Operator’s Manual POWER WAVE 455M/STT€¦ · 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or

POWER WAVE ® 455M/STT ®

Operator’s Manual

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM771-C | Issue D ate 13-Jan

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

10957,11153, 11877,11944

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After hours? Use “Ask the Experts” at lincolnelectric.comA Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA: Email: [email protected]

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

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing 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 oridler by pushing on the throttle control rodswhile 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

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 WARNINGS

Diesel 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. 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 prod-ucts.

5.d. 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.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iiiSAFETYiii

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 manufacturerʼsrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs 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.

WELDING and CUTTINGSPARKS 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 hotmaterials 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.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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 LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, 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 leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits 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 dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils 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 provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc 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 delʼélectricité 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, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

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 or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this 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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Support” and then “RegisterYour Product”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.

vi vi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ......................................................................................A-1Safety Precautions.................................................................................................A-2Select Suitable Location ........................................................................................A-2

Lifting...............................................................................................................A-2Stacking ..........................................................................................................A-2

Machine Grounding ...............................................................................................A-2High Frequency Protection ....................................................................................A-2Input Connection....................................................................................................A-2Input Fuse and Supply Wire Considerations .........................................................A-3Input Voltage Change Over Procedure..................................................................A-3Electrode and Work Cable Connections................................................................A-3Cable Inductance, and its Effects on Pulse Welding ............................................A-4Negative Electrode Polarity ...................................................................................A-4Voltage Sensing ................................................................................................... A-4Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-5System Description................................................................................................A-5Configuring The System..................................................................................A-6,A-7Welding with Multiple Power Waves......................................................................A-8Control Cable Specifications..................................................................................A-8Multiple Arc Unsynchronized .................................................................................A-9I / O Receptacle Specifications............................................................................A-10

Dip Switch Settings and Locations...............................................................A-10Control Board Dip Switch ..............................................................................A-10Water Flow Sensor........................................................................................A-10

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1Graphic Symbols that appear on this machine or in this manual...........................B-2Definition of Welding Terms...................................................................................B-3General Description ...............................................................................................B-4Recommended Processes and Equipment ...........................................................B-4Required Equipment ..............................................................................................B-4Limitations..............................................................................................................B-4Duty Cycle and Time Period ..................................................................................B-4

Case Front Controls ........................................................................................B-5Nominal Procedures........................................................................................B-6Fringe Procedures...........................................................................................B-6Making a Weld ................................................................................................B-6Welding Adjustment ........................................................................................B-6Constant Voltage Welding...............................................................................B-7Pulse Welding .................................................................................................B-8

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Equipment ...............................................................................................C-1Factory Installed..............................................................................................C-1Field Installed..................................................................................................C-1Compatible Lincoln Equipment .......................................................................C-1

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Routine Maintenance.............................................................................................D-1Periodic Maintenance............................................................................................D-1Calibration Specification ........................................................................................D-1

________________________________________________________________________

vii vii TABLE OF CONTENTSPage

Troubleshooting ..............................................................................................Section EHow to use Troubleshooting Guide .......................................................................E-1Using the Status LED to Troubleshoot System Problems .....................................E-2Error Codes For Power Waves..............................................................................E-3Troubleshooting Guide.............................................................................E-4 thru E-7

________________________________________________________________________Wiring Diagram ............................................................................................Section F-1Connection Diagrams...........................................................................Section F-2, F-3Dimension Print............................................................................................Section F-4

________________________________________________________________________Parts Lists ...................................................................................................P-450 Series

________________________________________________________________________

A-1INSTALLATION

POWER WAVE® 455M/STT®

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE® 455M/STT® (K2203-1)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

208/230/460/575V - 60HZ.

200/220/440/575V - 50HZ.

OPENCIRCUIT

VOLTAGE

75 VDC

INPUTVOLTAGE /

FREQUENCY

208/50/60HZ230/50/60HZ460/50/60HZ575/50/60HZ

HEIGHT26.10 in663 mm

WIDTH19.86 in505 mm

DEPTH32.88 in835 mm

WEIGHT293 lbs.133 kg.

TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)

1101005040

TYPE 75°CGROUND WIRE IN

CONDUIT AWG SIZES (mm2)

6(16)6(16)10(6)10(6)

TYPE 75°CCOPPER WIRE IN

CONDUIT AWG SIZES(mm2)

4(25)4(25)8(10)10(6)

PROCESS CURRENT RANGES (DC)

MIG/MAGFCAWSMAWPulseSTT®

CURRENT

50-570 Average Amps 40-570 Average Amps30-570 Average Amps5-750 Peak Amps 40-325 Average Amps

PULSEVOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER(CIRCUIT BREAKER PROTECTED)

40 VDC AT10 AMPS

115VAC AT15* AMPS

PULSE ANDBACKGROUNDTIME RANGE

100 MICRO SEC. -3.3 SEC.

CURRENTRANGE/

STT®

5-575/5-325

PULSEFREQUENCY

0.15 - 1000 Hz

INPUTCURRENT

AMPS

58/53/25/22 82/78/37/31

49/45/23/1867/61/31/25

IDLEPOWER

400 WattsMax.

POWER FACTOR@ RATED OUTPUT

.95 MIN.

EFFICIENCY@ RATED OUTPUT

88%

OUTPUT CONDITIONS

[email protected]%570A@43V. 60%

[email protected]%500A@40V. 60%

OPERATING TEMPERATURE RANGE-20°C to +40°C

STORAGE TEMPERATURE RANGE-40°C to +40°C

* Earlier models used 10 amps circuit breaker.

LIFTING

Lift the machine by the lift bail only. The lift bail is designedto lift the power source only. Do not attempt to lift the PowerWave with accessories attached to it.

STACKING

Power Wave machines can be stacked to a maximum of 3high.

The bottom machine must always be placed on a firm,secure, level surface. There is a danger of machinestoppling over if this precaution is not taken.

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MACHINE GROUNDINGThe frame of the welder must be grounded. A ground termi-nal marked with the symbol is located inside the recon-nect/input access door for this purpose. See your local andnational electrical codes for proper grounding methods.

HIGH FREQUENCY PROTECTIONLocate the Power Wave® away from radio controlledmachinery.

The normal operation of the Power Wave®

may adversely affect the operation of RFcontrolled equipment, which may resultin bodily injury or damage to the equip-ment.

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INPUT CONNECTION

Only a qualified electrician should connect the inputleads to the Power Wave®. Connections should be madein accordance with all local and national electricalcodes and the connection diagram located on the insideof the reconnect/input access door of the machine.Failure to do so may result in bodily injury or death.

