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Lincoln Electric 455 Welder User Manual

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1. VOLTAGE 440 460V VOLTAGE 440 460V THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A o 200 208 Te 200 208 e o 150 200 208 220280 vill 22029w 220 230 WM o a 380 415V 380 4158 ST 380 415 440 460V a 440 460V dg 440 460V LL 19 440 460V D L d i 440 460V E e 550 575 560 6784 gt d LL THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A NOTE Turn main input power to the machine OFF before performing reconnect procedure Failure to do so will result in damage to the machine DO NOT switch the reconnect bar with machine power ON INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS 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 breakers also called inverse time or thermal magnetic circuit breakers Choose an input and grounding wire size according to local or national electrical codes Using fuses o
2. A 1 Safety realen iR REM 2 select Suitable Location eee denies A 2 SLACKING oes oes a Ut LI UU tan E LL C LAE A 2 Environmental Protection eee e ptt Rr Are A 2 2 Machine Grounding assis ie 2 High Frequency Protection 2 Input Connection nacti ettet tin 2 Input Fuse Supply Wire Considerations 3 Input Voltage Connection Procedure 3 Output ses 3 Voltage Sensing at the Work Piece 4 Power Wave Power Feed Wire Feeder 4 A 4 Electrode and Work Leads Electrode Positive Applications A 4 Electrode and Work Leads Electrode Negative Applications 0000000s00 A 4 Control Cable Connections TEE A 4 Power Feed Control Box Mounting A 4 eere reden menie ra Section B Safety Eiere B 1 Graphic Symbols that appear on this machine or in this B 2 General Descriptions entis B 3 Recommended Processes and Equipment sssssserennseeesrerrrnrrensrrnsttrnrrnnrn nnee nt B 3 Design F
3. 300419373 EE OL 300419373 NYOM OL 21 OL 031 emt NA DOS ua ms vor 249 vaoz H 9 ver OL om 031 SALVIS VN MKV o le 1 5 I 05 e ALINDYID VOL 3O LNOH3 HOIO3NNOO zezsy es 379V1d3934 ASN3S 39V110A 1310V1d303H 189 21 oL A009 60 iP POWER WAVE 455 STT LINCOLN E F 3 DIMENSION PRINT POWER WAVE 455 19 90 DIAGRAMS of o gt KH 5555 D Y i i 7 rh 77277 bt L LLL L mn i q st 8 S d S UR NNN NUN NNNNNN m POWER WAVE 455 STT LINCOLN 11 14 97 18241 3 NOTES POWER WAVE 455 STT LINCOLN NOTES POWER WAVE 455 STT LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Pr
4. Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas Ro eggo Yel HAE L t Cols Vil lu Qai Ye Cut Al ll WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it is BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR 1 gt EXEC HMA Sms CUCRITEOSSXSUEL GEO CF eU Rr de OE EL AMENER AIMS SAAT HAA Sei HAS APSA BHC palal d alayla aui y d al ply Gail guet Gras
5. In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks TT the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose t
6. coocoo 0005 20000 18 16 ro CET oor 3009 WORLOTT3 1 834 W3ISAS VOL D o n SINN ATddNS OL EIERE sod Jl leg 2408 HOUMS OL HOLMS O DIAGRAMS eb 1 O8 HOLIMS OL D s 901 OL 184 183 WOLIOB OL ent gt VEL 801 OL et 1 G8 HOLIMS OL 14371 OL eh an Q8 HOLIMS OL TH 1H OL po 1437 0 01 Vel gt VAL Id NOLLOB OL HOLIMS 193NNOO3H 40 HV3H SIHL 8L HOLIMS OL SLIVM SHHO SHO1SIS3H S170A 04N SUOLIOVAVI aen LNaNOdNO et 9N002 407102 0931 19913 53 STOBWAS 1 2 12313 30 3015 LHOIH Sp H3yINHOJSNVHL S3NHOVN TV NO BV3ddV 10N AVW O N NOILVY3dO_ASLS OSS X04 NOILISOd 31VIBdOMddv NO QV31 V 32V d N siy Aq paJeAo2 104 aq jou 31 sjaued eaunso ue au auo uo aui Ajuo 10 51 SIUL 3LON Li Je 801271803 OL 1 3682 EZ ME 3682 3982 NOLLVH3dO AG1G OGG 9 S NMOHS NOILDZNNOD 3OVIJ0A 404 NOLISOd 3lvisdOuddV NI HOLINS 39V1d EN 139205 037 40 Qv31 92 18 00 21 5 317031 40 3903 171
7. Step 2 PERFORM EXTERNAL RECOMMEND ED TESTS The second column labeled POSSIBLE AREAS MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 CONSULT LOCAL AUTHORIZED FIELD SERVICE FACILITY If you have exhausted all of the recommended tests in step 2 consult your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455 STT LINCOLN 8 E 2 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal covers are removed Input fuses keep blowing or input breaker keeps tripping Machine will not power up no lights no fan etc POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service facili ty for technical assistance Make certain that fuses or breakers are properly sized See Installation section of this manual for recommended
