POWER WAVE 455 ™ OPERATOR’S MANUAL IM583-A December, 1999 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. For use with machines having Code Numbers: 10372, 10553, 10555 R • 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 • Date of Purchase: Serial Number: Code Number: Model: Where Purchased:
Transcript
POWER WAVE 455™
OPERATOR’S MANUAL
IM583-ADecember, 1999
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.
For use with machines having Code Numbers: 10372, 10553, 10555
R
• 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 •
Date of Purchase:Serial Number:Code Number:Model:Where Purchased:
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework 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
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.
____________________________________________________1.d. Keep all equipment safety guards, covers
and devices in posit ion and in goodrepair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all othermoving parts when starting, operating orrepairing equipment.
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan. Do not attempt
to override the governor or idler by pushing on the throttlecontrol rods while the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGSDiesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
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 flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.e. Also see item 1.b. Mar ‘95
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
iiiSAFETYiii
Mar ‘95
WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu 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 appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu 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” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
Mar. ‘93
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.
Machine Grounding ...............................................................................................A-2High Frequency Protection ....................................................................................A-2Input Connection....................................................................................................A-2Input Fuse and Supply Wire Considerations .........................................................A-3Input Voltage Reconnect Procedure......................................................................A-3Output Connections...............................................................................................A-3Voltage Sensing at the Work Piece .......................................................................A-4Power Wave / Power Feed Wire Feeder Interconnections....................................A-4
Electrode and Work Leads - Electrode Positive Applications .........................A-4Electrode and Work Leads - Electrode Negative Applications........................A-4Control Cable Connections .............................................................................A-4Power Feed Control Box Mounting .................................................................A-4
Operation .........................................................................................................Section BSafety Instructions .................................................................................................B-1Graphic Symbols that appear on this machine or in this manual...........................B-2General Description...............................................................................................B-3Recommended Processes and Equipment ...........................................................B-3Design Features and Advantages .........................................................................B-3Additional Features................................................................................................B-3Welding Capability .................................................................................................B-4Limitations..............................................................................................................B-4Compatible Lincoln Equipment ..............................................................................B-4Power Source Operation .......................................................................................B-4
Duty Cycle and Time Period ...........................................................................B-4Case Front Controls ........................................................................................B-4Welding Adjustments ......................................................................................B-5Detailed Weld Mode Descriptions ...................................................................B-5
Troubleshooting ..............................................................................................Section ETroubleshooting the Power Wave / Power Feed System using the Status LED ...E-1Safety Precautions.................................................................................................E-2How to Use Troubleshooting Guide.......................................................................E-2Troubleshooting Guide ..........................................................................................E-3
Wiring Diagram and Dimension Print ............................................................Section F
Parts Lists ....................................................................................................P291 Series
Nov97
A-1INSTALLATION
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 ONLYINPUT VOLTS
ENVIRONMENTAL PROTECTIONThe 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 machine in adry, sheltered area.
LIFTINGLift 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.
MACHINE GROUNDING
The frame of the welder must be grounded. A groundterminal marked with the symbol is located insidethe reconnect/input access door for this purpose. Seeyour local and national electrical codes for propergrounding methods.
HIGH FREQUENCY PROTECTION
If possible, locate the Power Wave away from radiocontrolled machinery. The normal operation of thePower Wave may adversely affect the operation of RFcontrolled equipment, which may result in bodily injuryor damage to the equipment.
INPUT CONNECTION
Only a qualified electrician should connect the inputleads to the Power Wave. Connections should bemade in accordance with all local and national electri-cal codes and the connection diagram located on theinside of the reconnect/input access door of themachine. Failure to do so may result in bodily injuryor death.
Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe upper left case back next to the input access door.Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on theinside of the input access door or refer to Figure A.1following.
Read this entire installation section before youstart installation.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only qualified personnel shouldperform this installation.
• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug(located inside the reconnect input access door) toa proper safety (Earth) ground.
SELECT SUITABLE LOCATIONPlace the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides and bottom. Dirt, dust, or any foreignmaterial that can be drawn into the welder should bekept at a minimum. Using filters on the air intake toprevent dirt from building up restricts air flow. Donot use such filters. Failure to observe these precau-tions can result in excessive operating temperaturesand nuisance shutdowns.
This machine (above code 10500 only) is equippedwith F.A.N. (fan as needed) circuitry. The fan runswhenever the output is enabled, whether underloaded or open circuit conditions. The fan also runs fora period of time (approximately 5 minutes) after theoutput is disabled, to ensure all components are prop-erly cooled.
If desired, the F.A.N. feature can be disabled (causingthe fan to run whenever the power source is on). Todisable F.A.N., connect leads 444 and X3A togetherat the output of the solid state fan control relay, locat-ed on the back of the Control PC board enclosure.
STACKINGPower Wave machines can be stacked to a maximumof 3 high. The bottom machine must always beplaced on a firm, secure, level surface. There is adanger of machines toppling over if this precaution isnot taken.
