Lincoln Electric SVM156-A User Manual
SVM156-A
October, 2001
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
CONT AINED THROUGHOUT .
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
For use with machines having Code Numbers: 10675
10676
POWER WAVE 455/R
TM
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.
IEC 60974-1
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POWERWAVE 455/R
POWERWAVE 455/R
I ON
O OFF
CALIFORNIA PROPOSITION 65 WARNINGS
i i
SAFETY
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 weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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 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 Diesel Engines
The Above For Gasoline Engines
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ii ii
SAFETY
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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.
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.
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.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
iii iii
SAFETY
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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.
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.
Mar ‘95
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.
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
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
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.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
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.
iv iv
SAFETY
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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.
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.
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.
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 v
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
POWER W AVE 455/R
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual ................................................................................................................................P-377
RETURN TO MAIN MENU
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-4
Select Suitable Location..............................................................................................................A-4
Lifting....................................................................................................................................A-4
Stacking................................................................................................................................A-4
Machine Grounding .....................................................................................................................A-4
High Frequency Protection..........................................................................................................A-4
Input Connection.........................................................................................................................A-5
Input Fuse and Supply Wire Considerations........................................................................A-5
Input Voltage Change Over (For Multiple Input Voltage Machines Only).............................A-6
Welding with Multiple Power Waves...........................................................................................A-6
Electrode and Work Cable Connections.....................................................................................A-7
Negative Electrode Polarity.........................................................................................................A-7
Voltage Sensing..........................................................................................................................A-8
Work Voltage Sensing ..........................................................................................................A-9
Electrode Voltage Sensing...................................................................................................A-9
Power Wave / Power Feed Wire Feeder Interconnections.........................................................A-9
Control Cable Specifications ................................................................................................A-9
External I/O Connector.........................................................................................................A-9
Dip Switch Settings and Locations.....................................................................................A-10
Control Board Dip Switch ...................................................................................................A-10
Feed Head Board Dip Switch.............................................................................................A-10
Devicenet/Gateway Board Dip Switch, Bank (S2) ..............................................................A-11
Section A Section A
TABLE OF CONTENTS
- INSTALLATION SECTION -
POWER W AVE 455/R
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A-2 A-2
INSTALLATION
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TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
OUTPUT
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT
VOLTS
(K1761-1)
208/230/460V - 60HZ
200/220/440V - 50HZ
(K1761-2)
208/230/460/575V-60HZ
200/220/440V - 50HZ
OPEN
CIRCUIT
VOLTAGE
75 VDC
INPUT
VOLTAGE /
FREQUENCY
(K1761-1)
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
200/220V - 50HZ
440V - 50HZ
(K1761-2)
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ
208/230V - 60HZ
460V - 60HZ
575V - 60HZ
200/220V - 50HZ
440V - 50HZ
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
90/90
45
90/80
45
110/110
70
100/100
60
70/60
35
30
70/60
30
110/100
50
40
90/80
40
TYPE 75°C
GROUND WIRE
IN CONDUIT
AWG[IEC] SIZES
(mm2)
8 (10)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
8 (10)
10 (6)
8 (10)
10 (6)
10 (6)
8 (10)
10 (6)
6 (10)
10 (6)
10 (6)
8 (10)
10 (6)
TYPE 75°C
COPPER WIRE
IN CONDUIT
AWG[IEC] SIZES
(mm2)
4 (25)
8 (10)
4 (25)
8 (10)
4 (25)
8 (10)
4 (25)
8 (10)
4 (25)
10 (6)
10 (6)
6 (10)
10 (6)
4 (25)
8 (10)
10 (6)
8 (10)
10 (6)
INPUT AMPERE
RATING ON
NAMEPLATE
70/65
35
64/58
32
87/82
48
79/74
41
58/53
25
22
49/45
23
82/78
37
31
67/61
31
AMPS/
DUTY
CYCLE
450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
500/60%
500/60%
450/100%
450/100%
450/100%
400/100%
400/100%
570/60%
570/60%
570/60%
500/60%
500/60%
PROCESS CURRENT RANGES (DC)
MIG/MAG
FCAW
SMAW
Pulse
STT
CURRENT
50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps
40-325 Average Amps
PULSE
VOLTAGE
RANGE
5 - 55 VDC
AUXILIARY POWER
(CIRCUIT BREAKER
PROTECTED)
40 VDC @10 AMPS
115VAC @10 AMPS
PULSE AND
BACKGROUND
TIME RANGE
100 MICRO SEC.
-3.3 SEC.
