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 fumesoutdoors. ...
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 455M .................................................A-1Safety Precautions...................................
Page 9 - INSTALLATION
A-1 INSTALLATION POWER WAVE 455M A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS- FREQUENCY 208/230/460/575V - 60HZ. 200...
Page 10 - MACHINE GROUNDING; t h i s; 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. STACKING Power Wave machines can be stacked to a maximumof 3 high. The bottom machine must always be placed on afirm, secure, ...
Page 11 - do so will result in damage to the machine.; VOLTAGE; WORK CABLE SIZE AWG; CAUTION
A-3 INSTALLATION POWER WAVE 455M 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“inver...
Page 12 - NEGATIVE ELECTRODE POLARITY; Work Voltage Sensing”
A-4 INSTALLATION POWER WAVE 455M A-4 CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDING For Pulse Welding processes, cable inductance willcause the welding performance to degrade. For thetotal welding loop length less than 50 ft.( 15.24m), tradi- tional welding cables may be used without any effectso...
Page 13 - SYSTEM DESCRIPTION; • Do not touch electrically live
A-5 INSTALLATION POWER WAVE 455M 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 electro...
Page 14 - CONFIGURING THE SYSTEM; SINGLE HEAD FEEDER
A-6 INSTALLATION POWER WAVE 455M A-6 CONFIGURING THE SYSTEM For codes below 11100, consult the semi-automaticPower Feed instruction manual for configuration infor-mation about DIP switch settings. For codes above 11100, the power source will “AutoMap” the system eliminating most of the need to setDI...
Page 16 - TWO POWER WAVES
A-8 INSTALLATION POWER WAVE 455M A-8 WELDING WITH MULTIPLE POWERWAVES Special care must be taken when more than onePower Wave is welding simultaneously on a singlepart. Arc blow and arc interference may occur orbe magnified.------------------------------------------------------------------------ Eac...
Page 18 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS; WATER FLOW SENSOR
A-10 INSTALLATION POWER WAVE 455M A-10 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 Voltage ...
Page 19 - OPERATION; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
B-1 OPERATION B-1 POWER WAVE 455M SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and could...
Page 21 - DEFINITION OF WELDING TERMS
B-3 OPERATION B-3 POWER WAVE 455M DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will sel...
Page 22 - RECOMMENDED EQUIPMENT; Power Wave 455M – Semi-Automatic Operation; REQUIRED EQUIPMENT; • The Power Waves are not to be used in outdoor; DUTY CYCLE AND TIME PERIOD; GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Wire Drive Interface Module
DeviceNet Interface Module This module can be used for DeviceNet capability. Itw i l l h a s a 5 p i n s e a l e d m i n i c o n n e c t o r p e r A N S IB93.55M-1981. EtherNet/DeviceNet Module This module includes the DeviceNet and EtherNetcapability. The DeviceNet uses a 5 pin sealed miniconnector...
Page 23 - CASE FRONT CONTROLS; per table 3; CASE FRONT LAYOUT
B-5 OPERATION POWER WAVE 455M B-5 CASE FRONT CONTROLS All operator controls and adjustments are located onthe case front of the Power Wave. (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a...
Page 24 - NOMINAL PROCEDURES
B-6 OPERATION B-6 NOMINAL PROCEDURES The Power Wave is designed to operate with 3/4"electrode stick-out for CV and Pulse processes. FRINGE PROCEDURES Excessively short or long electrode stick-outs mayfunction only on a limited basis, if at all. MAKING A WELD The serviceability of a product or st...
Page 25 - • WELDING MODE; CONSTANT VOLTAGE WELDING; Synergic CV
Current Time CURRENT WAVE FORM (CV) B-7 OPERATION B-7 • WELDING MODE May be selected by name (CV/MIG, CC/Stick Crisp,Gouge, etc.) or by a mode number (10, 24, 71, etc.)depending on the Control Box options. Selecting awelding mode determines the output characteristics ofthe Power Wave power source. F...
Page 26 - PULSE WELDING; Current
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 27 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED Wire Drive Interface Module, K2205-1 FIELD INSTALLED Work Voltage Sense Lead Kit, K940Dual Cylinder Undercarriage, K1570-1.Gas Guard Regulator, K659-1Coaxial welding Cable, K1796Cool Arc 40 K1813-1 (115VAC)Water Flow Sensor, K1536-1Wire Drive ...
Page 28 - MAINTENANCE; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER WAVE 455M 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. ROUT...
Page 29 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER WAVE 455M 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 Troubleshootin...
Page 30 - Read the
E-2 TROUBLESHOOTING E-2 POWER WAVE 455M 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 feed head) has a status light, and when aproblem occurs it is important to note the condition ofea...
Page 31 - ERROR CODES FOR THE POWERWAVE; Indication
E-3 TROUBLESHOOTING E-3 POWER WAVE 455M 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 troubleshoot...
Page 32 - OUTPUT PROBLEMS
E-4 TROUBLESHOOTING E-4 POWER WAVE 455M Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact your local authorized Lincoln Electric Field Service Facility for tech...
Page 35 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER WAVE 455M 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 Depart...
Page 37 - CONNECTION DIAGRAM
F-3 CONNECTION DIAGRAM F-3 POWER WAVE 455M Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK
Page 38 - WER
F-4 DIAGRAMS F-4 POWER WAVE 455M 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 1 1-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455M
Page 39 - NOTES