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Use a three-phase supply line. A 1.75 inch (45 mm) diame-ter access hole for the input supply is located on the upperleft case back next to the input access door. Connect L1,L2, L3 and ground according to the Input Supply ConnectionDiagram decal located on the inside of the input accessdoor or refer to Figure A.1 on the following page.

SAFETY PRECAUTIONS Read this entire

installation section before you start installation.

ELECTRIC SHOCK can kill.

• Only qualified personnel should per-form this installation.

• Turn the input power OFF at the

disconnect switch or fuse box beforeworking on this equipment. Turn off the inputpower to any other equipment connected to thewelding system at the disconnect switch or fusebox before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave® grounding lug(located inside the reconnect input access door)to a proper safety (Earth) ground.

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SELECT SUITABLE LOCATIONDo not use Power Waves® in outdoor environments. ThePower Wave® power source should not be subjected tofalling water, nor should any parts of it be submerged inwater. Doing so may cause improper operation as well aspose a safety hazard. The best practice is to keep themachine in a dry, sheltered area.

Do not mount the POWER WAVE® 455M/STT® over com-bustible surfaces. Where there is a combustible surfacedirectly under stationary or fixed electrical equipment, thatsurface shall be covered with a steel plate at least .060"(1.6mm) thick, which shall extend not less than 5.90"(150mm) beyond the equipment on all sides.

Place the welder where clean cooling air can freely circulatein through the rear louvers and out through the case sidesand bottom. Dirt, dust, or any foreign material that can bedrawn into the welder should be kept at a minimum. Do notuse air filters on the air intake because the air flow will berestricted. Failure to observe these precautions can result inexcessive operating temperatures and nuisance shutdowns.

Machines are equipped with F.A.N. (fan as needed) circuitry.The fan runs whenever the output is enabled, whether underloaded or open circuit conditions. The fan also runs for aperiod of time (approximately 5 minutes) after the output isdisabled, to ensure all components are properly cooled.

If desired, the F.A.N. feature can be disabled (causing thefan to run whenever the power source is on).

To disable F.A.N., connect leads 444 and X3A together at theoutput of the solid state fan control relay, located on the back ofthe Control PC board enclosure. (See Wiring Diagram)

A-2INSTALLATION


A-2

WARNING

WARNING

CAUTION

CAUTION

A-3INSTALLATION


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 circuitbreakers 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 CHANGE OVER(FOR MULTIPLE INPUT VOLTAGEMACHINES ONLY)Welders are shipped connected for the highest inputvoltage listed on the rating plate. To move this connec-tion to a different input voltage, see the diagram locat-ed on the inside of the input access door. If the mainreconnect switch or link position is placed in the wrongposition, the welder will not produce output power.

If the Auxiliary (A) lead is placed in the wrong position,there are two possible results. If the lead is placed in aposition higher than the applied line voltage, thewelder may not come on at all. If the Auxiliary (A) leadis placed in a position lower than the applied line volt-age, the welder will not come on, and the two circuitbreakers or fuses in the reconnect area will open. Ifthis occurs, turn off the input voltage, properly connectthe (A) lead, reset the breakers, and try again. Formachines equipped with a fuse in the reconnect area,turn off the input voltage and replace the fuse with thespare fuse that is attached to the reconnect switch pin.

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure todo so will result in damage to the machine.

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

200-208V

220-230V

440-460V

550-575V

200-208V

220-230V

= 220-230V

220-230V

200-208V

220-230V

440-460V

550-575V

200-208V

U / L1

550-575V

440-460V 'A'

'A'

= 440-460V

'A'

S2

5198

VOLTAGEVOLTAGEVOLTAGE

VOLTAGE = 200-208V

TH

E L

INC

OL

N E

LE

CT

RIC

CO

. C

LE

VE

LA

ND

, OH

IO U

.S.A

.X

A

'A'

= 550-575V

CR1

W / L3

V / L2

440-460V

550-575V

.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.

.

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC SHOCKCAN KILL

ELECTRODE AND WORK CABLE CON-NECTIONSConnect a work lead of sufficient size and length (PerTable 1) between the proper output terminal on thepower source and the work. Be sure the connection tothe work makes tight metal-to-metal electrical contact.To avoid interference problems with other equipmentand to achieve the best possible operation, route allcables directly to the work and wire feeder. Avoidexcessive lengths and do not coil excess cable.

Minimum work and electrode cables sizes are as follows:TABLE A.1

(Current (60% Duty Cycle) MINIMUM COPPERWORK CABLE SIZE AWGUp To-100 Ft. Length (30 m)

400 Amps 2/0 (67 mm2)500 Amps 3/0 (85 mm2)600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommendedto reduce the cable inductance in long cable lengths.This is especially important in Pulse and STT® applica-tions.

When using inverter type power sources like thePower Waves, use the largest welding (electrodeand ground) cables that are practical. At least 2/0copper wire - even if the average output currentwould not normally require it. When pulsing, thepulse current can reach very high levels. Voltagedrops can become excessive, leading to poorwelding characteristics, if undersized weldingcables are used.------------------------------------------------------------------------

CAUTION

A-4INSTALLATION


A-4

CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDINGFor Pulse Welding processes, cable inductance will causethe welding performance to degrade. For the total weldingloop length less than 50 feet, traditional welding cables maybe used without any effects on welding performance. For thetotal welding loop length greater than 50 feet, the K1796Coaxial Welding Cables are recommended. The welding looplength is defined as the total of electrode cable length (A) +work cable length (B) + work length (C) (See Figure A.2).

For long work piece lengths, a sliding work connection shouldbe considered to keep the total welding loop length less than50 feet. (See Figure A.3.)

Output connections on some Power Waves® are made via 1/2-13 threaded output studs located beneath the spring loaded out-put cover at the bottom of the case front.

Most welding applications run with the electrode being positive(+). For those applications, connect the electrode cable betweenthe wire feeder and the positive (+) output stud on the powersource (located beneath the spring loaded output cover near thebottom of the case front). Connect the other end of the electrodecable to the wire drive feed plate. The electrode cable lug mustbe against the feed plate. Be sure the connection to the feedplate makes tight metal-to-metal electrical contact. The electrodecable should be sized according to the specifications given in thework cable connections section. Connect a work lead from thenegative (-) power source output stud to the work piece. Thework piece connection must be firm and secure, especially ifpulse welding is planned.

When welding with the STT® process, use the positive outputconnection labeled “STT®” for STT® welding. (If desired ,otherwelding modes can be used on this stud; however, the averageoutput current will be limited to 325 amps.) For non-STT®

processes, use the positive output connection labeled “PowerWave®”, so that the full output range of the machine is available.