STT
PARAMETERS
40-325 AMPS
CURRENT
RANGE
5 - 570
PULSE
FREQUENCY
0.15 - 1000 Hz
INPUT
CURRENT
AMPS
70/65/35
87/82/48
64/58/32
79/74/41
58/53/25/22
82/78/37/31
49/45/23
67/61/31
IDLE
POWER
400 Watts
MAX
POWER FACTOR
@ RATED OUTPUT
0.89 MIN
0.95 MIN
EFFICIENCY
@ RATED OUTPUT
88%
OUTPUT
CONDITIONS
450A@38V 100%
570A@43V 60%
400A@36V 100%
500A@40V 60%
450@38V 100%
570@43V 60%
400@36V 100%
500A@40V 60%
A-3 A-3
INSTALLATION
POWER W AVE 455/R
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TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1), (K1761-2)
(continued)
PHYSICAL DIMENSIONS
TEMPERATURE RANGES
HEIGHT
26.10 in
663 mm
WIDTH
19.86 in
505 mm
DEPTH
32.88 in
835 mm
WEIGHT
(K1761-1) 247 lbs.
112 kg.
(K1761-2) 254 lbs.
115 kg.
OPERA TING TEMPERA TURE RANGE
-20°C to +40°C
STORA GE TEMPERA TURE RANGE
-40°C to +40°C
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the dis-
connect switch or fuse box before working on this
equipment. Turn of f the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to a
proper safety (Earth) ground.
SELECT SUITABLE LOCATION
Do not use Power Waves in outdoor environments. The
Power Wave power source should not be subjected to
falling water, nor should any parts of it be submerged
in water. Doing so may cause improper operation as
well as pose a safety hazard. The best practice is to
keep the machine in a dry, sheltered area.
Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at
a minimum. Do not use air filters on the air intake,
because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N.
(fan as needed) circuitry. The fan runs whenever the
output is enabled, whether under loaded or open circuit
conditions. The fan also runs for a period of time
(approximately 5 minutes) after the output is disabled,
to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing
the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the
output of the solid state fan control relay , located on the
back of the Control PC board enclosure. (See the
Wiring Diagram.)
DO NOT MOUNT 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 .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
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 a maximum of
three high.
The bottom machine must always be placed on a firm,
secure, level surface. There is a danger of machines
toppling over if this precaution is not taken.
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.
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-4 A-4
INSTALLATION
POWER W AVE 455/R
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CAUTION
CAUTION
WARNING
CAUTION
INPUT CONNECTION
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.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to the Tec hnical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommended 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.
A-5 A-5
INSTALLATION
POWER W AVE 455/R
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WARNING
NOTE:Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
FIGURE A.1
(K1761-1) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
(K1761-2) CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
VOLTAGE=220-230V
220-230V
200-208V
220-230V
380-415V
440-460V
200-208V
U / L1
440-460V
380-415V
.
inspecting or servicing machine.
Do not operate with covers
.
removed.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
.
'A'
'A'
VOLTAGE=380-415V
'A'
S23847
VOLTAGE=200-208V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
A
'A'
VOLTAGE=440-460V
CR1
W / L3
V / L2
380-415V
440-460V
Disconnect input power before
INPUT SUPPLY CONNECTION DIAGRAM
WARNING
ELECTRIC
SHOCK
CAN KILL
ELECTRIC
SHOCK
CAN KILL
WARNING
INPUT SUPPLY CONNECTION DIAGRAM
WARNING
Disconnect input power before
inspecting or servicing machine.
Do not operate with covers
ELECTRIC
SHOCK
CAN KILL
removed.