WARNING
WARNING
A-3INSTALLATION
POWER WAVE 455
A-3
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONSRefer 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“inverse time” or “thermal/magnetic” circuit breakers).Choose an input and grounding wire size according tolocal or national electrical codes. Using fuses or cir-cuit breakers smaller than recommended may result in“nuisance” shut-offs from welder inrush currents, evenif the machine is not being used at high currents.
INPUT VOLTAGE RECONNECT PROCEDURE
Only a qualified electrician should connect the inputleads to the Power Wave. Connections should bemade in accordance with all local and national electri-cal codes and the connection diagram located on theinside of the reconnect/input access door of themachine. Failure to do so may result in bodily injury ordeath.------------------------------------------------------------------------
Welders are shipped connected for the highest inputvoltage listed on the rating plate. To move this con-nection to a different input voltage, refer to reconnect
instructions located on the inside of the input accessdoor or in Figure A.1. If the main reconnect switch isplaced in the wrong position, the welder will not pro-duce output power. If the Auxiliary (“A”) lead is placedin the wrong position, there are two possible results.If the lead is placed in a position higher than theapplied line voltage, the welder may not come on atall. If the Auxiliary (“A”) lead is placed in a positionlower than the applied line voltage, the welder will notcome on, and the two circuit breakers in the reconnectarea will open. If this occurs, turn off the input volt-age, properly connect the “A” lead, reset the breakers,and try again.
OUTPUT CONNECTIONS
Use the largest welding (electrode and ground) cablespossible — at least 2/0, 4/0 preferred, copper wire —even if the average output current would not normallyrequire it. When pulsing, the pulse current canexceeds 650 amps. Voltage drops can becomeexcessive, leading to poor welding characteristics, ifundersized welding cables are used.
To avoid interference problems with other equipmentand to achieve the best possible operation, route allcables directly to the work or wire feeder. Avoidexcessive lengths, bundle the electrode and groundcables together where practical, and do not coilexcess cable.
FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/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’
S23847VOLTAGE=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
NOTE: Turn main input power to the machine OFF before performing reconnect procedure. Failure to doso will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON.
WARNING
S24196
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
550-575V
VOLTAGE=440-460V VOLTAGE=550-575V
’A’ ’A’
A
440-460V
.
inspecting or servicing machine. U / L1
Disconnect input power before
.Do not operate with covers
removed.
V / L2
.Do not touch electrically live parts.
CR1
W / L3
INPUT SUPPLY CONNECTION DIAGRAM
.
use or service this equipment.
Only qualified persons should install,
440-460V
550-575V
A-4INSTALLATION
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 availablefor this purpose.
To enable the work piece voltage sensing lead, ajumper must be removed from the Control PC Boardas follows:
1) Turn the Power Wave 455 power OFF.
2) Remove the front nameplate from the Power Wave455 by removing the six screws from the name-plate. Save the screws for re-use.
3) Locate P26, located on the upper right edge of theControl PC Board. It is a 16 pin connector withonly two wires going into it. Unplug P26. It shouldremain attached to the main harness.
4) Install the front nameplate on the Power Wave 455by replacing the six screws saved in Step 2.
5) Plug a Sense Lead into the Sense LeadReceptacle. Note: Only the lead marked ‘WORK’is used. The lead marked ‘ELECT’ can be cut offand discarded.
6) Connect the WORK sense lead clamp to the piecebeing welded.
The Power Wave 455 will now use the external workpiece Sense Lead to sense arc voltage in all weldingmodes. If the Sense Lead is enabled but not connect-ed to the work piece, extremely high welding outputcurrents may result.
To restore normal work piece sensing (at the outputterminals) reconnect P26 to the Control PC board.The Sense Lead can then be disconnected.
POWER WAVE / POWER FEED WIREFEEDER INTERCONNECTIONS
ELECTRODE & WORK LEADS —ELECTRODE POSITIVE APPLICATIONS
Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-trode cable between the wire feeder and the positive(+) output stud on the power source (located beneaththe spring loaded output cover near the bottom of thecase front).
A work lead must be run from the negative (-) powersource output stud to the work piece. The work piececonnection must be firm and secure, especially ifpulse welding is planned. Excessive voltage drops atthe work piece connection often result in unsatisfacto-ry pulse welding performance.
ELECTRODE & WORK LEADS —ELECTRODE NEGATIVE APPLICATIONS
When negative electrode polarity is required, such asin some Innershield™ applications, install as above,except reverse the output connections at the powersource (electrode cable to the negative (-) stud, andwork cable to the positive (+) stud).
CONTROL CABLE CONNECTIONS
Connect the control cable between the wire feederand power source. The power source wire feederconnection is located under the spring loaded outputcover, near the bottom of the case front. The controlcable is keyed and polarized, so it can be installed inonly one way.
For neatness and convenience sake, both the elec-trode and control cables can be routed behind the leftor right strain reliefs (under the spring loaded outputcover), and along the channels formed into the baseof the Power Wave, out the back of the channels, andthen to the wire feeder.