Do Not connect the STT® and Power Wave® stud together.Paralleling the connection will bypass the STT® circuitry andseverely deteriorate STT® welding performance.

For additional Safety information regarding the electrode andwork cable set-up, See the standard "SAFETY INFORMA-TION" located in the front of the Instruction Manuals.

Excessive voltage drops caused by poor work piececonnections often result in unsatisfactory welding per-formance.------------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITYWhen negative electrode polarity is required, such as insome Innershield applications, reverse the output connec-tions at the power source (electrode cable to the negative (-)stud, and work cable to the positive (+) stud).

When operating with electrode polarity negative the"Electrode Sense Polarity" DIP switch must be set to the"Negative" position on the Wire Drive Feed Head PC Board.The default setting of the switch is positive electrode polarity.Consult the Power Feed® instruction manual for furtherdetails.

VOLTAGE SENSINGThe best arc performance occurs when the PowerWaves® have accurate data about the arc conditions.Depending upon the process, inductance within the elec-trode and work lead cables can influence the voltageapparent at the studs of the welder. Voltage sense leadsimprove the accuracy of the arc conditions and can havea dramatic effect on performance. Sense Lead Kits(K940-10, -25 or -50) are available for this purpose.

If the voltage sensing is enabled but the sense leads aremissing, improperly connected, or if the electrode polar-ity switch is improperly configured, extremely highwelding outputs may occur. ------------------------------------------------------------------------

The ELECTRODE sense lead (67) is built into the controlcable, and is automatically enabled for all semi-automaticprocesses. The WORK sense lead (21) connects to thePower Wave® at the four pin connector located underneaththe output stud cover. By default the WORK voltage is moni-tored at the output stud in the POWER WAVE® 455M/STT®.For more information on the WORK sense lead (21), see"Work Voltage Sensing” in the following paragraph.

All constant current processes sense the voltage at the out-put studs of the POWER WAVE® 455M/STT® by default.

CAUTION

CAUTION

B

A

C

FIGURE A.2

POWERWAVE

WORK

A

C

B

POWERWAVE

FIGURE A.4

K1796 COAXIAL CABLE

MEASURE FROM ENDOF OUTER JACKET OFCABLE

C

A

B

WORK

SLIDING WORK CONNECTION

FIGURE A.3

A-5INSTALLATION


A-5

Electrode Voltage SensingEnabling 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.

Important: The electrode polarity must be config-ured at the feed head for all semi-automaticprocesses. Failure to do so may result in extreme-ly high welding outputs.------------------------------------------------------------------------

POWER WAVE TO SEMI-AUTOMAT-IC POWER FEED® WIRE FEEDERINTERCONNECTIONS

The POWER WAVE® 455M/STT® and semi-automaticPOWER FEED® family communicate via a 5 conductorcontrol cable (K1543). The control cable consists of twopower leads, one twisted pair for digital communication,and one lead for voltage sensing. The cables aredesigned to be connected end to end for ease of exten-sion. The output receptacle on the POWER WAVE®

455M/STT® is located beneath the spring loaded outputcover at the bottom of the case front. The input recepta-cle on the Power Feed® is typically located at the back ofthe feeder, or on the bottom of the user interface.

For convenience sake, the electrode and control cablescan be routed behind the left or right strain reliefs (underthe spring loaded output cover), and along the channelsformed into the base of the Power Wave®, out the back ofthe channels, and then to the wire feeder.

Due to the flexibility of the platform the configuration mayvary. The following is a general description of the sys-tem.

SYSTEM DESCRIPTION

The POWER WAVE® 455M/STT® and Power Feed® Mfamily of products utilize a digital communication systemcalled ArcLink. Simply put, ArcLink allows large amountsof information to be passed at very high speeds betweencomponents (nodes) in the system. The system requiresonly two wires for communication, and because of itsbus-like structure, the components may be connected tothe network in any order, thus simplifying the system set-up.

Each "system" must contain only one power source.The number of wire feeders is determined by the typeof wire feeder. Refer to the wire feeder instructionmanual for details

Enable the voltage sense leads as follows:TABLE A.2

Process Electrode Voltage Work VoltageSensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optionalGMAW-P 67 lead required 21 lead optionalFCAW 67 lead required 21 lead optionalSTT® 67 lead required 21 lead requiredGTAW Voltage sense at studs Voltage sense at studsGMAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optionalCAC-C Voltage sense at studs Voltage sense at studs* The electrode voltage 67 sense lead is integral to the

control cable to the wire feeder.

Work Voltage SensingThe standard POWER WAVE® 455M/STT® is shippedwith the work voltage sense lead enabled.

For processes requiring work voltage sensing, connectthe (21) work voltage sense lead (K940) from thePower Wave work sense lead receptacle to the workpiece. Attach the sense lead to the work piece as closeto the weld as practical, but not in the return currentpath. Enable the work voltage sensing in the PowerWave as follows:

• Do not touch electrically live parts orelectrodes with your skin or wet cloth-ing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

--------------------------------------------------------------

1. Turn off power to the power source at the disconnectswitch.

2. Remove the front cover from the powersource.

3. The control board is on the left side of thepower source. Locate the 8-position DIPswitch and look for switch 8 of the DIPswitch.

4. Using a pencil or other small object, slidethe switch right to the OFF position if thework sense lead is NOT connected.Conversely, slide the switch to the ON position if thework sense lead is present.

5. Replace the cover and screws. The PC board will“read” the switch at power up, and configure thework voltage sense lead appropriately.

O N1

23

45

67

8

CAUTION

WARNING

A-6INSTALLATION


A-6

CONFIGURING THE SYSTEM

For codes below 11100, consult the semi-automaticPower Feed® instruction manual for configurationinformation about DIP switch settings.

For codes above 11100, the power source will “AutoMap” the system eliminating most of the need to setDIP switches to configure the system.

If a system can not be “Auto Mapped” then the statuslight on the power source will blink green fast and thewelder output will be disabled. If a system is not“Auto-mappable”, then consult the instruction manualfor the accessory being used for configuration infor-mation about DIP switch settings, or consult your localLincoln sales representative.

POWER WAVE POWER WAVE 455M/STT455M/STT ®

®POWER WPOWER WAVE VE 455M/STT455M/STT

®

®

POWER WPOWER WAVE VE 455M/STT455M/STT

®

®

POWER WPOWER WAVE 455M/STTVE 455M/STT

WIRE WIRE DRIVEDRIVEMODULEMODULE

ROBOT ROBOTPLC ControllerPLC Controlleranalog Interfaceanalog Interface

etc. etc.