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
W / L3
V / L2
U / L1
VOLTAGE = 440-460V
200-208V
'A'
220-230V
440-460V
550-575V
VOLTAGE = 200-208V
CR1
200-208V
220-230V
440-460V
550-575V
'A'
S25198
VOLTAGE = 550-575V
200-208V
'A'
220-230V
440-460V
550-575V
'A'
XA
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
A-6 A-6
INSTALLATION
POWER W AVE 455/R
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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
located on the inside of the input access door. (Figure
A.1.) If the main reconnect switch or link position is
placed in the wrong position, the welder will not produce output power.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in
a position higher than the applied line voltage, the
welder may not come on at all. If the auxiliary (A) lead
is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this occurs,
turn off the input voltage, properly connect the (A) lead,
reset the breakers, and try again.
WELDING WITH MUL TIPLE POWER
WAVES
Special care must be taken when more than one Power
Wave is welding simultaneously on a single part. Arc
blow and arc interference may occur or be magnified.
Each power source requires a work lead from the work
terminal to the welding fixture. Do not combine all of the
work leads into one lead. The welding travel directions
should be in the direction moving away from the work
lead as shown in Figure A.2. Connect all of the work
sense leads from each power source to the work piece
at the end of the weld.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves.
CAUTION
FIGURE A.2 – MULTIPLE POWER WAVE CONNECTIONS
TWO POWER WAVES
SENSE LEAD
ELECTRODE
ELECTRODE
SENSE LEAD
CONNECT ALL WORK
SENSE LEADS AT THE
END OF THE JOINT
CONNECT ALL WELDING
WORK LEADS AT THE
BEGINNING OF THE JOINT
TRAVEL
DIRECTION
WORK LEAD WORK LEAD
POWERWAVE 455/R
I ON
O OFF
POWERWAVE 455/R
I ON
O OFF
When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
Do not attempt to supply shielding gas for two or more
guns from only one regulator.
If an anti-spatter system is in use, each gun must have
its own anti-spatter system. See Figure A.2.
ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (per
Table A.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 or wire feeder. Avoid excessive lengths and do not coil excess cable. Do not tightly bundle the electrode and work cables together.
Use K1796 coaxial welding cables wherever possible.
Minimum work and electrode cables sizes are as
follows:
T ABLE 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)
When using an inverter type power source like the
Power Wave, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not normally require it.
When pulsing, the pulse current can reach very high
levels. Voltage drops can become excessive, leading
to poor welding characteristics, if undersized welding
cables are used.
Most welding applications run with the electrode being
positive (+). For those applications, connect one end of
the electrode cable to the positive (+) output terminal
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 using the stud, lockwasher, and
nut provided on 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 Table A.1.
Connect a work lead from the negative (-) power
source output terminal to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
Excessive voltage drops caused by poor work piece
connections often result in unsatisfactory welding performance.
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 terminal; however, their 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 terminals
together. Paralleling the terminals will bypass STT circuitry and severely deteriorate STT 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 (-) terminal, and work cable to the positive
(+) terminal).
When operating with electrode polarity negative, the
Dip switch 7 must be set to ON on the Wire Feed Head
PC Board. The default setting of the switch is OFF to
represent positive electrode polarity.
To set the Negative Polarity switch on Wire Feed Head
PC board, refer to the section DIP SWITCH
SETTINGS AND LOCATIONS.
A-7 A-7
INSTALLATION
POWER W AVE 455/R
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CAUTION
CAUTION
CAUTION
VOLTAGE SENSING
The best arc performance occurs when the Power
Wave has 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 terminals of the welder. Voltage
sense leads improve the accuracy of the arc conditions
and can have a dramatic effect on performance.
If the voltage sensing is enabled but the sense leads
are missing or improperly connected, extremely high
welding outputs may occur.
Do not tightly bundle the work sense lead to the work
lead.
The sense leads connect to the Power Wave at the
four-pin connector located underneath the output terminal cover. Lead 67 senses electrode voltage. Lead
21 senses work voltage.