A-5INSTALLATION
POWER WAVE 455
A-5
POWER FEED CONTROL BOXMOUNTING
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 control the Power Wave / Power Feed weld-ing system.) Complete details for separating the con-trol box from the wire drive are contained in the PowerFeed Instruction Manual. Once separated, mountinginstructions are as follows:
1. Disconnect the input power from the Power Wave.
2. Separate the control box from the wire drive on thePower Feed wire feeder, and remove the controlpanels (see the Power Feed Instruction Manual fordetails).
3. Remove the front nameplate from the Power Waveby removing six screws from the metal nameplate.Save the screws for re-use.
4. Connect the 6-pin connector that comes out theback of the control box to the 6-pin receptacle thatis tie-wrapped to the harnessing inside the rectan-gular opening in the power source. It will be nec-essary to remove one or two of the wire ties inorder to give enough slack to the power sourceconnector and leads.
5. Position the control box over the rectangular holein the Power Wave case front, being careful not topinch any leads between the control box and thecase front. Align the four holes in the back of thecontrol box with the four threaded mounting holesin the case front. Secure the control box in placewith four of the screws saved from the previousstep.
6. Reassemble the control box.
The Power Feed Wire Drive can now be connected tothe power source wire feeder connector. This con-nector is located under the spring loaded outputcover, near the bottom of the case front. The controlcable is keyed and polarized, so it can be installed inonly one way. (To ensure proper electrode voltagesensing, always connect the Wire Drive to the PowerSource wire feeder connector. Do not connect it tothe optional Output Receptacle which may be presenton the Power Feed Control Box.)
B-1OPERATIONB-1
POWER WAVE 455
OPERATING INSTRUCTIONSRead 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 yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can bedangerous.• Keep your head out of fumes.
• Use ventilation or exhaust to removefumes from breathing zone.
WELDING SPARKS can causefire or explosion.• Keep flammable material away.
• Do not weld on containers that have held com-bustibles.
ARC RAYS can burn.• Wear eye, ear, and body protection.
Observe additional Safety Guidelinesdetailed in the beginning of this manual.
WARNING
B-2OPERATIONB-2
POWER WAVE 455
INPUT POWER
ON
OFF
HIGH TEMPERATURE
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 VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVEGROUND
WARNING
GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL
U0
U1
U2
I1
I2
SMAW
B-3OPERATIONB-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. Properlyequipped, it can support the GMAW, GMAW-P,FCAW, SMAW, GTAW and CAC-A processes.
RECOMMENDED PROCESSES ANDEQUIPMENT
RECOMMENDED PROCESSES
The Power Wave can be set up in a number of config-urations, some requiring optional equipment. Eachmachine is factory preprogrammed with multiple weld-ing procedures, typically including GMAW, GMAW-P,FCAW, SMAW, GTAW and CAC-A, for a variety ofmaterials, including mild steel, stainless steel, coredwires, and aluminum.
RECOMMENDED EQUIPMENT
The Power Wave 455 must be used with the PowerFeed family of wire feeders. These feeders arerequired to access and make use of the many of thewelding features contained in the Power Wave 455.
DESIGN FEATURES AND ADVANTAGES
A unique feature of the Power Wave is the ability tofunction without any controls, when used with PowerFeed wire feeders. All power source control informa-tion comes to the Power Wave from a Power Feedwire feeder.
The following chart lists the power source parametersthat can be changed from the Power Feed wire feed-er, and gives examples of each. (Optional equipmentmay be required to access some of the following para-meters.)
ADDITIONAL DESIGN FEATURES ANDADVANTAGES
• Designed to NEMA EW-1, IEC 974-1 and CSAStandards.
• Qualifies for “S” mark on nameplate, which means itcan be used in areas where there is increased riskof electric shock.
• Multiple process output ranges: 5 - 570 amps.
• Easy access for input connections. Connectionsare simple strip and clamp (no lugs required).
• F.A.N. (fan as needed). (On codes above 10500only) Cooling fan runs only when necessary.
• Modular construction for easy servicing.
• Thermostatically protected.
• Electronic over current protection.
• Input over voltage protection.
• Utilizes digital signal processing and microprocessorcontrol.
• Simple, reliable input voltage change over.
• All system components communicate and transferinformation.
• Auto device recognition simplifies accessory cableconnections.
Current (CC modes), Voltage (CV modes),Wire Feed Speed (synergic modes)
.500 to 1.500 (only in Pulse modes)
-10.0 to +10.0
B-4OPERATION
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, a thermostat will shut offthe output until the machine cools to a reasonableoperating temperature.
LIMITATIONS
• The Power Wave is not recommended for process-es other than those listed.
• The Power Wave can only be used with PowerFeed wire feeders. Other models of Lincoln feed-ers, or any models of non-Lincoln wire feeders, can-not be used.
COMPATIBLE LINCOLN EQUIPMENT
All Lincoln Power Feed™ Wire Feeders.
POWER SOURCE OPERATION
DUTY CYCLE AND TIME PERIOD
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 duty cycle is based upon a tenminute period. A 60% duty cycle represents 6 minutesof welding and 4 minutes of idling in a ten minute peri-od.