TYPICALTYPICAL /HARD /HARD AUTAUTOMAOMATIONTION(using Wire Drive Module and PF10R(using Wire Drive Module and PF10R

PF10R PF10R

® ®

SINGLE HEAD FEEDER

SINGLE HEAD BOOM FEEDER

DUAL HEAD FEEDER

Up to 4 Feeders Allowed

Up to 4 Feed Heads Allowed

FH 1

Dual Head

A-7INSTALLATION


A-7

ALALTERNATERNATE HARD TE HARD AUTAUTOMAOMATION TION APPLICAAPPLICATIONTION(using a UI, WD Module, and PF-10R)(using a UI, WD Module, and PF-10R)

POWER WPOWER WAVEVE455M/STT455M/STT

WIREWIREDRIVE DRIVE MODULEMODULE(FH1)(FH1)

PF-10R PF-10R®

®

System that is NOT “Auto Mappable”:

In this case the individual feed heads need to be assigned to the dual head control and the PW455 auto map-ping disabled and the Equipment Groups set on (See figure A-6). (See the Feeder documentation for informa-tion on setting the feeder DIP switches)

Combination Hard Automation Application(w/ Semi-Auto, Wire Drive Module, and PF10R)

Dual Head Boom Feeder(using two single heads)

FH1 FH2

PF10RPower Wave®

455M/STT®

Power Wave®

455M/STT®

Dual Head

Dual Head

WireDriveModule(FH1)

A-8INSTALLATION


A-8

WELDING WITH MULTIPLE POWERWAVES®

Special care must be taken when more than onePower Wave® is welding simultaneously on a sin-gle part. Arc blow and arc interference may occuror be magnified.------------------------------------------------------------------------

Each power source requires a work lead from thework stud to the welding fixture. Do not combine all ofthe work leads into one lead. The welding travel direc-tions should be in the direction moving away from thework lead as shown below. Connect all of the worksense leads from each power source to the workpiece at the end of the weld.

For the best results when pulse welding, set the wiresize and wire feed speed the same for all the PowerWaves®. When these parameters are identical, thepulsing frequency will be the same, helping to stabilizethe arcs.

Every welding gun requires a separate shielding gasregulator for proper flow rate and shielding gas cover-age.

Do not attempt to supply shielding gas for two or moreguns from only one regulator.

If an anti-spatter system is in use then each gun musthave its own anti-spatter system. (See Figure A.4)

FIGURE A.4

- +

POWERWAVE

- +

POWERWAVE

Connect All WorkSense Leads at the Endof the Joint

Connect All WeldingWork Leads at theBeginning of the Joint

TravelDirection

- +

POWER WAVE

- +

POWER WAVE

TWO POWER WAVES®

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave® / Power Feed® system.

The use of non-standard cables, especially inlengths greater than 25 feet, can lead to communi-cation problems (system shutdowns), poor motoracceleration (poor arc starting) and low wire dri-ving force (wire feeding problems).------------------------------------------------------------------------The K1543 series of control cables can be connectedend to end for ease of extension. Do not exceed morethan 100 feet (30.5 m) total control cable length.

CAUTION

CAUTION

A-9INSTALLATION


A-9

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

Work #2Sense # 2

PowerSource

#2

PowerSource

#1

Arc #1

Arc #2

Work #1Sense #1

Work # 2 PowerSource

#2

PowerSource

#1

Arc #1

Arc #2

Work # 1

Sense #1Sense # 2

Current Flow

PowerSource

#1

PowerSource

#2

Work #1Sense #1

Work #2Sense #2

Arc #2

Arc #1

Current Flow

Ø Current flow from Arc #1affects sense lead #2

Ø Current flow from Arc #2affects sense lead #1

Ø Neither sense lead picks upthe correct work voltage,causing starting and weldingarc instability.

BAD

Ø Sense #1 is only affected by weldcurrent from Arc #1

Ø Sense #2 is only affected by weldcurrent from Arc #2

Ø Due to voltage drops across work piece,Arc voltage may be low, causing needfor deviation from standard procedures.

BETTER

Ø Both Sense leads are out of the currentpaths.

Ø Both Sense leads detect arc voltageaccurately.

Ø No voltage drop between Arc and Senselead.

Ø Best starts, best arcs, most reliableresults.

BEST

Current Flow

�

A-10INSTALLATION


A-10

I / O RECEPTACLE SPECIFICATIONSTABLE 3

WIRE FEEDER RECEPTACLE S1PIN LEAD# FUNCTION

A 53 Communication Bus LB 54 Communication Bus HC 67A Electrode Voltage SenseD 52 0vdcE 51 +40vdc

TABLE 4VOLTAGE SENSE RECEPTACLE S2PIN LEAD# FUNCTION3 21A Work Voltage Sense

TABLE 5RS232 RECEPTACLE S3

PIN LEAD# FUNCTION2 253 RS232 Receive3 254 RS232 Transmit4 # S3 Pin55 # S3 Pin46 # # S3 Pin2020 # # S3 Pin67 251 RS232 Common

DIP SWITCH SETTINGS AND LOCATIONS

DIP switches on the P.C. Boards allow for customconfiguration of the Power Wave®. To access the DIPswitches:• Turn off power at the disconnect switch.• Remove the top four screws securing the front

access panel.• Loosen, but do not completely remove, the bottom

two screws holding the access panel.• Open the access panel, allowing the weight of the

panel to be carried by the bottom two screws. Makesure to prevent the weight of the access panel fromhanging on the harness.

• Adjust the DIP switches as necessary.• Replace the panel and screws, and restore power.

CONTROL BOARD DIP SWITCH:switch 1 = reserved for future useswitch 2 = reserved for future useswitch 3 = equipment group 1 selcted (default=off)switch 4 = equipment group 2 selcted (default=off)switch 5 = reserved for future useswitch 6 = reserved for future useswitch 7 = auto mappingswitch 8 = work sense lead

(See Figure A.6 for Dual Head Boom Feeder)

switch 7 auto mappingoff (default) auto mapping enable

on auto mapping disabled

switch 8 work sense leadoff work sense lead not connected

*on (default) work sense lead connected* The POWER WAVE® 455M/STT® comes supplied

with a work Voltage Sense Lead Kit (K940).

WATER FLOW SENSORWater cooled guns can be damaged very quickly ifthey are used even momentarily without water flowing.A water flow sensor is recommended for those watercoolers that do not have an integral flow sensor.Recommended practice is to install a water flow sen-sor such as K1536-1 on the water return line of thetorch. When fully integrated into the welding system,the sensor will prevent welding if no water flow is pre-sent.

