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Lincoln Electric POWER WAVE 455 manual

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Table of contents for the manual

  • Page 1

    PO WER W A VE 455 S TT ™ IEC 974-1 OPERA TOR’S MANUAL IM641 May, 1999 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOU[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 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 observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

  • Page 6

    Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

  • Page 7

    vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - Power Wave 455..........................................................A-1 Safety Precautions............................................................................[...]

  • Page 8

    A-1 INST ALLA TION POWER WAVE 455 STT A-1 TECHNICAL SPECIFICA TIONS - PO WER W A VE 455/STT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 208V - 60HZ. 230V - 60HZ. 460V - 60HZ. 575V - 60HZ. 200V - 50HZ. 220V - 50HZ. 440V - 50HZ. 550V - 50HZ. OPEN CIRCUIT [...]

  • Page 9

    any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area. LIFTING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to i[...]

  • Page 10

    A-3 INST ALLA TION POWER WAVE 455 STT A-3 FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommend- ed super lag fuse or delay type brea[...]

  • Page 11

    A-4 INST ALLA TION POWER WAVE 455 STT A-4 V OL T A GE SENSING A T THE W ORKPIECE A four-pin work piece voltage sense lead connector is located beneath the output stud cover. The use of a work piece sense lead is optional for most welding modes, but it is strongly recommended for use with the STT welding mode. K940-10 & -25 Voltage Sense Lead Ki[...]

  • Page 12

    A-5 INST ALLA TION POWER WAVE 455 STT A-5 PO WER FEED CONTROL BO X MOUNTING In some installations, it may be desirable to mount the Wire Feeder control box directly to the front of the Power Wave power source. (The control box is the box containing the knobs, switches and displays nec- essary to control the Power Wave / Power Feed weld- ing system.[...]

  • Page 13

    B-1 OPERA TION B-1 POWER WAVE 455 STT OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always[...]

  • Page 14

    B-2 OPERA TION B-2 POWER WAVE 455 STT INPUT PO WER ON OFF HIGH TEMPERA TURE MA CHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT PO WER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT V O LTA G E INPUT V OL T A GE OUTPUT V OL T A GE INPUT CURRENT OUTPUT CURRENT PRO TECTIVE GROUND W ARNING [...]

  • Page 15

    B-3 OPERA TION B-3 GENERAL DESCRIPTION The POWER WAVE 455 STT is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW, GMAW- P, FCAW, SMAW, GTAW, CAC-A and STT process- es. RECOMMENDED PR OCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Powe[...]

  • Page 16

    B-4 OPERA TION POWER WAVE 455 STT B-4 WELDING CAP ABILITY The POWER WAVE 455 STT is rated at 60 Hz. 450A@ 38V. 100% duty cycle or 570A@ 43V 60% duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V 60% duty cycle. The machine is capable of higher outputs at lower duty cycles. For the STT process only, the machine is rated at 325 amps, 100% dut[...]

  • Page 17

    B-5 OPERA TION B-5 WELDING ADJUSTMENTS All adjustments are made on the system component known as the control box, which contains the switch- es, knobs and digital displays necessary to control both the Power Wave and a Power Feed wire feeder. Typically, the control box is supplied as part of the wire feeder. It can be mounted directly on the wire f[...]

  • Page 18

    B-6 OPERA TION B-6 Instead, an arc length adjustment is provided. The machine “knows” what the best arc length is at the given wire feed speed but allows the operator to change it. The arc length trim (usually referred to simply as “trim”) can be adjusted between 0.500 and 1.500 on the control box’s Volts/Trim display. A Trim of 1.000 mea[...]

  • Page 19

    C-1 A CCESSORIES C-1 OPTIONS / A CCESSORIES F A CT OR Y INCLUDED A CCESSORIES K940-10 & -25 Voltage Sense Lead Kits- used for voltage sensing at the workpiece. See the INSTALLA- TION section for more details on proper use. FIELD INST ALLED The following options/accessories are available for your Power Wave from your local Lincoln Distributor. K[...]

  • Page 20

    D-1 MAINTENANCE D-1 POWER WAVE 455 STT SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE Routine maintenance consists of periodically[...]

  • Page 21

    E-1 TR OUBLESHOO TING E-1 POWER WAVE 455 STT USING THE ST A TUS LED T O TR OUBLESHOO T SYSTEM PROBLEMS The Status LED on the pow er source case front can help diagnose problems do wn to the system component (pow er source, wire f eeder , wire dr iv e, etc.) le vel. If, f or any reason, the system does not appear to be working properly , alwa ys che[...]

  • Page 22

    E-2 TR OUBLESHOO TING E-2 POWER WAVE 455 STT HOW TO USE TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all sa[...]

  • Page 23

    E-3 TR OUBLESHOO TING E-3 POWER WAVE 455 STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 24

    E-4 TR OUBLESHOO TING E-4 POWER WAVE 455 STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 25

    E-5 TR OUBLESHOO TING E-5 POWER WAVE 455 STT Observe all Safety Guidelines detailed throughout this manual TROUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 26

    F-1 DIA GRAMS F-1 POWER WAVE 455 STT     9656/62523%25:        ?[...]

  • Page 27

    F-2 DIA GRAMS F-2 POWER WAVE 455 STT   $       [...]

  • Page 28

    F-3 DIA GRAMS F-3 POWER WAVE 455 STT  $ $ ! # ## #$ #" "$  ! 11-14-97 M18241 &!"(([...]

  • Page 29

    NO TES POWER WAVE 455 STT[...]

  • Page 30

    NO TES POWER WAVE 455 STT[...]

  • Page 31

    Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the coupon below. The hardbound book contain[...]

  • Page 32

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL[...]

  • Page 33

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]