CASE FRONT CONTROLS
All operator controls and adjustments are located onthe case front of the Power Wave.
1. POWER SWITCH: Controls input power to thePower Wave.
2. STATUS LIGHT: A two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated as follows:
NOTE: The Power Wave 455 status light will flashgreen, and sometimes red and green, for up to oneminute when the Power Wave 455 is first turned on.This is a normal situation as the machine goesthrough a self test at power up.
3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled until themachine cools down. When cool, the light goesout and output is enabled.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAK-ER: Protects 110 volt AC case front receptacleauxiliary supply.
LightCondition
Steady Green
BlinkingGreen
A l t e r n a t i n gGreen andRed
Steady Red
Blinking Red
Meaning
System OK. Power source communicating nor-mally with wire feeder and its components.
Nothing connected to Wire FeederReceptacle.
Recoverable system fault.SeeTroubleshooting Section.
Non-recoverable system fault. Must turnpower source off, find source of error, andturn power back on to reset. SeeTroubleshooting Section.
See Troubleshooting Section.
B-5OPERATIONB-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 feeder. It can be mounted directly on the wirefeeder itself, or mounted separately, as might be donein a welding boom installation.
Because the control box can be configured with manydifferent options, your system may not have all of thefollowing adjustments. Regardless of availability, allcontrols are described below. For further information,consult the Power Feed wire feeder instruction manual.
1. WFS / AMPS:In synergic welding modes (synergic CV, pulseGMAW) WFS (wire feed speed) is the dominantcontrol parameter, controlling all other variables.The user adjusts WFS according to factors such asweld size, penetration requirements, heat input, etc.The Power Wave then uses the WFS setting toadjust its output characteristics (output voltage, out-put current) according to pre-programmed settingscontained in the Power Wave. In non-synergicmodes, the WFS control changes the wire feedspeed according to the desired procedure.
In constant current modes (stick, TIG) this controladjusts the output current, in amps.
2. VOLTS / TRIM:In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAWonly) the user can change the Trim setting to adjustthe arc length. It is adjustable from 0.500 to 1.500.A Trim setting of 1.000 is a good starting point formost conditions.
3. 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 characteristicsof the Power Wave power source. For a morecomplete description of the welding modes avail-able in the Power Wave, see the explanationbelow.
4. ARC CONTROL:Also known as Inductance or Wave Control. Allowsoperator to vary the arc characteristics from “soft”to “harsh” in all weld modes. It is adjustable from -
10.0 to +10.0, with a nominal setting of 00.0. (Thenominal setting of 00.0 may be displayed as OFFon some Power Feed wire feeder control panels.)See the Welding Mode descriptions, below, fordetailed explanations of how the Arc Control affectseach mode.
DETAILED WELD MODE DESCRIPTIONS
CONSTANT VOLTAGE (CV/WELD, CV/MIG,CV/FLUX CORED) PROCEDURES
For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-wares at the factory. This preprogrammed voltage isthe best average voltage for the procedure at thegiven wire feed speed. If the wire feed speed ischanged on the wire feeder, the voltage automaticallychanges with it.
In some cases, the operator may want to change thepreprogrammed voltages; for example, to compensatefor cable and fixture voltage drops. The preset volt-ages can be adjusted on the wire feeder’s Voltagedisplay. When a change is made to the voltage atone wire feed speed, this change is applied to allother wire feed speed settings. For example, if theoperator turns up the voltage by 10 percent, themachine automatically increases the preset voltagesat all the other wire feed speeds by 10 percent. Thepreset voltage, programmed at the factory, may bechanged with the wire feeder VOLTS adjustment.
The Arc Control adjusts the inductance. (This adjust-ment is often referred to as “pinch”. Inductance isinversely proportional to pinch.) Increasing the ArcControl setting decreases the inductance, whichresults in the arc getting colder and pinched tighter.Decreasing the Arc Control setting increases theinductance, which results in the arc getting wider(reduced pinch).
GMAW PULSE PROCEDURES
In these procedures, the actual voltage greatlydepends on the waveform used. The peak currents,background currents, rise times, fall times, and pulsetimes all affect the actual voltage. The actual voltagefor a given wire feed speed is not directly predictableunless the waveform is known. In this case, it is notpractical to preset an actual voltage for the procedure.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.
POWER WAVE 455
B-6OPERATIONB-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 Trim setting less than 1.000decreases the preset arc lengths. The arc length trimadjustment is factored in at all wire feed speed set-tings. Increasing the Trim by 10 percent at a givenwire feed speed also increases all the other arc lengthtrim settings of the procedure by 10 percent.
The Power Wave utilizes a control scheme known asadaptive control in all pulse modes. Because thePower Wave utilizes adaptive control, it can adjust thepulsing parameters based on changes in the arc dueto changes in the electrical stickout of the electrode.(Electrical stickout is the distance from the contact toto the workpiece.) The Power Wave is optimizedfor use with a .75” stickout. The adaptive behavioris programmed to support a stickout range from .5” to1.25”. In the low and high end of the wire feed speedranges of most processes, the adaptive behavior maybe restricted. This is a physical restriction due toreaching the edge of the operating range for theprocess.
