im905 powerwave 455m - lincoln electric · 2014-06-19 · ii safety ii arc rays can burn. 4.a. use...

POWER WAVE 455 M™

OPERATOR’S MANUAL

IM905January, 2007

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers: 11375

IEC 60974-1

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2007 Lincoln Global Inc.

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 fumesoutdoors.

____________________________________________________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 ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ʻ95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding 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 rightside, 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 can

kill.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 welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the 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 GASES

can 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. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on 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.

AUG 06

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 explode

if damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Jan, 07

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 folllow 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.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉ

Pour 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 LʼArc

1. 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 dansles 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 POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

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.

Mar. ʻ93

vSAFETYv

viSAFETYvi

viivii

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:

WARNING

This 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 “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICY

The 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.

ixix TABLE OF CONTENTSPage

Installation .......................................................................................................Section A

Technical Specifications - POWER WAVE 455M .................................................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-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-6Alternate Hard Automatic Application....................................................................A-7Combination Hard Automation Application............................................................A-7Dual Head Boom Feeder .......................................................................................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-4Case Front Controls...............................................................................................B-5Nominal Procedures ..............................................................................................B-6

Fringe Procedures...........................................................................................B-6Making a Weld ................................................................................................B-6Welding Adjustment ........................................................................................B-6

Constant 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

________________________________________________________________________

x x TABLE OF CONTENTSPage

Troubleshooting ..............................................................................................Section E

How 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-6

________________________________________________________________________Wiring Diagram ............................................................................................Section F-1

Connection Diagrams ..................................................................................Section F-2

Dimension Print............................................................................................Section F-3

________________________________________________________________________

Parts Lists ...................................................................................................P-547 Series

________________________________________________________________________

A-1INSTALLATION

POWER WAVE 455M (CE)

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-5)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

PHYSICAL DIMENSIONS

PROCESS CURRENT RANGE (DC) CURRENT

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT

VOLTS

380V - 60HZ.380V - 50HZ.415V - 60HZ.415V - 50HZ.

OPEN

CIRCUIT

VOLTAGE

75 VDC

INPUT

VOLTAGE /

FREQUENCY

380V HZ.415V HZ.

HEIGHT

663 mm(26.10 in)

WIDTH

505 mm(19.86 in)

DEPTH

835 mm(32.88 in)

WEIGHT

114 kg.(250 lbs.)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

40A40A

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG[IEC] SIZES

(mm2)

10 (6)10 (6)

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG[IEC] SIZES

(mm2)

8 (10)8 (10)

INPUT AMPERE

RATING ON

NAMEPLATE

36A33A

DUTY

CYCLE

100%100%

MIG/MAGFCAWSMAWGTAWPulse

50-570 Amps40-570 Amps30-570 Amps15-500 Amps5-750 Amps

PULSE

VOLTAGE

RANGE

5 - 55 VDC

AUXILIARY

POWER

40 VDC AT10 AMPS

220 VAC AT5 AMPS

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC. -3.3 SEC.

CURRENT

RANGE

AMPS

5 - 570A

PULSE

FREQUENCY

0.15 - 1000 Hz

INPUT CURRENT

AMPS

36A36A33A33A

INPUT CURRENT

AMPS

48A48A44A44A

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

400A@36V. 100% 400A@36V. 100% 400A@36V. 100% 400A@36V. 100%

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

500A@40V. 60%500A@40V. 60%500A@40V. 60%500A@40V. 60%

OPERATING TEMPERATURE RANGE

-20°C to 40°CSTORAGE TEMPERATURE RANGE

-40°C to 40°C

LIFTING

Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave with accessories attached to it.

STACKING

Power Wave machines can be stacked to a maximumof 3 high.

The bottom machine must always be placed on afirm, secure, level surface. There is a danger ofmachines toppling over if this precaution is nottaken.

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

MACHINE GROUNDINGThe frame of the welder must be grounded. A groundterminal marked with the symbol is located insidethe reconnect/input access door for this purpose. Seeyour local and national electrical codes for propergrounding methods.