CONTROL BOARD (DIP Switch Location)

FIGURE A.5

FIGURE A.6

B-1OPERATIONB-1


SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.


• Do not touch electrically live parts orelectrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.• Do not use AC welder if your cloth-

ing, gloves or work area is damp or ifworking on, under or inside work-piece.Use the following equipment:-DC manual (stick) welder.-AC welder with reduced voltagecontrol.

• Do not operate with panels removed.• Disconnect input power before ser-

vicing.------------------------------------------------------------------------ONLY QUALIFIED PERSONS SHOULD INSTALL,USE OR SERVICE THIS EQUIPMENT. READ ANDFOLLOW THE MANUFACTURERʼS INSTRUC-TIONS, EMPLOYERʼS SAFETY PRACTICES ANDMATERIAL SAFETY DATA SHEETS (MSDS) FORCONSUMABLES.

------------------------------------------------------------------------

READ THIS WARNING, PROTECT YOURSELF &OTHERS.

FUMES AND GASES can bedangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the arc,or both,to keep fumes and gases fromyour breathing zone and general area.

WELDING SPARKS can causefire or explosion.

• Do not weld near flammable material.

• Do not weld on containers which haveheld flammable material.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

-----------------------------------------------------------------------

WARNING

B-2OPERATIONB-2


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 ORCAUTION

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

SMAW

B-3OPERATIONB-3


DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all weldingprocess variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity ofsingle knob control. The machine will select the cor-rect voltage and amperage based on the wire feedspeed (WFS) set by the operator.

455M• 455 Modular

WFS• Wire Feed Speed

CC• Constant Current

CV• Constant Voltage

GMAW• Gas Metal Arc welding

GMAW-P• Gas Metal Arc welding-(Pulse Arc)

GMAW-S• Gas Metal Arc welding-(Short Circuiting Arc)

GTAW• Gas Tungsten Arc welding

GTAW-P• Gas Tungsten Arc welding-(Pulse Arc)

PAW• Plasma Arc welding

SMAW• Shielded Metal Arc welding

SW• Stud Arc Welding

SAW• Submerged Arc Welding

SAW-S• Submerged Arc Welding-(Series)

STT®

• Surface Tension Transfer

FCAW• Flux Core Arc Welding

CAC• Carbon Arc Cutting

DeviceNet Interface ModuleThis module can be used for DeviceNet capability. Itwill has a 5 pin sealed mini connector per ANSIB93.55M-1981.

RECOMMENDED EQUIPMENT

POWER WAVE® 455M/STT® – Semi-AutomaticOperation

Semi Automatic Power Waves® can only be used withArcLink compatible Power Feed® semi-automatic wirefeeders and modules. In addition, the Power Feed®

semi-automatic wire feeders may require optionalequipment to access certain weld modes in the PowerWave®. Other models of Lincoln feeders, or any mod-els of non-Lincoln wire feeders, cannot be used.

All welding programs and procedures are selectedthrough the Power Feed® M semi-automatic user inter-face

REQUIRED EQUIPMENTAny ArcLink compatible semi-automatic wire feedingequipment. Specifically, the semi-automatic PowerFeed® M family.

LIMITATIONS

• The Power Waves® are not to be used in outdoorenvironments.

------------------------------------------------------------------------

• Only ArcLink compatible Power Feed® semi-auto-matic wire feeders and users interfaces may beused. Other Lincoln wire feeders or non-Lincoln wirefeeders cannot be used.

• POWER WAVE® 455M/STT® Output LimitationsThe POWER WAVE® 455M/STT® will support maxi-mum average output current of 570 Amps (@ 60%duty cycle) on the standard Power Wave® stud, and amaximum average output current of 325 amps(100% duty cycle) on the STT® stud.

DUTY CYCLE AND TIME PERIODThe Power Feed® wire feeders are capable of weldingat a 100% duty cycle (continuous welding). The powersource will be the limiting factor in determining systemduty cycle capability. Note that the duty cycle is basedupon a ten minute period. A 60% duty cycle repre-sents 6 minutes of welding and 4 minutes of idling in aten minute period.

B-4OPERATIONB-4

GENERAL DESCRIPTIONThe Power Wave® semi-automatic power source isdesigned to be a part of a modular, multi-process weld-ing system. Depending on configuration, it can supportconstant current, constant voltage, STT® and pulsewelding modes.

The Power Wave® power source is designed to beused with the semi automatic family of Power Feed®

wire feeders, operating as a system. Each componentin the system has special circuitry to "talk with" theother system components, so each component (powersource, wire feeder, user interface) knows what theother is doing at all times. These components commu-nicate with ArcLink

The POWER WAVE® 455M/STT® is a high perfor-mance, digitally controlled inverter welding powersource capable of complex, high-speed waveform con-trol. Properly equipped, it can support the GMAW,GMAW-P, FCAW, SMAW, GTAW, STT® and CAC-Aprocesses. It carries an output rating of either 450amps, 38 volts; or 400 amps, 36 volts (both at 100%duty cycle), depending on input voltage and frequency.The STT® process is supported at currents up to 325amps at 100% duty cycle.

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSESThe POWER WAVE® 455M/STT® can be set up in anumber of configurations, some requiring optionalequipment or welding programs. Each machine is fac-tory preprogrammed with multiple welding procedures,typically including GMAW, GMAW-P, FCAW, SMAW,GTAW, STT® and CAC-A for a variety of materials,including mild steel, stainless steel, cored wires, andaluminum.

The POWER WAVE® 455M/STT® is recommended forsemi-automatic welding with ArcLink compatible equip-ment like the Power Feed® M series of feeders. ThePOWER WAVE® 455M/STT® can have a number ofmodules installed that allow the machine to be used inRobotic and hard automation applications.

Wire Drive Interface ModuleFor Robotic platforms the Wire Drive Control Module isrequired to drive the PF-10R wire drive. This modulecan be factory installed through our automation divi-sion or field installed for robotic applications.

The Wire Drive Control Module is also be equippedwith a terminal strip for making simple input signal con-nections. It can be used to externally control the basicwire drive function. It is divided into three groups:Trigger group, Cold Inch group, and Shutdown group.


WARNING

B-5OPERATION


B-5

CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave®. (See Figure B.1)

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, per table B.1.

NOTE: The POWER WAVE® 455M/STT® status lightwill flash green, and sometimes red and green, for upto one minute when the machine is first turned on.This is a normal situation as the machine goesthrough a self test at power up.