The Arc Control adjustment allows the pulse frequen-cy to be varied. Increasing the Arc Control causes thefrequency setting to increase, while decreasing theArc Control causes the frequency to decrease.Varying the Arc Control, and hence, the pulse fre-quency, affects the droplet transfer and allows fine-tuning for different welding positions.
CONSTANT CURRENT (CC/STICK, CC/TIG)PROCEDURES
Stick welding can be performed by choosing one ofthe stick welding modes. Check the Power Feed wirefeeder Operator’s Manual for instructions on how toenergize the output terminals on the Power Wave.(Certain options energize the terminals automaticallywhile other options require a manual adjustment toenergize the terminals.) The output current is set bythe Amps control on the Power Feed wire feeder. TheVolts/Trim adjustment has no effect in this mode.
The Arc Control adjusts the arc force. Increasing theArc Control setting increases the arc force, makingthe arc more harsh but less likely to stick. Decreasingthe Arc Control setting decreases the arc force, mak-ing the arc softer and smoother.
ARC GOUGING PROCEDURES
Arc gouging can be performed by choosing the arcgouging weld mode. Doing so automatically ener-gizes the output terminals on the Power Wave, mak-ing the power source immediately ready to weld. Theoutput current is set by the Amps control on thePower Weld wire feeder. The Volts/Trim adjustmenthas no effect in this mode.
The Arc Control adjusts the arc force. Increasing theArc Control setting increases the arc force, makingthe arc more harsh but less likely to stick. Decreasingthe Arc Control setting decreases the arc force, mak-ing the arc softer and smoother.
POWER WAVE 455
C-1ACCESSORIESC-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 Voltage Sense Lead Kit- 10 foot voltagesense lead kit.
K940-25 Voltage Sense Lead Kit- 25 foot voltagesense lead kit, if additional length is required.
K940-50 Voltage Sense Lead Kit- 50 foot voltagesense lead kit, if additional length is required.
POWER WAVE 455
D-1MAINTENANCED-1
POWER WAVE 455
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
Routine maintenance consists of periodicallyblowing out the machine, using a low pressureairstream, to remove accumulated dust and dirtfrom the intake and outlet louvers, and the coolingchannels in the machine.
WARNING
E-1TROUBLESHOOTINGE-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 working properly, always check the
color of the Status LED, and refer to the followingchart to help you determine which system compo-nent (power source, wire feeder, wire drive, etc.)may be faulty. Replace the components identifiedas potentially faulty with known good compo-nents, and the system should operate normally.
Status LED is solid green (no blinking).
Status LED is blinking green.
Status LED is solid red (no blinking).
Status LED is blinking red and green.
Status LED is blinking red.
System operating normally.
1. Normal condition for the first few seconds after thepower is turned on.
2. Wire feeder and/or its components are not prop-erly configured and/or connected together. Referto wire feeder instruction manual(s) for wire feederconfiguration information.
1. Indicates that nothing is connected to the WireFeeder Receptacle. Connect a Power Feed WireFeeder to the wire feeder receptacle.
2. Power source cannot communicate with the wirefeeder and/or its components due to a problemwithin the power source. Contact an authorizedLincoln Electric Service facility.
1. If the Thermal LED is also lit, see “Yellow ThermalLED Lit” in the Main Troubleshooting Chart.
2. Input voltage is too high or too low. Make certainthat input voltage is proper, according to theRating Plate located on the rear of the machine.
3. Power source is having trouble communicatingwith wire feeder or its components. Turn machineoff. Disconnect control cable from the WireFeeder Receptacle. Turn power back on. IfStatus LED then blinks green, the problem is withthe wire feeder. If light is still blinking red andgreen, contact an authorized Lincoln Field Servicefacility.
1. Error code display. Contact an authroized LincolnField Service Shop.
E-2TROUBLESHOOTINGE-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 warranty. For your safety, please observe all safety notes and precautionsdetailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshootingthis equipment.
CAUTION
WARNING
If for any reason you do not understand the test procedures or are unable to perform the tests/repairssafely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
This Troubleshooting Guide is provided to helpyou locate and correct possible machine misad-justments. Simply follow the three-step procedurelisted below.
Step 1. LOCATE PROBLEM (SYMPTOM)
Look under the column labeled “PROBLEM(SYMPTOMS).” This column describes possiblesymptoms that your machine may exhibit. Findthe listing that best describes the symptom thatyour machine is exhibiting.
Step 2. PERFORM EXTERNAL RECOMMEND-ED TESTS
The second column labeled “POSSIBLE AREASOF MISADJUSTMENT(S)” lists the obviousexternal possibilities that may contribute to themachine symptom. Perform these tests/checks inthe order listed. In general, these tests can beconducted without removing the case wrap-around cover.