HIGH FREQUENCY PROTECTIONLocate the Power Wave away from radio controlledmachinery.

The normal operation of the Power Wave may

adversely affect the operation of RF controlled

equipment, which may result in bodily injury or

damage to the equipment.

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

SAFETY PRECAUTIONS Read this

entire installation section before you start installa-

tion.

ELECTRIC SHOCK can kill.

•• OOnnllyy qquuaalliiffiieedd ppeerrssoonnnneell sshhoouulldd ppeerr--ffoorrmm tthhiiss iinnssttaallllaattiioonn..

•• TTuurrnn tthhee iinnppuutt ppoowweerr OOFFFF aatt tthhee

disconnectt sswiittch oor ffuse boox bbeeffoorreewwoorrkkiinngg oonn tthhiiss eeqquuiippmmeenntt.. TTuurrnn ooffff tthhee iinnppuutt ppoowweerr ttooany other equipment connectteed to thhe weldiing syysstteem aatttthhee ddiissccoonnnneecctt sswwiittcchh oorr ffuussee bbooxx bbeeffoorree wwoorrkkiinngg oonnthe equipment.

• Do not touch eellectriccally hott parts..

•• AAllwwaayyss ccoonnnneecctt tthhee Power Wave 455M (CE) ggrroouunnddiinngglluugg ((llooccaatteedd iinnssiiddee tthhee rreeccoonnnneecctt iinnppuutt aacccceessss ddoooorr)) ttooaa pprrooppeerr ssaaffeettyy ((EEaarrtthh)) ggrroouunndd..

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SELECT SUITABLE LOCATIONDo not use Power Wave 455M (CE) in outdoor environ-ments. The Power Wave 455M (CE) power source shouldnot be subjected to falling water, nor should any parts of itbe submerged in water. Doing so may cause improper oper-ation as well as pose a safety hazard. The best practice is tokeep the machine in a dry, sheltered area.

Do not mount the Power Wave 455M (CE) over combustiblesurfaces. Where there is a combustible surface directlyunder stationary or fixed electrical equipment, that surfaceshall 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 disableF.A.N., connect leads 444 and X3A together at the output ofthe solid state fan control relay, located on the back of theControl PC board enclosure. (See Wiring Diagram)

A-2INSTALLATION


A-2

WARNING

CAUTION

• Lift only with equipment of

adequate lifting capacity.

• Be sure machine is stable

when lifting.• Do not lift this machine using

lift bail if it is equipped with aheavy accessory such as trail-er or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

Do not stack the Power Wave 455M (CE) on top of

any other machine.

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

WARNING

A-3INSTALLATION A-3

INPUT CONNECTION

Only a qualified electrician shouldconnect the inpu t leads to t hePow er Wave 455M (CE) .Connections should be made inaccor dance wi th a l l loca l and

national electrical codes and the connection dia-gram located on the inside of the reconnect/inputaccess door of the machine. Failure to do so mayresult in bodily injury or death.

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

Use a three-phase supply line. A 45 mm (1.75 inch)diameter access hole for the input supply is located onthe upper left case back next to the input access door.Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on the

inside of the input access door or refer to Figure A.1.

INPUT FUSE AND SUPPLY WIRE

CONSIDERATIONS

Refer to the Technical Specifications at the beginning ofthis Installation section for recommended fuse and wiresizes. Fuse the input circuit with the recommended superlag fuse or delay type breakers (also called “inverse time” or“thermal/magnetic” circuit breakers). Choose an input andgrounding wire size according to local or national electricalcodes. Using fuses or circuit breakers smaller than recom-mended may result in “nuisance” shut-offs from welderinrush currents, even if the machine is not being used athigh currents.

NOTE: Turn main inpuut power to thee machine OOFFFF bbeeforre ppeerforrmmiinng ccoonnnnecttiioonn pproocceedduurree.. FFaaiilluurree ttoo ddoo ssoo wwiillllrreessuulltt iinn ddaammaaggee ttoo the machine.

