Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455 ....................................................A-1Safety Precautions.................................
Page 9 - INSTALLATION; OUTPUT
A-1 INSTALLATION POWER WAVE 455/STT A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT (K1518-4) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS 208/230/460/575V - 60HZ. 200/220/440/575V ...
Page 10 - • Do not lift this machine using lift; MACHINE GROUNDING; Read this entire installation section before you; SELECT SUITABLE LOCATION
LIFTING Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave with accessories attached to it. LIMIT ON STACKING FALLING EQUIPMENT can cause injury. • Do not lift this machine using lift bale if it is equipped with a heav...
Page 11 - do so will result in damage to the machine.; VOLTAGE; MINIMUM COPPER; CAUTION
A-3 INSTALLATION POWER WAVE 455/STT A-3 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginningof this Installation section for recommended fuse andwire sizes. Fuse the input circuit with the recommend- ed super lag fuse or delay type breakers (also called“in...
Page 12 - NEGATIVE ELECTRODE POLARITY
A-4 INSTALLATION POWER WAVE 455/STT A-4 CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDING For Pulse Welding processes, cable inductance will causethe welding performance to degrade. For the total weldingloop length less than 50 feet, traditional welding cables maybe used without any effects on weldi...
Page 13 - • Do not touch electrically live parts or
A-5 INSTALLATION POWER WAVE 455/STT A-5 Electrode Voltage Sensing Enabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead is internal to the cable to thewire feeder and always connected when a wire feederis present. I mportant: The elec...
Page 14 - SYSTEM DESCRIPTION; System Model
A-6 INSTALLATION POWER WAVE 455/STT A-6 SYSTEM DESCRIPTION The Power Wave 455/STT and Power Feed 10/11family of products utilize a digital communication sys-tem called Linc-Net. Simply put, Linc-Net allows largeamounts of information to be passed at very highspeeds between components (nodes) in the ...
Page 15 - Simple System
A-7 INSTALLATION POWER WAVE 455/STT A-7 FIGURE A.8 Simple System SYSTEM SET-UP Basic Rules • Each group is required to have one user interface. No group may have more than one user interface. • Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads. ...
Page 16 - Multiple Group System
A-8 INSTALLATION POWER WAVE 455/STT A-8 FIGURE A.9 Multiple Group System No “ FH0 Alllowed! FIGURE A.10 Single Group Multi-Head System No “ FH0 Alllowed! T h e D u a l H e a doption allows the abil-ity to maintain 2 setso f p r o c e d u r e s . I fm o r e t h e n 2 h e a d sare used, odd # ’ s use ...
Page 18 - TWO POWER WAVES
A-10 INSTALLATION POWER WAVE 455/STT A-10 FIGURE A.2 - + POWERWAVE - + POWERWAVE Connect All WorkSense Leads at the Endof the Joint Connect All WeldingWork Leads at theBeginning of the Joint Travel Direction - + POWER WAVE - + POWER WAVE TWO POWER WAVES CAUTION CAUTION
Page 19 - BAD; BETTER; BEST
A-11 INSTALLATION POWER WAVE 455 A-11 MULTIPLE ARC SENSE LEAD AND WORKLEAD PLACEMENT GUIDELINES Work #2 Sense #2 Power Source #2 Power Source #1 Arc #1 Arc #2 Work #1 Sense #1 Work # 2 Power Source #2 Power Source #1 Arc #1 Arc #2 Work # 1 Sense #1 Sense # 2 Current Flow Power Source #1 Power Source...
Page 20 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS; WATER FLOW SENSOR
A-12 INSTALLATION POWER WAVE 455/STT A-12 I / O RECEPTACLE SPECIFICATIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc E 51 +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Volta...
Page 21 - OPERATION; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
B-1 OPERATION B-1 POWER WAVE 455/STT SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wetclothing. • Insulate yourself from the work and ground. • Always ...