Step 3. CONSULT LOCAL AUTHORIZEDFIELD SERVICE FACILITY
If you have exhausted all of the recommendedtests in step 2, consult your local AuthorizedField Service Facility.
E-3TROUBLESHOOTINGE-3
POWER WAVE 455
Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTIONIf 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 technical assistance.
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.
Input fuses keep blowing, or inputbreaker keeps tripping.
Machine will not power up (nolights, no fan, etc.)
Contact your local authorizedLincoln Electric Field Service facili-ty for technical assistance.
1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.
2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.
3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.
1. Make certain that the PowerSwitch (SW1) is in the “ON”position.
2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset. Also, check input volt-age selection, below.
3. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.
If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.
E-4TROUBLESHOOTINGE-4
POWER WAVE 455
Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTIONIf 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 technical assistance.
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMSWire feeder won’t work. No lights,apparently no power to wire feeder.
Thermal LED is lit.
Machine won’t weld, can’t get anyoutput. (CR1 will not pull in.)
1. Circuit breaker CB1 (on casefront) may have opened.Reset.
2. Control cable between thepower source and wire feederis “open”. Check continuity onall 5 leads from end to end inthe control cable.
3. Check for 40 volts DC on pinsD (+40) and E (common) ofthe Wire Feeder Receptacle.If 40 volts DC is not present,and CB1 is reset, contact anauthorized Lincoln ElectricService facility.
1. Fan thermostat has opened. Checkfor proper fan operation. (Fan shouldrun whenever main power is on.)Check for material blocking intake orexhaust louvers, or for excessive dirtclogging cooing channels in machine.
2. Secondary rectifier thermostat hasopened. After machine has cooled,reduce load, duty cycle, or both.Check for material blocking intake orexhaust louvers.
1. Input voltage is too low or too high.Make certain that input voltage isproper, according to the Rating Platelocated on the rear of the machine.
2. If the Thermal LED is also lit, see“Yellow Thermal LED is Lit” section.
3. Primary current limit has beenexceeded. Possible short in outputcircuit. Turn machine off. Remove allloads from the output of the machine.Turn back on. If condition persists,turn power off, and contact an autho-rized Lincoln Electric Field Servicefacility.
If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.
E-5TROUBLESHOOTINGE-5
POWER WAVE 455
Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTIONIf 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 technical assistance.
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure
Machine won’t produce full output.
For no apparent reason, the weld-ing characteristics have changed.
Auxiliary receptacle is “dead” — noauxiliary voltage .
Secondary current limit has beenexceeded, and the machine hasphased back to protect itself.Adjust procedure or reduce load tolower current draw from themachine.
1. Input voltage may be too low,limiting output capability of thepower source. Make certainthat the input voltage is prop-er, according to the RatingPlate located on the rear ofthe machine.
2. Input may be “single phased”.Make certain the input voltageis proper on all three inputlines.
1. Check for proper Wire FeedSpeed setting. In CV MIGand FCAW modes, check forproper Voltage setting. In theMIG/MAG pulse modes,check the Trim setting. Thesecontrols are on the wire feed-er.
2. Check for proper shieldinggas mix and flow.
3. Check for loose or faulty weldcables and cable connections.
1. Circuit breaker CB2 (on casefront) may have opened.Reset.
2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.
If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.
F-1DIAGRAMSF-1
POWER WAVE 455
31
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
16
BD #1
12
TRANSFORMER
TO CURRENT
BD #2
16
PRIMARY
(TOP
LEFT)
TRANSFORMER
RECT.
TO CURRENT
F4
TO SWITCH
THERM.
C3
D4
TO
OUTPUT RECT
273
274
TO
J27
J22
SECONDARY
(BOTTOM
LEFT)
PRIMARY
(BOTTOM
LEFT)
SECONDARY
(TOP
LEFT)
MAIN TRANSFORMER
LEFT SIDE
N.D.
TO CURRENT
3ELECTRODE
21A
WORK
4
4
MAIN CHOKE
L1
3
TP1
2
H1A
++
P6
TO AUX #2
J20
612B
54A
67A
TO SW1
67B
TO J61
CB3
612A
612
H1
TO AUX #1
TO SOLID STATE RELAY
4
TO CB4
C1
612A
AUXILIARY TRANSFORMER #1
TO
AUX #2
H1A
TO
H5
S4
CB2
6 1
(440-460)
H5A
P81
3(380-415)
H3
H4A
H2
2(220-230)
H3A
H2A
H1
(200-208)
4
AUXILIARY TRANSFORMER #2
5
4
6
SWITCH BOARD #1
J21A,J21B
TO SW1
RECONNECT PANEL
CB3
10A CIRCUIT
BREAKER
1
’A’
J32,J40
J50,J81
403
406
TO J23
D2
10W
2.7
AUX. #1
1
THERM
CHOKE
TO
10W
2.7
10W
2.7
TO J22
CB2
L2
N.D.
C3
TO224
224A
AC
52A
1
432
TRANSFORMER
218
TO CURRENT
TRANSFORMER
D1 800V
.022
POS
POS
2.7
10W
N.D.