WARNING

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

ELECTRODE AND WORK CABLE

CONNECTIONSConnect 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. Toavoid interference problems with other equipment and toachieve the best possible operation, route all cablesdirectly to the work and wire feeder. Avoid excessivelengths and do not coil excess cable.Minimum work and electrode cable sizes are as follows:

TABLE A.1

Current (60% Duty Cycle) MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-30 m (100 Ft.Length) 400 Amps 67 mm2 (2/0)

500 Amps 85 mm2 (3/0)600 Amps 85 mm2 (3/0)

NOTE: K1796 coaxial welding cable is recommended toreduce the cable inductance in long cable lengths. Thisis especially important when Pulse welding up to 350amps.

When using inverter type power sources like the

Power Waves, use the largest welding (electrode and

work) cables that are practical. At least 67 mm2 2/0

copper wire - even if the average output current

would not normally require it. When pulsing, the

pulse current can reach very high levels. Voltage

drops can become excessive, leading to poor weld-

ing characteristics, if undersized welding cables are

used.

CAUTION

W / L3

V / L2

U / L1

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA S24190

use or service this equipment.

Do not touch electrically live parts.

removed.

Only qualified persons should install,

Do not operate with covers

inspecting or servicing machine.

Disconnect input power before

.

.

.

.

CR1

INPUT SUPPLY CONNECTION DIAGRAM


A-4INSTALLATION


A-4

CABLE INDUCTANCE, AND ITS AFFECT

ON PULSE WELDINGFor Pulse Welding processes, cable inductance willcause the welding performance to degrade. For thetotal welding loop length less than 15.24m (50 ft.), tra-ditional welding cables may be used without anyeffects on welding performance. For the total weldingloop length greater than 15.24m (50 ft.), the K1796Coaxial Welding Cables are recommended. The weld-ing loop length is defined as the total of electrodecable length (A) + work cable length (B) + work length(C) (See Figure A.3).

For long work piece lengths, a sliding ground shouldbe considered to keep the total welding loop lengthless than 15.24m (50 ft.). (See Figure A.4.)

Output connections on some Power Waves are madevia 1/2-13 threaded output studs located beneath thespring loaded output cover at the bottom of the casefront.

Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-trode cable between the wire feeder and the positive(+) output stud on the power source (located beneaththe spring loaded output cover near the bottom of thecase front). Connect the other end of the electrodecable to the wire drive feed plate. The electrode cablelug must be against the feed plate. Be sure the con-nection to the feed plate makes tight metal-to-metalelectrical contact. The electrode cable should be sizedaccording to the specifications given in the work cableconnections section. Connect a work lead from thenegative (-) power source output stud to the workpiece. The work piece connection must be firm andsecure, especially if pulse welding is planned.

For additional Safety information regarding the elec-trode and work cable set-up, See the standard "SAFE-TY INFORMATION" located in the front of theInstruction Manuals.

Excessive voltage drops caused by poor work

piece connections often result in unsatisfactory

welding performance.

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

NEGATIVE ELECTRODE POLARITYWhen negative electrode polarity is required, such asin some Innershield applications, switch the outputconnections at the power source (electrode cable tothe negative (-) stud, and work cable to the positive (+)stud).

When operating with electrode polarity negative the"Electrode Sense Polarity" DIP switch must be set tothe "Negative" position on the Wire Drive Feed HeadPC Board. The default setting of the switch is positiveelectrode polarity. Consult the Power Feed instructionmanual for further details.

VOLTAGE SENSINGThe best arc performance occurs when the PowerWaves have accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence theapparent voltage at the studs of the welder. Voltagesense leads improve the accuracy of the arc conditionsand can have a dramatic effect on performance.Sense Lead Kits (K940-10, -25 or -50) are available forthis purpose.

If the voltage sensing is enabled but the sense

leads are missing, improperly connected, or if the

electrode polarity switch is improperly configured,

extremely high welding outputs may occur.

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

The ELECTRODE sense lead (67) is built into the con-trol cable, and is automatically enabled for all semi-automatic processes. The WORK sense lead (21) con-nects to the Power Wave 455M (CE) at the four pinconnector located underneath the output stud cover.By default the WORK voltage is monitored at the out-put stud in the Power Wave 455M (CE). For moreinformation on the WORK sense lead (21), see "Work

Voltage Sensing” in the following paragraph.

