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; OUTPUT; FCAW
A-1 INSTALLATION POWER WAVE 455 A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 455 OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS 208V - 60HZ.230V - 60HZ.400V - 60HZ.460V - 60HZ.575V - 60HZ.200V - 50HZ.220V - 50HZ.4...
Page 9 - ENVIRONMENTAL PROTECTION; MACHINE GROUNDING; ELECTRIC SHOCK can kill.; • Only qualified personnel should; SELECT SUITABLE LOCATION; STACKING
A-2 INSTALLATION POWER WAVE 455 A-2 ENVIRONMENTAL PROTECTION The Power Wave power source is rated IP21S andshould not be subjected to falling water, nor shouldany 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 ...
Page 10 - Fuse the input circuit with the recommend-; OUTPUT CONNECTIONS; FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
A-3 INSTALLATION POWER WAVE 455 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“invers...
Page 11 - CONTROL CABLE CONNECTIONS
A-4 INSTALLATION POWER WAVE 455 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 may be used if desired. Sense Lead Kits (K490-10, -25 or -50) are ...
Page 12 - Disconnect the input power from the Power Wave.
A-5 INSTALLATION POWER WAVE 455 A-5 P OW E R F E E D C O N T R O L B OXMOUNTING In some installations, it may be desirable to mount theWire Feeder control box directly to the front of thePower Wave power source. (The control box is thebox containing the knobs, switches and displays nec-essary to con...
Page 13 - OPERATION; OPERATING INSTRUCTIONS
B-1 OPERATION B-1 POWER WAVE 455 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 yoursel...
Page 15 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; DESIGN FEATURES AND ADVANTAGES; Parameter; Examples
B-3 OPERATION B-3 POWER WAVE 455 GENERAL DESCRIPTION The Power Wave 455 is a high performance, digitallycontrolled inverter welding power source capable ofcomplex, high-speed waveform control. Properlye q u i p p e d , i t c a n s u p p o r t t h e G M A W , G M A W - P ,FCAW, SMAW, GTAW and CAC-A p...
Page 16 - WELDING CAPABILITY; DUTY CYCLE AND TIME PERIOD
B-4 OPERATION POWER WAVE 455 B-4 WELDING CAPABILITY The POWER WAVE 455 is rated at 60 Hz. 450A@38V. 100% duty cycle or 570A@ 43V 60% duty cycle -50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V60% duty cycle. The machine is capable of higher out-puts at lower duty cycles. If the duty cycle is exceeded,...
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; The adaptive behavior; ARC GOUGING PROCEDURES
B-6 OPERATION B-6 The arc length trim (usually referred to simply as“trim”) can be adjusted between 0.500 and 1.500 onthe control box’s Volts/Trim display. A Trim of 1.000means that no adjustments will be made to the presetarc lengths. A Trim greater than 1.000 increases thepreset arc lengths. A Tri...
Page 19 - ACCESSORIES; OPTIONS / ACCESSORIES; FACTORY INSTALLED; K1570-1 Dual Cylinder Undercarriage; 0 foot voltage
C-1 ACCESSORIES C-1 OPTIONS / ACCESSORIES FACTORY INSTALLED There are no factory installed options available for thePower Wave machines. FIELD INSTALLED The following options/accessories are available foryour Power Wave from your local Lincoln Distributor. K1570-1 Dual Cylinder Undercarriage K940-10...
Page 20 - MAINTENANCE; SAFETY PRECAUTIONS; • Only Qualified personnel should; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER WAVE 455 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. ROUTI...
Page 21 - TROUBLESHOOTING; Status LED is blinking green.
E-1 TROUBLESHOOTING E-1 POWER WAVE 455 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 worki...
Page 22 - HOW TO USE TROUBLESHOOTING GUIDE
E-2 TROUBLESHOOTING E-2 POWER WAVE 455 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 warran...
Page 23 - Observe all Safety Guidelines detailed throughout this manual; TROUBLESHOOTING GUIDE; Observe Safety Guidelines; CAUTION; OUTPUT PROBLEMS
E-3 TROUBLESHOOTING E-3 POWER WAVE 455 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/repair...
Page 25 - Machine won’t produce full output.
E-5 TROUBLESHOOTING E-5 POWER WAVE 455 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/repair...
Page 26 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER WAVE 455 3 1 L3A 18 TO AUX #1 TO CURRENT 32 33 4 POS X2 4 POWER BD RECTIFIER J24 NEG TO J32 NEG NEG NEG POWER BD RECT C3 + 32 TO J81 L1A A H1D 31 TO J61 612B S4 TO CB3 (TOP) 2 FRONT OF MACHINE 110V RECEPTACLE TO TP3 TO CONTACTOR TO CONTACTOR TO RECONNECT PANEL 11 TO SWITCH 11 ...
Page 28 - DIMENSION PRINT - POWER WAVE 455
F-3 DIAGRAMS F-3 POWER WAVE 455 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 B M18241 DIMENSION PRINT - POWER WAVE 455
Page 29 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
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 ...