TRANSFORMER
15
.022
800V
POS
RECTIFIER
INPUT
U
SWITCH
TO
RECONNECT
L1A
T2 TO SW1
503
234
4 5 7
L3A
8
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
4
TO SUPPLY LINES
G
AC1
POS
AC2
J22
3 4
254
253
7654321
6
DCBA
218765
(220-230)
H3A
H2 H1
H2
H3
(200-208)
N
H1
(24V)
R
(115V)
(51V)
6
5
H4
W R+
19D
J50 (115V)
403
503
506
404
235
604
405 1B
239
238
406 1W
TO MAIN TRANS
1 1
2B
214
213
212
N.D.
212
50
NEG
CB1
32
221
1
9865
POWER BD
TO
TO AUX #1
2T1
3
T2
TO
J61
CR1
6612
SW1
CB4
H1D
9
T3
T1
L2
WORK
ELECTRODE
206A
J27
TO
S4
31
J81
CR1
X4
S3
RS232
CONNECTOR
REAR OF MACHINE
ELECTRODE
4
LOAD
LINE
SW1
POWER
G3051-1
S1
WIRE
FEEDER
RECEPTACLE
FAN
CB4
6A CIRCUIT
BREAKER
TM
POWER WAVE 455 WIRING DIAGRAM
S2
VOLTAGE
SENSE
RECEPTACLE
D
202A
TO TP3
TRANSFORMER
+
NEG
NEG
AC3
T3 L3
TO SW1
WV
CB4
S2
H4A
RECONNECT PANEL
202
2
2
3
14
8
TO
251
11
S3
12
253
1
254
2 3
J40
+
C4
13
14
POWER BOARD
H5A
H5
(440-460)
H4
U
(380-415)
TO J20
-
202
+
X5
TO RECT THERM
224A
CHOKE
-
WORK
LEFT SIDE OF MACHINE
CONTROL BOARD
N.C.
X5
H5
H4
444
H3
H2
RECONNECT SWITCH
TO SWITCH BD #2
THIS AREA VIEWED FROM REAR OF MACHINE
TO L7
206A
405
404
1
TO CURRENT
X3A
TO SOLID STATE RELAY
TO AUX#1
P6
USER
INTERFACE
220
14
15
CURRENT
800V
.022
800V
.022
P91
CURRENT
TRANSDUCER
TO J24
TO J22
50
CB1
10A CIRCUIT
BREAKER
TP2
TO
WORK
1W
2W
C2
ELECTRODE
N.A.
206
N.A.
THERMAL LED (Y)
TO J20
STATUS LED (R/G)
52
1B
.05/600V
2B
TO R1
876541 3876543216
15
14
J21B
J21A
506
239
TO SWITCH
TO J23
11
21
3 7
TRANSFORMER
TO R1
291
THERM.
TO J21A
216
211
213
TO SWITCH BD #1
20C
TO INPUT RECT
19C
POS
TO SWITCH BD #1
N.B.
NEG
TO INPUT RECT
TO SWITCH BD #2
20D
19D
14
J20,J26
7
98
1
12
16
710
L1
J23
8
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
11 6
J22,J61
56
1
J24,J31
228
L2
TO
225
50
22
S1
TO
67B
51A
54A
52
13
CURRENT
12
J27
TO
11
TO
10
67A
98
POWER BD
J20
CB1
L2
TO
.05/600V
TO MAIN TRANS
TRANSFORMER
87
J60
6
231
543
232
2
604
238
X3
601
3
INPUT BOARD
4
17
18
1
2
10
5
21A
53A
2
51A
51
3
52A
4
1
53A
54
E
53
TO AUX#1
J31
S1
TO
51
X1
53
X3A
TO
SOLID STATE RELAY
274
TP4
J32
273
STATUS LED
AC
POS
NEG
POS
POS
654
J60
J50
J40
TO
231
THERM.
TP3
220
2W
1211
10
9
J26
9 10
7651 3211
13
12
10
13
4
43
54
12
1
42
AUX #1
J25
380-415V
3R
3W
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
TO
1
CB3
6
440-460V
220-230V
200-208V
65432116
15
141
211
1
216
218
444
50WT
221
222
223
224
225
226
TO
J31
1
LED
J31
THERMAL
5 6 7 8 9 10 11
12
RECT.
4
P91
TO
N.D.
L7
235
F2
F2
SECONDARY
(BOTTOM
RIGHT)
BD #1
PRIMARY
(TOP
RIGHT)
13
SECONDARY
(TOP
RIGHT) RIGHT SIDE
15
16
PRIMARY
(BOTTOM
RIGHT)
C5
17
BD #2
TO SWITCH
F1
F1
SWITCH BOARD #2
20D
TO RECONNECT SWITCH
TO
CR1
J23
AUX #1
222
223
3
214
2
51BK
TO FAN
233
X1
WH5
CONNECTION SHOWN IS FOR 440-460V OPERATION.