Page 23 - RECOMMENDED EQUIPMENT; Semi-Automatic Operation; REQUIRED EQUIPMENT; DUTY CYCLE AND TIME PERIOD; GENERAL DESCRIPTION; RECOMMENDED PROCESSES
RECOMMENDED EQUIPMENT Power Wave 455/STT – Semi-Automatic Operation Semi Automatic Power Waves can only be used withLinc-Net compatible Power Feed semi-automatic wirefeeders. In addition, the Power Feed semi-automaticw i r e f e e d e r s m a y r e q u i r e o p t i o n a l e q u i p m e n t t oacce...
Page 24 - CASE FRONT CONTROLS; per table 3; CASE FRONT LAYOUT
B-4 OPERATION POWER WAVE 455/STT B-4 CASE FRONT CONTROLS All operator controls and adjustments are located onthe case front of the Power Wave. (See Figure A.4) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation i...
Page 25 - NOMINAL PROCEDURES
B-5 OPERATION B-5 NOMINAL PROCEDURES The Power Wave is designed to operate with 3/4"electrode stick-out for CV and Pulse processes and a1/2" stick-out for STT processes. FRINGE PROCEDURES Excessively short or long electrode stick-outs mayfunction only on a limited basis, if at all. MAKING A ...
Page 26 - WELDING MODE
B-6 OPERATION B-6 • VOLTS / TRIM: In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage. In pulse synergic welding modes (pulse GMAW only)the user can change the Trim setting to adjust the arclength. It is adjustable from 0.500 to 1.500. A Trim set-ting of 1.000...
Page 27 - CONSTANT VOLTAGE WELDING; Synergic CV; Current
B-7 OPERATION B-7 CONSTANT VOLTAGE WELDING Synergic CV : For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The nominal preprogrammed volt-age is the best average voltage for a given wire feedspeed, but may be adjusted to pref...
Page 28 - PULSE WELDING
B-8 OPERATION B-8 PULSE WELDING Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. The...
Page 29 - STT WELDING
B-9 OPERATION B-9 STT WELDING The pictures illustrate the waveshape of current forthe process. They are not drawn to scale, and areintended only for the purpose of showing how the vari-ables effect the waveform. Trim in the STT mode adjusts the tailout and back-g r o u n d p o r t i o n o f t h e w ...
Page 30 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED Work Voltage Sense Lead Kit, K940Dual Cylinder Undercarriage, K1570-1. *Gas Guard Regulator, K659-1Coaxial welding Cable, K1796PowerWave WaterCooler, K1767-1 *Water Flow Sensor, K1536-1 *The Dual Cylinder Underc...
Page 31 - MAINTENANCE; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER WAVE 455/STT SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the d i s c o n n e c t s w i t c h o r f u s e b o xbefore working on this equipment. • Do not touch electrically hot parts. R...
Page 32 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER WAVE 455/STT If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshoo...
Page 33 - Read the
E-2 TROUBLESHOOTING E-2 POWER WAVE 455/STT USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed asa system. Each component (power source, user inter-face, and feedhead) has a status light, and when aproblem occurs it is important to note the condition of...
Page 34 - ERROR CODES FOR THE POWERWAVE; Indication
E-3 TROUBLESHOOTING E-3 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troublesh...
Page 35 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
E-4 TROUBLESHOOTING E-4 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/re...
Page 38 - PROBLEMS; contact
E-7 TROUBLESHOOTING E-7 POWER WAVE 455/STT Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troublesh...
Page 39 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER WAVE 455/STT NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Dep...
Page 40 - CONNECTION DIAGRAM; WIRE
F-2 CONNECTION DIAGRAM F-2 POWER WAVE 455/STT Connection Diagram Semi-automatic "Simple System" (Electrode Positive,CV/Pulse Configuration shown) POWER WAVE / STT CV/PULSE STUD WIRE FEEDER CONTROL CABLE K1543 TO WORK WORK SENSE
Page 41 - STT STUD
F-3 DIAGRAMS F-3 POWER WAVE 455 Connection Diagram Semi-automatic "Simple System" (Electrode Positive, STT Configuration shown) POWER WAVE / STT STT STUD WIRE FEEDER CONTROL CABLE K1543 TO WORK WORK SENSE
Page 42 - WER
F-4 DIAGRAMS F-4 POWER WAVE 455/STT 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 11-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455
Page 43 - NOTES
Page 44 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...