Enable the voltage sense leads as follows:
TABLE A.2
Process Electrode V olta ge Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional
GMAW-P 67 lead required 21 lead optional
FCAW 67 lead required 21 lead optional
STT 67 lead required 21 lead required
GTAW Voltage sense at Voltage sense at
terminals terminals
SAW 67 lead required 21 lead optional
* The electrode voltage 67 sense lead is integral to the con-
trol cable to the wire feeder.
A-8 A-8
INSTALLATION
POWER W AVE 455/R
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POWER
WAVE 455/R
I ON
O OFF
POWERWAVE 455/R
FIGURE A.3 – DIP SWITCH LOCATION
CAUTION
REMOVE
FRONT
COVER
WIRE FEED
HEAD BOARD
ON RIGHT
CONTROL
BOARD
ON LEFT
WORK V OLT A GE SENSING
The Power Wave is shipped from the factory with the
work sense lead enabled.
For processes requiring work voltage sensing, connect
the (21) work voltage sense lead from the Power Wave
to the work. Attach the sense lead to the work as close
to the weld as practical. To enable the work voltage
sensing in the Power Wave, refer to the section DIP
SWITCH SETTINGS AND LOCATIONS.
ELECTRODE V OLT A GE SENSING
Enabling or disabling electrode voltage sensing is automatically configured through software. Electrode sense
lead 67 must be connected at the wire feeder.
POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS
Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Wave is located under the spring loaded
output cover, near the bottom of the case front. The
control cable is keyed and polarized to prevent improper connection.
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.
Output connections on some Power Waves are made
via 1/2-13 threaded output terminals located beneath
the spring-loaded output cover at the bottom of the
case front. On machines which carry the CE mark, output connections are made via Twist-Mate receptacles,
also located beneath the spring-loaded output cover at
the bottom of the case front.
A work lead must be run from the negative (-) power
source output connection to the work piece. The work
piece connection must be firm and secure, especially if
pulse welding is planned.
Excessive voltage drops at the work piece connection
often result in unsatisfactory pulse welding performance.
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
The use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration
(poor arc starting) and low wire driving force (wire feeding problems).
Lincoln control cables are copper 22 conductor cable in
a SO-type rubber jacket.
EXTERNAL I/O CONNECTOR
The Power Wave is equipped with a port for making simple input signal connections. The port is divided into
three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a “slave”
on the DeviceNet network, the Trigger and Cold Inch
Groups are disabled when the DeviceNet/Gateway is
active.
The Shutdown Group is always enabled. Shutdown 2 is
used for signaling low flow in the water cooler. Unused
shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See
Figure A.4)
A-9 A-9
INSTALLATION
POWER W AVE 455/R
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CAUTION
CAUTION
D
E
F
1
2
3
4
5
6
78
910
11
12
G
H
I
A
B
C
+15 VDC for Trigger Group
Trigger Input
Dual Procedure Input
4 Step Input
+15 VDC for Cold Inch Group
Cold Inch Forward
Cold Inch Reverse
Gas Purge Input
+15 for shutdown group
Shutdown1 input
Shutdown2 input
Reserved for future use
FIGURE A.4 – INPUT PORT CONNECTIONS
DIP SWITCH SETTINGS AND LOCATIONS
DIP switches on the PC boards allow for custom configuration of the Power Wave. Access the DIP switches as follows:
ELECTRIC SHOCK CAN KILL.
• 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.
• Turn off power at the disconnect switch.
• Remove the top four screws securing the front access
panel.
• Loosen, but do not completely remove, the bottom
two screws holding the access panel.
• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.
• Adjust the DIP switches as necessary. Using a pencil or other small object, slide the switch left for the
ON position or to the right for the OFF position, as
appropriate.
• Replace the panel and screws and restore power.