TABLE B.1Light

ConditionSteady Green

BlinkingGreen

A l t e r n a t i n gGreen andRed

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-ly with wire feeder and its components.

Occurs during a reset, and indicates thePOWER WAVE® 455M/STT® is mapping(identifying) each component in the system.Normal for first 1-10 seconds after power isturned on, or if the system configuration ischanged during operation

Non-recoverable system fault. If the PSStatus light is flashing any combination ofred and green, errors are present in thePOWER WAVE® 455M/STT® Read theerror code before the machine is turnedoff.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red witha long pause between digits. If more thanone code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off,and back on to reset. See TroubleshootingSection.

Non recoverable hardware fault. Generallyindicates nothing is connected to thePOWER WAVE® 455M/STT® wire feederreceptacle. See Trouble Shooting Section.

Not applicable.

5. 15* AMP AUXILIARY POWER CIRCUIT BREAKER:Protects 115 volt AC case front receptacleauxiliary supply.(* Earlier models used 10 amps circuit breaker).

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. DIAGNOSTIC CONNECTOR (RS-232)

8. WIRE FEEDER RECEPTACLE (S1 5-PIN)

9. NEGATIVE STUD

10. POSITIVE STUD

11. AUXILIARY OUTPUT

12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)

13. ROBOTIC WIRE FEEDER RECEPTACLE(OPTIONAL)

14. I/O CONNECTOR (OPTIONAL)

15. STT® STUD

16. ETHERNET CONNECTOR (OPTIONAL)

FIGURE B.1

3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled and thefan continues to run, until the machine cools down.When cool, the l ight goes out and output isenabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.

11

1015

47

14

1

13

32

5

6

12

16

8

9

CASE FRONT LAYOUTPOWER WAVE® 455M/STT®

( NORTH AMERICAN )

B-6OPERATIONB-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 structure utiliz-ing the welding programs is and must be the soleresponsibility of the builder/user. Many variablesbeyond the control of The Lincoln ElectricCompany affect the results obtained in applyingthese programs. These variables include, but arenot limited to, welding procedure, plate chemistryand temperature, weldment design, fabricationmethods and service requirements. The availablerange of a welding program may not be suitablefor all applications, and the build/user is and mustbe solely responsible for welding program selec-tion.------------------------------------------------------------------------

The steps for operating the Power Wave® will varydepending upon the options installed in the user inter-face (control box) of the welding system. The flexibilityof the Power Wave® system lets the user customizeoperation for the best performance.

First, consider the desired welding process and thepart to be welded. Choose an electrode material,diameter, shielding gas and process (GMAW, GMAW-P, etc.)

Second, find the program in the welding software thatbest matches the desired welding process. The stan-dard software shipped with the Power Waves® encom-passes a wide range of common processes and willmeet most needs. If a special welding program isdesired, contact the local Lincoln Electric sales repre-sentative.

To make a weld, the Power Wave® needs to know thedesired welding parameters. The Power Feed® (PF)family of feeders communicate settings to the PowerWave® through control cable connection. Arc length,wire feed speed, arc control, etc. are all communicat-ed digitally via the control cable.

WELDING ADJUSTMENTS

All adjustments are made on the system componentknown as the User Interface (Control Box), which con-tains the switches, knobs, and digital displays neces-sary to control both the Power Wave® and a PowerFeed® wire feeder. Typically, the Control Box is sup-plied as part of the wire feeder. It can be mounteddirectly on the wire feeder itself, the front of the powersource, or mounted separately, as might be done in awelding 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 manu-al.

• WFS / AMPS:In synergic welding modes (synergic CV, pulseGMAW, STT®), WFS (wire feed speed) is the domi-nant control parameter, controlling all other vari-ables. The user adjusts WFS according to factorssuch as weld size, penetration requirements, heatinput, etc. The Power Wave then uses the WFS set-ting to adjust its output characteristics (output volt-age, output current) according to pre-programmedsettings contained in the POWER WAVE®

455M/STT®. In non-synergic modes, the WFS controlbehaves more like a conventional CV power sourcewhere WFS and voltage are independent adjust-ments. Therefore to maintain the arc characteristics,the operator must adjust the voltage to compensatefor any changes made to the WFS.

In constant current modes (stick, TIG) this controladjusts the output current, in amps.

• VOLTS / TRIM:In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only)the user can change the Trim setting to adjust thearc length. It is adjustable from 0.500 to 1.500. ATrim setting of 1.000 is a good starting point for mostconditions.

Power Wave® 455/STT® Only: In STT® modes, theuser can adjust the Trim setting to change the overallheat input to the weld.


WARNING

Current

Time

WAVE CONTROL +10.0

WAVE CONTROL -10.0

WAVE CONTROL 0.00

CURRENT WAVE FORM (CV)

B-7OPERATIONB-7

• WELDING MODEMay 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 more com-plete description of the welding modes available inthe Power Wave®, see the explanation below.

• ARC CONTROLAlso known as Inductance or Wave Control. Allowsoperator to vary the arc characteristics from "soft" to"harsh" in all weld modes. It is adjustable from -10.0to +10.0, with a nominal setting of 00.0 (The nominalsetting of 00.0 may be displayed as OFF on somePower Feed® wire feeder control panels). See theWelding Mode descriptions, below, for detailedexplanations of how the Arc Control affects eachmode.

CONSTANT VOLTAGE WELDINGSynergic CV:For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The nominal preprogrammed volt-age is the best average voltage for a given wire feedspeed, but may be adjusted to preference. When thewire feed speed changes, the Power Wave® automati-cally adjusts the voltage level correspondingly tomaintain similar arc characteristics throughout theWFS range.

Non Synergic CV:This type of CV mode behaves more like a conven-tional CV power source. Voltage and WFS are inde-pendent adjustments. Therefore to maintain the arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS.

All CV Modes:Arc Control, often referred to as wave control, adjuststhe inductance of the wave shape. The wave controladjustment is similar to the "pinch" function in that it isinversely proportional to inductance. Therefore,increasing wave control greater than 0.0 results in aharsher, colder arc while decreasing the wave controlto less than 0.0 provides a softer, hotter arc.(See Figure B.2)


FIGURE B.2

B-8OPERATIONB-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. Theexact voltage for a given wire feed speed can only bepredicted when all the pulsing waveform parametersare known. Using a preset voltage becomes impracti-cal, and instead the arc length is set by adjusting"trim".

Trim adjusts the arc length and ranges from 0.50 to1.50, with a nominal value of 1.00. Trim values greaterthan 1.00 increase the arc length, while values lessthan 1.00 decrease the arc length.