All constant current processes sense the voltage at theoutput studs of the Power Wave 455M (CE) by default.

CAUTION

CAUTION

B

A

C

FIGURE A.3

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.4

A-5INSTALLATION


A-5

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead is internal to the cable to thewire feeder and always connected when a wire feederis present.

Important: The electrode polarity must be config-

ured at the feed head for all semi-automatic

processes. Failure to do so may result in extreme-

ly high welding outputs.

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

POWER WAVE TO SEMI-AUTOMAT-

IC POWER FEED WIRE FEEDER

INTERCONNECTIONS

The Power Wave 455M (CE) 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(CE) is located beneath the spring loaded output cover atthe bottom of the case front. The input receptacle on thePower Feed is typically located at the back of the 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 455M (CE), outthe back of the 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. For specific configuration information, consult thesemi-automatic Power Feed instruction manual.

SYSTEM DESCRIPTION

The Power Wave 455M (CE) and Power Feed M familyof products utilize a digital communication system calledArcLink. Simply put, ArcLink allows large amounts ofinformation 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 Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optionalGMAW-P 67 lead required 21 lead optionalFCAW 67 lead required 21 lead optionalGTAW Voltage sense at studs Voltage sense at studsGMAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optionalCAC Voltage sense at studs Voltage sense at studs

* The electrode voltage 67 sense lead is integral tothe control cable to the wire feeder.

Work Voltage Sensing

The standard Power Wave 455Mʼs default to the workstud (work sense lead disabled)

For processes requiring work voltage sensing, con-nect the (21) work voltage sense lead (K940) from thePower Wave work sense lead receptacle to the workpiece. Attach the sense lead to the work piece asclose to the weld as practical, but not in the return cur-rent path. Enable the work voltage sensing in thePower Wave as follows:

• Do not touch electr ically l iveparts or electrodes with yourskin or wet clothing.

• Insulate yourself from the workand ground.

• Always wear dry insulating gloves.

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

1. Turn off power to the power source at the discon-nect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side ofthe power source. Locate the 8-positionDIP switch and look for switch 8 of theDIP switch.

4. Using a pencil or other small object,slide the switch right to the OFF posi-tion if the work sense lead is NOT con-nected. Conversely, slide the switch tothe ON position if the work sense leadis 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 configuration infor-mation 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

455M(CE)

ROBOT

PLC CONTROLLER

ANALOG INTERFACE

etc.

POWER WAVE 455M(CE)

POWER WAVE

455M(CE)

POWER WAVE

455M(CE) FEED HEAD

SINGLE HEAD FEEDER DUAL HEAD FEEDER

SINGLE HEAD BOOM FEEDER

FH 1

PF-10R

Typical Robotic/ Hard Automation

(using Wire Drive Module and PF-10R)

UP TO 4 FEEDERS

ALLOWED

UP TO 4 FEED HEADS

ALLOWED

WIREDRIVEMODULE

A-7INSTALLATION


A-7

In this case the individual feed heads need to be assigned to the dual head control and the PW455M auto map-ping disabled and the Equipment Groups set. (See the Feeder documentation for information on setting thefeeder DIP switches)

System that is NOT "Auto Mappable"



POWER WAVE

455M (CE)

DUAL HEAD

DUAL HEAD

ALTERNATE HARD AUTOMATIC APPLICATION

(using a UI, WD Module, and PF-10R)

COMBINATION HARD AUTOMATION APPLICATION

(w/ Semi-Auto, WD Module, and PF-10R)

DUAL HEAD BOOM FEEDER

(using two single heads)

PF-10R

FH-1 FH-2

PF-10RWIRE

DRIVE

MODULE

(FH1)

WIRE

DRIVE

MODULE

(FH1)

A-8INSTALLATION


A-8

WELDING WITH MULTIPLE POWER

WAVES

Special care must be taken when more than one

Power Wave is welding simultaneously on a single

part. Arc blow and arc interference may occur or

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.2)

