waveform. Optimizes metal transfer to reduce spatter and improve
stability. Simplifies process selection and controls heat input.
• Surface Tension Transfer (STT)
(1)
is a Waveform Control process
that uses current controls to adjust the heat independent of wire
feed speed, provides low heat input without overheating or burning through. Distortion, spatter and smoke are reduced.
• The Power Wave 455 features Ethernet and DeviceNet compatibility, as well as ArcLink, the leading communication protocol for
welding and the best choice for seamless, time critical integration
to the power source and networked equipment.
• State-of-the-Art Inverter technology provides high power efficiency,
excellent welding performance and a lightweight, compact design.
Rigorous environmental, mechanical and weld testing ensures
ruggedness and reliability.
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
www.lincolnelectric.com
[2]
A CLOSER LOOK
PERFORMANCE
• The Power Waves contains a large library of welding programs or
“weld modes.” Each weld mode is a specific software program that
defines the output characteristics of the power source for simple
processes like Stick and TIG to more complex processes like
Synergic MIG (GMAW) and Pulsed MIG (GMAW-P). Weld modes
were developed to handle a broad range of applications. They
may be tuned to a specific electrode type, electrode diameter,
gas type or application.
• All Power Waves share a common digital control platform to
maximize interoperability, interchangeability and compatible
software tools.
• Power Wave Robotic Welding Systems feature weld mode selection,
PRE-FLOW, RUN-IN, ARC CONTROL, BURNBACK, POST-FLOW
and CRATER that provide the operators full control over the
welding procedure and sequence.
• Synergic welding eliminates the need to independently set the wire
feed speed and voltage. Synergic welding automatically sets both
voltage and pulse characteristics based on the wire feed speed.
FEATURES
• When connected to Fanuc robot, welding software is accessible via
the Robot’s teach pendant or a computer via the RS232 serial port.
• Welding software is upgradable via the RS232 serial port or via a
network using the optional Ethernet module.
• Add, customize or replace Lincoln updated welding waveforms for
every application using a laptop and Lincoln’s Wave Designer
Software.
• Simple, reliable input voltage changeover.
• Auto device recognition simplifies accessory cable connections.
• Individual status light for each system component.
• DeviceNet or Ethernet modules can be field installed.
Nextweld incorporates Lincoln's technologies,
processes and products to create a technologically
advanced arc welding platform. Waveform Control
Technology™, power electronics and digital communications provide the foundation for Nextweld
innovations, including Surface Tension Transfer®,
Pulse-On-Pulse™, Chopper Technology™,
ArcLink™ and many more. Try Nextweld products
for ultimate arc control, high efficiency/reliability,
and seamless system integration.
WHAT IS NEXTWELD™?
(1) Power Wave 455M/STT only
FANUC Robot
Teach Pendant
Welding Software
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
www.lincolnelectric.com
[3]
A CLOSER LOOK
Key Controls
Power Wave 455M Robotic and 455M/STT Robotic Front Panel.
1. Thermal Light
2. Power Supply Status Light
3. On/Off Switch
4. Optional Communication Module Status Light
(DeviceNet or Ethernet)
5. Feeder Status Light
Power Wave 455M Robotic and 455M/STT Robotic Front Panel.
Front Lower Panel
1. Devicenet or Ethernet/DeviceNet Receptacle (optional)
2. ArcLink Receptacle
3. Work Sense Lead Receptacle
4. RS-232 Diagnostic Receptacle
5. External Input Connector
6. STT Stud (not shown)
7. Positive Output Stud
8. CB1 (10A) 40VDC
9. 115VAC Receptacle
10. CB1 (10A) 40VDC
11. Negative Output Stud
11
10
9
8
7
1
2
3
4
5
6
4
1
2
3
1. Communication Interface Module -
DeviceNet or Ethernet/DeviceNet upgrades can
be field installed.
1
5
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