Most pulse welding programs are synergic. As thewire feed speed is adjusted, the Power Wave willautomatically recalculate the waveform parameters tomaintain similar arc properties.


Current

WAVE CONTROL -10.0

WAVE CONTROL 0.0

WAVE CONTROL +10.0

Time

FIGURE B.3

CURRENT WAVE FORM (PULSE)

The Power Wave® utilizes "adaptive control" to com-pensate for changes in electrical stick-out while weld-ing. (Electrical stick-out is the distance from the con-tact tip to the work piece.) The Power Wave® wave-forms are optimized for a 0.75" (19mm) stick-out. Theadaptive behavior supports a range of stickouts from0.50" (13mm) to 1.25" (32mm). At very low or highwire feed speeds, the adaptive range may be less dueto reaching physical limitations of the welding process.

Arc Control, often referred to as wave control, in pulseprograms usually adjusts the focus or shape of thearc. Wave control values greater than 0.0 increase thepulse frequency while decreasing the background cur-rent, resulting in a tight, stiff arc best for high speedsheet metal welding. Wave control values less than0.0 decrease the pulse frequency while increasing thebackground current, for a soft arc good for out-of-posi-tion welding.(See Figure B.3)

B-9OPERATIONB-9STT® WELDING

The pictures illustrate the wave shape of current forthe process. They are not drawn to scale, and areintended only for the purpose of showing how the vari-ables effect the waveform.

Trim in the STT® mode adjusts the tail out and back-ground portion of the waveform. For open rootprocesses, the tail out is fixed, and the trim affectsonly the background level. Trim values greater than1.0 add more energy to the weld and make the weldpuddle hotter; trim values less than 1.0 reduce energyto weld A nominal value of 1.0 will work for most appli-cations. (See Figure B.4)

For most programs, peak current is adjusted by arccontrol, also referred to as wave control. A wave con-trol value of +10.0 maximizes the peak current, whilea wave control of -10.0 minimizes peak current. Ingeneral, the peak current is proportional to the arclength. (See Figure B.5)

NOTE: The ranges on Wave Control and Trim aredependent on the weld programs. The values shownare typical ranges.


Current

Time

Time

Current

FIGURE B.4

FIGURE B.5

Trim 1.50

Trim 1.00

Trim 0.50

WAVE CONTROL -10.0

WAVE CONTROL 0.0

WAVE CONTROL +10.0

C-1ACCESSORIESC-1

OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED Work Voltage Sense Lead Kit, K940Dual Cylinder Undercarriage, K1570-1. *Gas Guard Regulator, K659-1Coaxial welding Cable, K1796Power Wave® Water Cooler, K1767-1 *Water Flow Sensor, K1536-1Wire Drive Interface Module, K2205-1DeviceNet interface Module, K2206-1Ethernet Interface Module, K2207-1

*The Dual Cylinder Undercarriage, K1570-1 is notcompatible in combination with the Power Wave®

Water Cooler K1767-1.

COMPATIBLE LINCOLN EQUIPMENT

Any ArcLink compatible semi-automatic wire feedingequipment. Specifically, the semi-automatic PowerFeed® M family. If the wire drive interface module isinstalled the machine is compatible with the PowerFeed® 10R wire feeder.


D-1MAINTENANCED-1


SAFETY PRECAUTIONS


• Only Qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equip-ment.

• Do not touch electrically hot parts.

------------------------------------------------------------------------

ROUTINE MAINTENANCERoutine maintenance consists of periodically blowingout the machine, using a low pressure airstream, toremove accumulated dust and dirt from the intake andoutlet louvers, and the cooling channels in the

machine.

PERIODIC MAINTENANCECalibration of the POWER WAVE® 455M/STT® is criti-cal to its operation. Generally speaking the calibrationwill not need adjustment. However, neglected orimproperly calibrated machines may not yield satisfac-tory weld performance. To ensure optimal perfor-mance, the calibration of output Voltage and Currentshould be checked yearly.

CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at the facto-ry. Generally speaking the machine calibration will notneed adjustment. However, if the weld performancechanges, or the yearly calibration check reveals aproblem, contact the Lincoln Electric Company for thecalibration software utility.

The calibration procedure itself requires the use of aresistive load bank, and certified actual meters for volt-age and current. The accuracy of the calibration will bedirectly affected by the accuracy of the measuringequipment you use. Detailed instructions are availablewith the utility.

WARNING

E-1TROUBLESHOOTINGE-1


If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING



USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS

The Power Wave® / Power Feed® are best diagnosedas a system. Each component (power source, userinterface, and feed head) has a status light, and whena problem occurs it is important to note the conditionof each. In addition, errors displayed on the user inter-face in most cases indicate only that a problem existsin the power source, not what the problem may be.Therefore, prior to cycling power to the system,check the power source status light for errorsequences as noted below. This is especiallyimportant if the user interface displays "Err 006"or "Err 100" .

Included in this section is information about the powersource Status LED, and some basic troubleshootingcharts for both machine and weld performance.

The STATUS LIGHT is a two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated in the followingchart.

NOTE: The POWER WAVE® 455M/STT® status lightwill flash green, and sometimes red and green, for upto one minute when the machine is first turned on.This is a normal situation as the machine goesthrough a self test at power up.

LIGHT CONDITIONStatus LED is solid green (no blinking).

Status LED is blinking green.

Status LED is blinking red and green.

Status LED is solid red (no blinking).

Status LED is blinking red.

MEANING1. System OK. Power source communicating normally

with wire feeder and its components.

2. Occurs during a reset, and indicates the POWERWAVE® 455M/STT® is mapping (identifying) eachcomponent in the system. Normal for first 1-10 sec-onds after power is turned on, or if the system con-figuration is changed during operation.

3. Non-recoverable system fault. If the PS Status lightis flashing any combination of red and green, errorsare present in the POWER WAVE® 455M/STT®.Read the error code before the machine isturned off.

Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will beseparated by a green light.

To clear the error, turn power source off, and backon to reset.

Non recoverable hardware fault. Generally indicatesnothing is connected to the POWER WAVE®

455M/STT® wire feeder receptacle. See TroubleShooting Section.

Not applicable.



Observe all Safety Guidelines detailed throughout this manual


CAUTION

ERROR CODES FOR THE POWERWAVEThe following is a list of possible error codes that the POWER WAVE® 455M/STT® can output via the status light(see "Troubleshooting the Power Wave® / Power Feed® System Using the Status LED." If connected to a PowerFeed®-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interfacedisplay.