FIGURE A.2

- +

POWERWAVE

Connect All WorkSense Leads at the Endof the Joint

Connect All WeldingWork Leads at theBeginning of the Joint

TravelDirection

- +

POWER WAVE

- +

POWERWAVE

- +

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 in

lengths greater than 7.62 (25 feet), can lead to

communication problems (system shutdowns),

poor motor acceleration (poor arc starting) and

low wire driving 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

A-10INSTALLATION


A-10

I / O RECEPTACLE SPECIFICATIONSTABLE 3

WIRE FEEDER RECEPTACLE S1

PIN LEAD# FUNCTION

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

TABLE 4

VOLTAGE SENSE RECEPTACLE S2

PIN LEAD# FUNCTION

3 21A Work Voltage Sense

TABLE 5

RS232 RECEPTACLE S3

PIN LEAD# FUNCTION

2 253 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 selected (default=off)switch 4 = equipment group 2 selected (default=off)switch 5 = reserved for future useswitch 6 = reserved for future useswitch 7 = auto mappingswitch 8 = work sense lead

switch 7 auto mapping

off auto mapping enable-default

on auto mapping disabled

switch 8 work sense lead

off work sense lead not connected-default

on work sense lead connected

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.3

B-1OPERATIONB-1


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


• Do not touch electrically live partsor electrodes 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 orif working on, under or inside work-piece.Use the following equipment:-DC manual (stick) welder.-AC welder w ith reduced vol tagecontrol.

• Do not oper ate w i th pane lsremoved.

• Disconnect input power before ser-vicing.

-------------------------------------------------------------ONLY QUALIFIED PERSONS SHOULD INSTALL,USE OR SERVICE THIS EQUIPMENT. READ ANDFOLLOW THE MANUFACTURER’S INSTRUC-TIONS, EMPLOYER’S SAFETY PRACTICES ANDMATERIAL SAFETY DATA SHEETS (MSDS) FORCONSUMABLES.

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

READ THIS WARNING, PROTECT YOURSELF &OTHERS.

FUMES AND GASES can be

dangerous.

• 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 cause

fire 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

PROTECTIVE

GROUND

WARNING OR

CAUTION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS 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

•455Modular

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)

FCAW

• Flux Core Arc Welding

CAC

• Carbon Arc Cutting

DeviceNet Interface Module

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

EtherNet/DeviceNet Module

This module includes the DeviceNet and EtherNetcapability. The DeviceNet uses a 5 pin sealed miniconnector per ANSI B93.55M-1981. The EtherNetuses a RJ5 connector.

RECOMMENDED EQUIPMENT

Power Wave 455M (CE) – Semi-Automatic

Operation

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

environments.

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

• Only ArcLink compatible Power Feed semi-automat-ic wire feeders and users interfaces may be used.Other Lincoln wire feeders or non-Lincoln wire feed-ers cannot be used.

• Power Wave 455M (CE) Output LimitationsThe Power Wave 455M (CE) will support maximumaverage output current of 500 Amps @ 60% dutycycle.

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 455M (CE) semi-automatic powersource is designed to be a part of a modular, multi-process welding system. Depending on configuration,it can support constant current, constant voltage, andpulse welding modes.

The Power Wave 455M (CE) power source isdesigned to be used with the semi automatic family ofPower Feed wire feeders, operating as a system.Each component in the system has special circuitry to"talk with" the other system components, so eachcomponent (power source, wire feeder, user interface)knows what the other is doing at all times. These com-ponents communicate with ArcLink

The Power Wave 455M (CE) is a high performance,digitally controlled inverter welding power sourcecapable of complex, high-speed waveform control.Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW, and CAC processes. It car-ries an output rating of 400 amps, 36 volts (at 100%duty cycle).

RECOMMENDED PROCESSES AND

EQUIPMENT

RECOMMENDED PROCESSESThe Power Wave 455M (CE) can be set up in a num-ber of configurations, some requiring optional equip-ment or welding programs. Each machine is factorypreprogrammed with multiple welding procedures, typ-ically including GMAW, GMAW-P, FCAW, GTAW, andCAC for a variety of materials, including mild steel,stainless steel, cored wires, and aluminum.