8. 16 connector with only two wires going into it Unplug P26 It should remain attached to the main harness Install the front nameplate on the Power Wave 455 by replacing the six screws saved in Step 2 5 Plug a Sense Lead into the Sense Lead Receptacle Note Only the lead marked WORK is used The lead marked ELECT can be cut off and discarded 6 Connect the WORK sense lead clamp to the piece being welded The Power Wave 455 will now use the external work piece Sense Lead to sense arc voltage in all welding modes If the Sense Lead is enabled but not connect ed to the work piece extremely high welding output currents may result To restore normal work piece sensing at the output terminals reconnect P26 to the Control PC board The Sense Lead can then be disconnected NOTE Power Wave 455 STT machines are shipped with the jumper removed voltage sensing lead enabled A Sense Lead Kit must be used in all weld ing modes POWER WAVE POWER FEED WIRE FEEDER INTERCONNECTIONS ELECTRODE amp WORK LEADS ELECTRODE POSITIVE APPLICATIONS Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feeder and the positive output stud on the power source On Power Wave 455 STT machines use the positive output connection labeled STT for welding If desired other welding modes can be used on this stud ho
9. 40 12492 7 aen 14340402 9 1 6 9N002 90102 Qv1 18513 H3d STOSWAS 1V21H19373 3000 TOHLOZTE TNOLLYN 384 WalSAS VOL 9 oI SENT 1915 OL 31411934 HOUMS 4103NNOO3Y 01 DIAGRAMS Zog OL YSX va lex OL SX boy Aen 31715 0105 01 Hawvaua a seul be 069249276353 auvos 1 71 1038 OL O3N 002 2 Z 08 HOLIMS OL 1034 1ndNIOL H 604 Q8 HOLIMS OL OB HOLMS OL HOLIMS 193NNOO3H 7 ANIHOVW 40 WOH SIHL 3INIHOVM 30 341 LHD HANHOASNVHL AUVITIXNV S3NIOVM 71 NO HY3ddV LON AYN TN NOIL VER dO 9f Obb S NNOHS NOILDZNNOD 39VLTOA LNANI NOLLO3NNOO ALVHdOMddV NO QV31 V 39v TN NOIL YH34O 09 08 SI NMOHS 23 02 39V L 10A ANANI 303 NOLIISOd JLVIYdOYddY NI HOLINS 32774 EN 7133008 037 40 0 31 2 78 SNIV QG OHLV3 5837 037 30 3903 1V14 1 3 ven o YOLDVINOD 01 mA Sn OL don Y 103990038 OL 1009 50 5 MHaonaswvul 08 MOINS O1 az Im OL WaNUOASNVEL Nm Dl rk 202 L HOLIMS 9 1331 HAWHOA
10. Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e naedoe6008 CORRE THEN EA e i 9 E Vi ML IF AT LS AIX uie Jo ALD a gll pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUBS ISUCRSREUCT RRR ez 12 Sal amp s ESSA dis 4 lan cl ysl n e A READ AND UNDERSTAND THE MANUFACTURER 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES 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 A ETRE 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera
11. a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln El
12. fuse and breaker sizes Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle or both There is internal damage to the power source Contact an authorized Lincoln Electric Service facility Make certain that the Power Switch SW1 is in the position Circuit breaker CB4 in recon nect area may have opened Reset Also check input volt age selection below Input voltage selection made improperly Power down check input voltage reconnect according to diagram on reconnect cover RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455 STT LINCOLN 8 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Wire feeder won t work No lights Circuit breaker CB1 on case apparently no power to wire feeder front may have opened Reset Control cable
13. this control adjusts the output current in amps 2 VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse synergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 500 to 1 500 A Trim setting of 1 000 is a good starting point for most conditions In STT modes the user can adjust the Trim setting to change the overall heat input to the weld 3 WELDING MODE May be selected by name CV MIG CC Stick Crisp Gouge etc or by a mode number 10 24 71 etc depending on the control box options Selecting a welding mode determines the output characteristics of the Power Wave power source For a more complete description of the welding modes avail able in the Power Wave see the explanation below 4 ARC CONTROL Also known as Inductance or Wave Control Allows operator 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 setting of 00 0 may be displayed as OFF on some Power Feed wire feeder control panels See the Welding Mode descriptions below for detailed explanations of how the Arc Control affects each mode DETAILED WELD MODE DESCRIPTIONS CONSTANT VOLTAGE CV WELD CV MIG CV FLUX CORED PROCEDURES For each wire feed speed a corresponding voltage is preprogrammed into t