Error Code # Description11 CAN communication bus off.12 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage(Left side facing machine)

33 Capacitor "B" under voltage (Right side facing machine)

34 Capacitor "A" over voltage (Left side facing machine)

35 Capacitor "B" over voltage

(Right side facing machine)

36 Thermal error

37 Soft start error

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

IndicationProbably due to excessive number of communication errors.UI is no longer responding to the Power Source. The most likelycause is a fault/bad connection in the communication leads or con-trol cable.

Contact the Service Department for instructions on reloading theWelding Software.Contact the Service Department for instructions on reloading theWelding Software.Contact the Service Department for instructions on reloading theWelding Software.Excessive Primary current present. May be related to a short in themain transformer or output rectifier.Low voltage on the main capacitors. May be caused by improperinput configuration. When accompanied by an overvoltage error on the same side, itindicates no capacitor voltage present on that side, and is usuallythe result of an open or short in the primary side of the machine.Excess voltage on the main capacitors. May be caused by improp-er input configuration.

When accompanied by an under voltage error on the same side, itindicates no capacitor voltage present on that side, and is usuallythe result of an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cyclelimit of the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.The secondary (weld) current limit has been exceeded. When thisoccurs the machine output will phase back to 100 amps, typicallyresulting in a condition referred to as "noodle welding"

NOTE: The secondary limit is 570 amps for the standard stud, and325 amps for the STT® stud.

The maximum voltage difference between the main capacitors hasbeen exceeded. May be accompanied by errors 32-35.

Indicates machine is running on single phase input power. Usuallycaused by the loss of the middle leg (L2).Error codes that contain three or four digits are defined as fatalerrors. These codes generally indicate internal errors on the PSControl Board. If cycling the input power on the machine does notclear the error, try reloading the operating system. If this fails,replace the control board.




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)

POSSIBLECAUSE

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.)

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assis-tance.

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.





PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


OUTPUT PROBLEMS

Thermal LED is lit.

Machine wonʼt weld, canʼt get anyoutput. (CR1 will not pull in.)

1. Fan thermostat has opened.Check for proper fan operation.(Fan should run whenever out-put power is on.) Check formaterial blocking intake orexhaust louvers, or for excessivedirt clogging cooling channels inmachine.

2. Secondary rectifier or Chokethermostat has opened. Aftermachine has cooled, reduceload, duty cycle, or both. Checkfor material blocking intake orexhaust louvers.

3. DC Bus PC board thermostathas opened check for excessiveload on 40VDC supply.

1. Input voltage is too low or toohigh. Make certain that inputvoltage is proper, according tothe Rating Plate located on therear 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 out-put circuit. Turn machine off.Remove all loads from the out-put of the machine. Turn backon. If condition persists, turnpower off, and contact an autho-rized Lincoln Electric FieldService facility.

4. This problem wil l normally beaccompanied by an error code.Error codes are displayed as aseries of red and green flashes bythe status l ight. See"Troubleshooting the Power Wave ®/Power Feed® System Using theStatus LED" section of this text.






PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure, especially a procedurewith high WFS.

Machine wonʼt produce full output.

Auxiliary receptacle is “dead” noauxiliary voltage .

1.Secondary current limit has beenexceeded, and the machine hasphased back to protect itself.

2. Adjust procedure or reduce loadto lower current draw from themachine.

3. A single phase input (loss of L2)will reduce the secondary cur-rent limit from 570 Amps to 325Amps.

1. Input voltage may be too low,limiting output capability of thepower source. Make certain thatthe input voltage is proper,according to the Rating Platelocated on the rear of themachine.

2. Input may be “single phased”.Make certain the input voltage isproper on all three Input lines.

3. STT® machines only: May beexceeding the 325 amp limit onthe STT® output terminal.

4. Secondary current or voltage notbe properly calibrated. Checkvalues displayed on the PowerFeed® 10/11 verses readings onan external meter.

1. Circuit breaker CB2 (on casefront) may have opened. Reset.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.






CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


General degradation of the weld per-formance

Excessively long and erratic arc.

In the STT® mode, the arc is exces-sively long and erratic.

In the STT® mode, the spatter ishigher than normal and the arc isinconsistent.

1.Check for feeding problems, badconnections, excessive loops incabling, etc.

2. Verify weld mode is correct forprocesses.

3. The power source may requirecalibration.

4. Check the actual current dis-played on the Power Feed® 10 vs.actual current measured via exter-nal meter.

5. Check the actual voltage dis-played on the Power Feed® 10 vs.actual voltage measured via exter-nal meter.

6. Check the actual WFS displayedon the Power Feed® 10 vs. actualWFS measured via externalmeter.

1. Check for proper configurationand implementation of voltagesensing circuits.

1. Check that the (21) work senselead is connected, and configuredproperly.

1. Check that the (21) work senselead is connected, and configuredproperly. (Dip Switch Set)

2. Verify that the electrode lead isconnected to the STT® stud andnot the “POWER WAVE®” stud.

3 Check that the “POWER WAVE®”stud is not electrically connected to the STT® stud.

If all recommended possible areas ofmisadjustments have been checkedand the problem persists, contactyour local Lincoln AuthorizedField Service Facility.

F-1DIAGRAMSF-1


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F-2CONNECTION DIAGRAMF-2


Connection Diagram Semi-automatic "Simple System"(Electrode Positive, CV/Pulse Configuration shown)

POWER WAVE / STT

STT STUD

WIREFEEDER

CONTROL CABLE K1543

TOWORK

WORK SENSE

F-3CONNECTION DIAGRAMF-3

POWER WAVE 455/STT®

Connection Diagram Semi-automatic "Simple System"(Electrode Positive, STT® Configuration shown)

POWER WAVE / STT

STT STUD

WIREFEEDER

CONTROL CABLE K1543

TOWORK

WORK SENSE

F-4DIMENSION PRINTF-4


M18

241

A.0

1

32.88

14.62

19.16

19.90

9.48

12.35

19.00

22.63

26.10

23.12

23.51

4.21

12.90

6.75

3.47

10°

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 toremove 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 pararemover 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 fazerserviço.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.

Need Help?

Lincoln Electric “Rapid Response” Service!

Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you no later than the following business day.

• For Service outside the USA: Email [email protected]

Cleveland, Ohio 44117-1199 USA TEL: 1.216.481.8100 FAX: 1.216.486.1751 WEB SITE: lincolnelectric.comFor Service in the USA and Canada: Call 1.888.935.3877 For Service outside the USA: Email [email protected]

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Copyright © Lincoln Global Inc.

Documents

Operator’s Manual POWER WAVE 455M/STT€¦ · 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or