CONTROL BOARD DIP SWITCH:
switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8 = work sense lead
switch 8 work sense lead
off work sense lead not connected
on work sense lead connected
FEED HEAD BOARD DIP SWITCH:
switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = negative polarity switch
switch 8 = high speed gear
switch 7 electrode polarity
off positive
on negative
switch 8 wire drive gear
off low speed gear
on high speed gear
A-10 A-10
INSTALLATION
POWER W AVE 455/R
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CONTROL BOARD
(LOCATED IN
CONTROL BOX
BEHIND CASE
FRONT)
FEED HEAD
BOARD
(LOCATED IN
CONTROL
BOX BEHIND
CASE FRONT)
BANK S1
BANK S2
RIGHT
LEFT
DEVICENET/
GATEWAY
BOARD
(LOCATED
BEHIND
FRONT
COVER)
FRONT
COVER
CASE FRONT
OPENING IN
CASE FRONT
TO ACCESS
CONTROL
BOX
WARNING
DEVICENET/GATEWAY BOARD
DIP SWITCH, BANK (S2):
switch 1,2 = configure the baud rate
for DeviceNET
Prior to S24958-6 software
switch 1 switch 2 baud rate
off off ------on off 125K
off on 250K
on on 500
S24958-6 and later software
switch 1 switch 2 baud rate
off off 125K
off on 250K
on off 500K
on on 500K
Programmable value. Consult local Lincoln Technical
representative.
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8 = reserved for future use
A-11 A-11
INSTALLATION
POWER W AVE 455/R
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A-12 A-12
NOTES
POWER W AVE 455/R
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Operation...............................................................................................................................Section B
Safety Precautions......................................................................................................................B-2
Graphic Symbols .........................................................................................................................B-3
General Description ....................................................................................................................B-4
Design Features and Advantages........................................................................................B-4
Recommended Processes and Equipment.................................................................................B-5
Recommended Processes....................................................................................................B-5
Recommended Equipment...................................................................................................B-5
Required Equipment.............................................................................................................B-5
Limitations.............................................................................................................................B-5
Duty Cycle and Time Period.................................................................................................B-5
Case Front Controls....................................................................................................................B-6
Welding Mode Descriptions ........................................................................................................B-7
Constant Voltage Welding ....................................................................................................B-7
Pulse Welding.................................................................................................................. .....B-8
STT Welding.........................................................................................................................B-9
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
POWER W AVE 455/R
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SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the electrode and
drive mechanism are always electrically
energized and could remain energized
several seconds after the welding ceases.
• 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.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the beginning
of this manual.
B-2 B-2
OPERATION
POWER W AVE 455/R
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WARNING
B-3 B-3
OPERATION
POWER W AVE 455/R
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INPUT POWER
ON
OFF
HIGH TEMPERA TURE
MACHINE STATUS
CIRCUIT BREAKER
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
THREE PHASE
DIRECT CURRENT
GMAW
FCAW
GTAW
OPEN CIRCUIT VOLTAGE
INPUT VOLTA GE
OUTPUT VOLTA GE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
U
0
U
1
U
2
I
1
I
2
SMAW
GENERAL DESCRIPTION
The Power Wave power source is designed to be a part
of a modular, multi-process welding system.
Depending on configuration, it can support constant
current, constant voltage, Surface Tension Transfer
and pulse welding modes.
The Power Wave power source is designed to be used
with the family of Power Feed wire feeders, operating
as a system. Each component in the system has special circuitry to “talk with” the other system components, so each component (power source, wire feeder,
electrical accessories) knows what the other is doing at
all times. The components communicate using ArcLink
protocol.
Robotic systems can communicate with other industrial machines via DeviceNET protocol. The result is a
highly intrigated and flexible welding cell.
The Power Wave 455/R is a high performance, digitally controlled inverter welding power source capable of
complex, high-speed waveform control. Properly
equipped, it can support the GMAW, GMAW-P, FCAW,
GT A W and STTprocesses. It carries an output rating of
either 450 amps, 38 volts; or 400 amps, 36 volts (both
at 100% duty cycle), depending on input voltage and
frequency . The Surface Tension transfer process (STT)
is supported at currents up to 325 amps, at 100% duty
cycle.
If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.
DESIGN FEATURES AND ADVANTAGES
• Designed to the IEC 974-1 Standard.
• Power Wave 455 multiple process output ranges:
5 - 570 amps
• Easy access for input connections. Connections are
simple strip and clamp (no lugs required).
• F.A.N. (Fan As Needed). Cooling fan runs only when
necessary (above Code 10500 only, and all STT
machines).
