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
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 and...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455..........................................................A-1Safety Precautions...............................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT; OUTPUT
A-1 INSTALLATION POWER WAVE 455 STT A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 455/STT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS 208V - 60HZ.230V - 60HZ.460V - 60HZ.575V - 60HZ.200V - 50HZ.220V - 50HZ.440V ...
Page 9 - LIFTING; MACHINE GROUNDING; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.; SELECT SUITABLE LOCATION; STACKING
any parts of it be submerged in water. Doing so maycause improper operation as well as pose a safetyhazard. The best practice is to keep the machine in adry, sheltered area. LIFTING Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift ...
Page 10 - FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR; OUTPUT CONNECTIONS; FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
A-3 INSTALLATION POWER WAVE 455 STT A-3 FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR 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 rec...
Page 11 - CONTROL CABLE CONNECTIONS
A-4 INSTALLATION POWER WAVE 455 STT A-4 VOLTAGE SENSING AT THE WORKPIECE A four-pin work piece voltage sense lead connector islocated beneath the output stud cover. The use of awork piece sense lead is optional for most weldingmodes, but it is strongly recommended for use withthe STT welding mode. K...
Page 13 - OPERATION; OPERATING INSTRUCTIONS
B-1 OPERATION B-1 POWER WAVE 455 STT OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth-ing. • Insulate you...
Page 15 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; DESIGN FEATURES AND ADVANTAGES; Parameter; Examples
B-3 OPERATION B-3 GENERAL DESCRIPTION The POWER WAVE 455 STT is a high performance,digitally controlled inverter welding power sourcecapable of complex, high-speed waveform control.Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW, CAC-A and STT process-es. RECOMMENDED PROCESSES A...
Page 16 - WELDING CAPABILITY; DUTY CYCLE AND TIME PERIOD
B-4 OPERATION POWER WAVE 455 STT B-4 WELDING CAPABILITY T h e P O W E R W A V E 4 5 5 S T T i s r a t e d a t 6 0 H z .450A@ 38V. 100% duty cycle or 570A@ 43V 60%duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or500A@40V 60% duty cycle. The machine is capableof higher outputs at lower duty cycles. Fo...
Page 17 - WELDING ADJUSTMENTS; GMAW PULSE PROCEDURES
B-5 OPERATION B-5 WELDING ADJUSTMENTS All adjustments are made on the system componentknown as the control box, which contains the switch-es, knobs and digital displays necessary to controlboth the Power Wave and a Power Feed wire feeder.Typically, the control box is supplied as part of thewire feed...
Page 18 - The Power Wave is optimized; ARC GOUGING PROCEDURES
B-6 OPERATION B-6 Instead, an arc length adjustment is provided. Themachine “knows” what the best arc length is at thegiven wire feed speed but allows the operator tochange it. The arc length trim (usually referred to simply as“trim”) can be adjusted between 0.500 and 1.500 onthe control box’s Volts...
Page 19 - ACCESSORIES; OPTIONS / ACCESSORIES; FACTORY INCLUDED ACCESSORIES; FIELD INSTALLED; K1570-1 Dual Cylinder Undercarriage
C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES FACTORY INCLUDED ACCESSORIES K940-10 & -25 Voltage Sense Lead Kits- used for voltage sensing at the workpiece. See the INSTALLA-TION section for more details on proper use. FIELD INSTALLED The following options/accessories are available foryour Power Wav...
Page 20 - 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 21 - TROUBLESHOOTING
E-1 TROUBLESHOOTING E-1 POWER WAVE 455 STT USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS The Status LED on the power source case frontcan help diagnose problems down to the systemcomponent (power source, wire feeder, wire drive,etc.) level. If, for any reason, the system does notappear to be w...
Page 22 - HOW TO USE TROUBLESHOOTING GUIDE
E-2 TROUBLESHOOTING E-2 POWER WAVE 455 STT HOW TO USE TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorizedrepairs per-formed on this equipment may result in danger to the technician and machine operator andwill invalidate your factory wa...
Page 23 - TROUBLESHOOTING GUIDE; CAUTION; OUTPUT PROBLEMS
E-3 TROUBLESHOOTING E-3 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 26 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER WAVE 455 STT 9656/62523%25: 5433493 .. 542;25 239 ! " # 5494 ! " 12/526%;5:55;:4123 # 54334/6241 # "! 6 45 $ " %$ %$ $ "! """$ / : $ % % $ & NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this ma...
Page 29 - NOTES
Page 31 - Lincoln Welding School; BASIC COURSE
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l ...