The Power Wave 455M (CE) is recommended forsemi-automatic welding with ArcLink compatibleequipment like the Power Feed M series of feeders.The Power Wave 455M (CE) can have a number ofmodules installed that allow the machine to be used inRobotic and hard automation applications.

Wire Drive Interface Module

For Robotic platforms the Wire Drive Control Moduleis required to drive the Power Feed-10R wire drive.This module can be factory installed through ourautomation division or field installed for robotic appli-cations.

The Wire Drive Control Module is also be equippedwith a terminal strip for making simple input signalconnections. It can be used to externally control thebasic wire drive function. It is divided into threegroups: Trigger group, Cold Inch group, andShutdown group.


WARNING

B-5OPERATION


B-5

CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave 455m (CE). (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 3.

NOTE: The Power Wave 455M (CE) status light willflash green, and sometimes red and green, for up toone minute when the machine is first turned on. Thisis a normal situation as the machine goes through aself test at power up.

Light

Condition

Steady Green

BlinkingGreen

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

Steady Red

Blinking Red

Meaning

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

Occurs during a reset, and indicates thePower Wave 455M (CE) is mapping (identi-fying) 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 (C E). Read the error

code before the machine is turned off.

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 the PowerWave 455M (CE) wire feeder receptacle.See Trouble Shooting Section.

Not applicable.

5. 5 AMP AUXILIARY POWER CIRCUIT BREAKER:Protects 220 volt AC case front receptacleauxiliary supply.

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. 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

10

4

6

14

1

7

32

5

8

12

13

9

15

CASE FRONT LAYOUT


TABLE 3

B-6OPERATIONB-6

NOMINAL PROCEDURES

The Power Wave 455M (CE) is designed to operatewith 19.1mm (3/4") electrode stick-out for CV andPulse 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 sole

responsibility of the builder/user. Many variables

beyond the control of The Lincoln Electric

Company affect the results obtained in applying

these programs. These variables include, but are

not limited to, welding procedure, plate chemistry

and temperature, weldment design, fabrication

methods and service requirements. The available

range of a welding program may not be suitable

for all applications, and the build/user is and must

be solely responsible for welding program selec-

tion.

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

The steps for operating the Power Wave 455M (CE)will vary depending upon the options installed in theuser interface (control box) of the welding system. Theflexibility of the Power Wave system lets the user cus-tomize operation 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 455M(CE) encompasses a wide range of common process-es and will meet most needs. If a special welding pro-gram is desired, contact the local Lincoln Electricsales representative.

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 455M (CE) and aPower Feed wire feeder. Typically, the Control Box issupplied 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) WFS (wire feed speed) is the dominant con-trol parameter, controlling all other variables. The useradjusts WFS according to factors such as weld size,penetration requirements, heat input, etc. The PowerWave then uses the WFS setting to adjust its outputcharacteristics (output voltage, output current) accord-ing to pre-programmed settings contained in thePower Wave 455M (CE). In non-synergic modes, theWFS control behaves more like a conventional CVpower source where WFS and voltage are indepen-dent adjustments. Therefore to maintain the arc char-acteristics, the operator must adjust the voltage tocompensate for 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 the arclength. It is adjustable from 0.500 to 1.500. A Trim set-ting of 1.000 is a good starting point for most condi-tions.


WARNING

Current

Time

CURRENT WAVE FORM (CV)

B-7OPERATIONB-7

• WELDING MODE

May be selected by name (CV/MIG, CC/Stick Crisp,Gouge, etc.) or by a mode number (10, 24, 71, etc.)depending on the Control Box options. Selecting awelding mode determines the output characteristics ofthe Power Wave power source. For a more completedescription of the welding modes available in thePower Wave, see the explanation below.

• ARC CONTROL

Also known as Inductance or Wave Control. Allowsoperator to vary the arc characteristics from "soft" to"harsh" in all weld modes. It is adjustable from -10.0 to+10.0, with a nominal setting of 00.0 (The nominal set-ting of 00.0 may be displayed as OFF on some PowerFeed wire feeder control panels). See the WeldingMode descriptions, below, for detailed explanations ofhow the Arc Control affects each mode.