• Modular construction for easy servicing.
• Thermostatically protected.
• Electronic over-current protection.
• Input over-voltage protection.
• Utilizes digital signal processing and microprocessor
control.
• Simple, reliable input voltage change over.
• All system components communicate and transfer
information.
• Auto device recognition simplifies accessory cable
connections.
B-4 B-4
OPERATION
POWER W AVE 455/R
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RECOMMENDED PROCESSES
AND EQUIPMENT
RECOMMENDED PROCESSES
The Power Wave 455/R can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW and STT
for a variety of materials, including mild steel, stainless
steel, cored wires, and aluminum. The STT process
supports mild steel and stainless steel welding.
The Power Wave 455/R is recommended only for
automatic or mechanized applications such as robotic
welding.
RECOMMENDED EQUIPMENT
Automatic Operation
All welding programs and procedures are set through
software for the robotic Power Wave. FANUC robots
equipped with RJ-3 controllers may communicate
directly with the Power Wave. Other pieces of equipment such as PLCs or computers can communicate
with the Power Wave using DeviceNET. All wire welding processes require a robotic Power Feed wire feeder.
REQUIRED EQUIPMENT
• PF-10/R Wire Feeder, K1780-1
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-
100
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 10 ft), K1804-1
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin
to 14 pin, 18 in), K1804-2
LIMITATIONS
• The Power Wave 455/R is not suitable for SMAW,
CAC-A or other processes not listed.
• Power Waves are not to be used in outdoor environments.
• Only ArcLink Power Feed wire feeders and user
interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.
DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at
a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that the duty cycle is based
upon a ten minute period. A60% duty cycle represents
6 minutes of welding and 4 minutes of idling in a ten
minute period.
B-5 B-5
OPERATION
POWER W AVE 455/R
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CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. ST ATUS LIGHT : Atwo color light that indicates system errors. Normal operation is a steady green
light. Error conditions are indicated, per Table B.1.
NOTE: The robotic Power Waves’ status light will flash
green, and sometimes red and green, for up to
one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
TABLE B.1
Light
Meaning
Condition
Steady System OK. Power source
Green communicating normally with
wire feeder and its components.
Blinking Normal for first 1-10 seconds
Green after power is turned on.
Alternating Non-recoverable system fault.
Green Must turn power source off, find
and Red source of error, and turn power
back on to reset. See
Troubleshooting Guide.
Steady See Troubleshooting Guide.
Red
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled until
the machine cools down. When cool, the light
goes out and output is enabled.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMPAUXILIARY POWER CIRCUITBREAKER:
Protects 115 volt AC case front receptacle auxiliary supply.
6. LEAD CONNECTOR S2 (SENSE LEAD)
7. 5-PIN ARC LINK S1
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
10. NEGATIVE OUTPUT TERMINAL
11. INTERFACE CONNECTOR S6
12. STT TERMINAL
13. POSITIVE OUTPUT TERMINAL
14. AUXILIARY OUTPUT
B-6 B-6
OPERATION
POWER W AVE 455/R
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POWERWAVE 455/R
I ON
O OFF
FIGURE B.1 – POWER WAVE CASE FRONT CONTROLS
1
11
12
13
2 3
4145
6
7
8
9
10
WELDING MODE DESCRIPTIONS
CONST ANT V OLT A GE WELDING
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special software at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed. With
synergic programs, when the wire feed speed changes,
the Power Wave will automatically adjust the corresponding voltage.
Wave control adjusts the inductance of the waveshape.
(This adjustment is often referred to as "pinch". Inductance is inversely proportional to pinch.) Increasing
wave control greater than 0 results in a harsher, colder
arc, while decreasing the wave control to less than 0
provides a softer, hotter arc. (See Figure B.2.)
B-7 B-7
OPERATION
POWER W AVE 455/R
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Current
Time
Wave Control +10.0
Wave Control -10.0
Wave Control 0.00
FIGURE B.2 – CV WAVE CONTROL CHARACTERISTICS
PULSE WELDING
Pulse welding procedures are set by controlling an
overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, background current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical, and instead the arc length is set by adjusting “trim.”