8
J60
13
5
COMPONENT VALUES:
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK
G=GREEN
NOTES:
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
N=BROWN
U=BLUE
R=RED
W=WHITE
RIGHT SIDE OF MACHINE
J27,J28
N.D MAY NOT APPEAR ON ALL MACHINES.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
J25
43J28
87653214 5 6
202A
226
TO RECONNECT SWITCH
12
20C
19C
228
109
33
J25
20
TO
251
TO J61
J20
TO J60
TO
601
291
D3
R1
TP7
1
CB2
10A CIRCUIT
BREAKER
7
234
233
232
J23
432F4
TO
F3
F3
TO FAN
H3
H4
W
H2A
X4
X3
X3
X2
J60
CR1
TO
TO POWER BD. RECTIFIER
3W
SOLID
STATE
RELAY
J24
TO
3R
206
65
S1
TO
1
NO
TE:
This
dia
gram
is fo
r ref
eren
ce o
nly.
It
may
not
be
accu
rate
for a
ll m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a p
artic
ular
cod
e is
pas
ted
insi
deth
e m
achi
ne o
n on
e of
the
encl
osur
e pa
nels
. If
the
diag
ram
is il
legi
ble,
writ
e to
the
Serv
ice
Dep
artm
ent f
or a
repl
acem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber..
F-2DIAGRAMSF-2
POWER WAVE 455
N.B.
17A
RECONNECT SWITCH
N.C.
17B
18B
++P91
CURRENT
TRANSDUCER
13
14B
CR1
T3
TO AUX #1
T2
TO SW1
L3
L3A
T1
W
L2
TO SWITCH BD #1
TO TOP RIGHT PRI
13B
THIS AREA VIEWED FROM REAR OF MACHINE
L1
TO SW1
L1A
TO BOTTOM RIGHT PRI
18A
TO SWITCH BD #2
17
TO TOP LEFT PRI
TO BOTTOM RIGHT PRI
TO AUX #1
TO SWITCH BD #1
14
TO TOP LEFT PRI
H5
TO TOP RIGHT PRI
13A
H6
14A
TO BOTTOM LEFT PRI
L2
S3
RS232
CONNECTOR
X4
TO SWITCH
BD #2
POS
AC3
AC2
TO J61
601
CB4
6A CIRCUIT
BREAKER
FAN
INPUT BOARD
TO BOTTOM LEFT PRI
A
POWER WAVE 455 (460 / 575V) WIRING DIAGRAM
TM
TO A SYSTEM GROUND PER
U
TO SUPPLY LINES
G
SWITCH BOARD #1
LEFT SIDE OF MACHINE
CONTROL BOARD
CB1
10A CIRCUIT
BREAKER
WORK
31
S1
WIRE
FEEDER
RECEPTACLE
FRONT OF MACHINE
110V RECEPTACLE
S4
SECONDARY
(BOTTOM
RIGHT)
SECONDARY
(TOP
RIGHT) RIGHT SIDE
N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 550-575V OPERATION.
AUXILIARY TRANSFORMER #2
RIGHT SIDE OF MACHINE
S2
VOLTAGE
SENSE
RECEPTACLE
CB2
5A CIRCUIT
BREAKER
SWITCH BOARD #2
CB3
10A CIRCUIT
BREAKER
AUXILIARY TRANSFORMER #1
POWER BOARD
NATIONAL ELECTRICAL CODE.
G3051-2
PRIMARY
(BOTTOM
LEFT)
CONNECTION SHOWN IS FOR 550-575V OPERATION.
(TOP)
ELECTRODE
SW1
POWER
TO SWITCH BD #2
’A’
440-460V
550-575V
RECTIFIER
REAR OF MACHINE
TO SWITCH
BD #1
POS
AC1
POWER BD RECTIFIER
SECONDARY
(TOP
LEFT)
OUTPUT RECT
MAIN TRANSFORMER
LEFT SIDE PRIMARY
(TOP
LEFT)
SECONDARY
(BOTTOM
LEFT)
32
NEG
INPUT
TO
J81
TO J60
CB2
TO SW1
RECONNECT PANEL
NEG
MAIN CHOKE
L1
SOLID
STATE
RELAY
PRIMARY
(BOTTOM
RIGHT)
PRIMARY
(TOP
RIGHT)
18
V
NO
TE:
This
dia
gram
is fo
r ref
eren
ce o
nly.
It
may
not
be
accu
rate
for a
ll m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a p
artic
ular
cod
e is
pas
ted
insi
deth
e m
achi
ne o
n on
e of
the
encl
osur
e pa
nels
. If
the
diag
ram
is il
legi
ble,
writ
e to
the
Serv
ice
Dep
artm
ent f
or a
repl
acem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber..
F-3DIAGRAMSF-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 M18
241
DIMENSION PRINT - POWER WAVE 455
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Educational Video Information Incentive Management $5.00 IM(ED-93) A New Approach to Industrial Economics $5.00 NA
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WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
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 INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-piración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-tien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
• 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 •