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 A.5)


FIGURE A.5

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 455M(CE) will automatically recalculate the waveform para-meters to maintain similar arc properties.


FIGURE A.6

Current

Time

CURRENT WAVE FORM (PULSE)

The Power Wave 455M (CE) utilizes "adaptive con-trol" to compensate for changes in electrical stick-outwhile welding. (Electrical stick-out is the distance fromthe contact tip to the work piece.) The Power Wavewaveforms are optimized for a 0.75" (19mm) stick-out.The adaptive behavior supports a range of stickoutsfrom 0.50" (13mm) to 1.25" (32mm). At very low orhigh wire feed speeds, the adaptive range may beless due to reaching physical limitations of the weldingprocess.

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 A.6)

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, K1796Cool-Arc 40 K2187-2 (230V AC)Water Flow Sensor, K1536-1Wire Drive Interface Module, K2205-1DeviceNet interface Module, K2206-1Ethernet Interface Module, K2207-1

COMPATIBLE LINCOLN EQUIPMENT

Any Arc-Link 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 equipment.

• 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 (CE) is critical toits operation. Generally speaking the calibration willnot need adjustment. However, neglected or improper-ly calibrated machines may not yield satisfactory weldperformance. To ensure optimal performance, the cali-bration of output Voltage and Current should bechecked 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 ACTION

This 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 TO

TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed asa system. Each component (power source, user inter-face, and feed head) has a status light, and when aproblem occurs it is important to note the condition ofeach. 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 error

sequences as noted below. This is especially

important if the user interface displays "Err 006"

or "Err 100" .

Included in this section is information about the powersource Status LED, and some basic troubleshooting

charts 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 (CE) status light willflash green, and sometimes red and green, for up toone minute when the machine is first turned on. Thisis a normal situation as the machine goes through aself 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 (CE) is mapping (identifying) each com-ponent in the system. Normal for first 1-10 secondsafter power is turned on, or if the system configura-tion 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 (CE). Read

the error code before the machine is turned 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 (CE)wire feeder receptacle. See Trouble Shooting Section.

Not applicable.



Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

CAUTION

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

Error Code #

11 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

Indication

Probably 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.

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)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE 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.)

Thermal LED is lit.

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.

1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.

2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.

3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.

1. Make certain that the PowerSwitch (SW1) is in the “ON”position.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset. Also, check input volt-age selection, below.

3. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.

1. Fan thermostat has opened.Check for proper fan opera-tion. (Fan should run whenev-er output power is on.) Checkfor material blocking intake orexhaust louvers, or for exces-sive dirt clogging cooling chan-nels in machine.

2. Secondary rectifier or Chokethermostat has opened. Aftermachine has cooled, reduceload, duty cycle, or both.Check for material blockingintake or exhaust louvers.

3. DC Bus PC board thermostathas opened check for exces-sive load on 40VDC supply.

If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local Lincoln

Authorized Field Service Facility.





PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMSMachine wonʼt weld, canʼt get any

output. (CR1 will not pull in.)

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

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 will 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.

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.







PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMSMachine wonʼt produce full output.

Auxiliary receptacle is “dead” noauxiliary voltage .

General degradation of the weldperformance

Excessively long and erratic arc.

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. 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.

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 10vs. actual current measured viaexternal meter.

5. Check the actual voltage dis-played on the Power Feed 10vs. actual voltage measured viaexternal 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.



F-1DIAGRAMSF-1


NO

TE

: T

his

dia

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m is

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onl

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It m

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F-2CONNECTION DIAGRAMF-2


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

POWER WAVE

WIREFEEDER

CONTROL CABLE K1543

TOWORK

F-3DIAGRAMSF-3


32

.88

26

.10

22

.63

12

.35

19

.00

19

.90

19

.16

9.4

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4.6

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11-1

4-97

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DIM

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AV

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55M

NOTES


WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

im905 powerwave 455m - lincoln electric · 2014-06-19 · ii safety ii arc rays can burn. 4.a. use...

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