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.
Most pulse welding programs are synergic. As the wire
feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain
similar arc properties.
The Power Wave utilizes “adaptive control” to compensate for changes in electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip
to the work piece.) The Power Wave waveforms are
optimized for a 0.75" (19mm) stick-out. The adaptive
behavior supports a range of stickouts from 0.50"
(13mm) to 1.25" (32mm). At very low or high wire feed
speeds, the adaptive range may be less due to reaching the physical limitations of the welding process.
Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave control
values less than 0 decrease the pulse frequency while
increasing the background current for a soft arc good
for out-of-position welding. (See Figure B.3.)
B-8 B-8
OPERATION
POWER W AVE 455/R
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Current
Time
Wave Control +10.0
Wave Control -10.0
Wave Control 0.00
FIGURE B.3 – PULSE WAVE CONTROL CHARACTERISTICS
STT WELDING
The pictures illustrate the waveshape of current for the
process. They are not drawn to scale, and are intended only for the purpose of showing how the variables
affect the waveform.
Trim in the STT mode adjusts the tailout and background portion of the waveform. Trim values greater
than 1.0 add more energy to the weld and make the
weld puddle hotter; trim values less than 1.0 reduce
energy to weld. A nominal value of 1.0 will work for
most applications. (See Figure B.4.)
B-9 B-9
OPERATION
POWER W AVE 455/R
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Current
Time
Trim 1.50
Trim 1.00
Trim 0.50
FIGURE B.4 – STT TRIM CONTROL CHARACTERISTICS
Current
Time
Wave Control +10.0
Wave Control -10.0
Wave Control 0.00
FIGURE B.5 – STT WAVE CONTROL CHARACTERISTICS
For most programs, peak current is adjusted by wave
control values. A value of +10.0 maximizes the peak
current, while a wave control of -10.0 minimizes peak
current. In general, the peak current is proportional to
torch arc length. (See Figure B.5.)
NOTE: The ranges on Wave Control and Trim are
dependent on the weld programs. The values
shown are typical ranges.
B-10 B-10
NOTES
POWER W AVE 455/R
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Accessories ..........................................................................................................................Section C
Optional Equipment ....................................................................................................................C-2
Factory Installed...................................................................................................................C-2
Field Installed .......................................................................................................................C-2
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
POWER W AVE 455/R
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OPTIONAL EQUIPMENT
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave 455R.
FIELD INSTALLED
• Gas Guard Regulator (K659-1)
The Gas Guard regulator is available as an optional accessory for the Power Feed Robotic wire drive
unit. Install the 5/8-18 male outlet on the regulator
to the proper 5/8-18 female gas inlet on the back
panel of the wire drive. Secure the fitting with the
flow adjuster key at the top.
• Voltage Sense Leads (K940-10, -25 or -50)
The voltage sense leads connect at the front of the
machine. (See Figure A.2.)
• Power W ave W ater Cooler (K1767-1)*
The K1767-1 is the recommended water cooler for
the Power Wave. Incorporated into the cooler is an
automatic flow sensor to detect low coolant flow. In
the event of a low flow condition, a fault signal is
sent to the Power Wave, and welding output automatically stops to protect the torch.
The water cooler is designed to cool only one welding
gun and should be not used to cool multiple guns or
other devices.
Water cooler manufacturers often specify additives
to the coolant such as fungicides or alkalies. Follow
the manufacturers’ recommendations to achieve
proper operation and long lifetime without clogging.
• Water Flow Sensor (K1536-1)
Water cooled guns can be damaged very quickly if
they are used even momentarily without water flowing. Recommend practice is to install a water flow
sensor such as on the water return line of the torch.
When fully integrated into the welding system, the
sensor will prevent welding if no water flow is present.
• Dual Cylinder Undercarriage, K1570-1*
• Coaxial Welding Cable, K1796
*The Dual Cylinder Undercarriage, K1570-1, is not
compatible in combination with the Power Wave
Water Cooler K1767-1.
C-2 C-2
ACCESSORIES
POWER W AVE 455/R
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