14. between the power source and wire feeder is open Check continuity on all 5 leads from end to end in the control cable Check for 40 volts DC on pins D 40 and E common of the Wire Feeder Receptacle If 40 volts DC is not present and CB1 is reset contact an authorized Lincoln Electric Service facility Thermal LED is lit Fan thermostat has opened Check for proper fan operation Fan should run whenever main power is on Check for material blocking intake or exhaust louvers or for excessive dirt H all recommended possible areas clogging cooing channels in machine Of misadjustments have Deen Secondary rectifier thermostat has checked and the problem persists opened After machine has cooled Contact your local Lincoln reduce load duty cycle or both Authorized Field Service Facility Check for material blocking intake or exhaust louvers Machine won t weld can t get any Input voltage is too low or too high output CR1 will not pull in Make certain that input voltage is proper according to the Rating Plate located on the rear of the machine If the Thermal LED is also lit see Yellow Thermal LED is Lit section Primary current limit has been exceeded Possible short in output circuit Turn machine off Remove all loads from the output of the machine Turn back on If condition persists turn power off and contact an autho rized Lincoln Electric Field Service facility CAUT
15. cables possible at least 2 0 4 0 preferred copper wire even if the average output current would not normally require it When pulsing the pulse current can exceeds 650 amps Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid excessive lengths bundle the electrode and ground cables together where practical and do not coil excess Cable POWER WAVE 455 STT LINCOLN 4 INSTALLATION 4 VOLTAGE SENSING AT THE WORKPIECE 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 amp 25 Voltage Sense Lead Kits 10 or 25 foot lead lengths are included with the Power Wave STT models If a longer lead length 50 foot is required see the ACCESSORY section To enable the work piece voltage sensing lead a jumper must be removed from the Control PC Board as follows 1 Turn the Power Wave 455 power OFF 2 Remove the front nameplate from the Power Wave 455 by removing the six screws from the name plate Save the screws for re use TZ Locate P26 located on the upper right edge of the Control PC Board It is
16. work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY 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 bare skin 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 full area 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 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
17. 3 3HI IS3HV3N Y N S310N 83 01 on venz 9882 O1 si T NIYAN Thor Lud 1N3BUDO OL 52 OI road 1 01 sod 2 1I3NNOIJY 01 2 01 ch 9 Ht HOLIAS A 011 CET AU ol HANHOASNVEL NIVW fexny 01 __ BEN 1 15 0705 01 vex waonaswvui Avis AVIS 005 01 1 le am OL LINY v9 ned 193440934 aa Za 01 01 VOR 82 F 2 INVHOVIG ONIHIM DN 3HOH9 43111934 08 YIMOd OL D L HAWHOASNVEL OL RL BEX She 01 H3WHOJSNVHI 3INIHOVM 30 341 1331 3012Y1N02 OL 1009750 5 9 197 01 H TANYA 123NN0238 01 eee 81 01 v9oz m OL 009 50 e MHaonasNvur ica 08 zer oL Z soa 504 5x SS ss oi sod HAMOd AvT3 31715 0105 631 511915 D Lee unam a A titoli tht St ems ost 1N05 H1MOd HAMS NON ead NMT dibus Hl us 01 OL Pal mr aeo SN VEL S mere 9 9 09 LLS SStm H3MOd
18. 3 mm 5 to 32 mm 1 25 In the low and high end of the wire feed speed ranges of most processes the adaptive behavior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process The Arc Control adjustment allows the pulse frequen cy to be varied Increasing the Arc Control causes the frequency setting to increase while decreasing the Arc Control causes the frequency to decrease Varying the Arc Control and hence the pulse fre quency affects the droplet transfer and allows fine tuning for different welding positions CONSTANT CURRENT CC STICK CC TIG PROCEDURES Stick welding can be performed by choosing one of the stick welding modes Check the Power Feed wire feeder Operators Manual for instructions on how to energize the output terminals on the Power Wave Certain options energize the terminals automatically while other options require a manual adjustment to energize the terminals The output current is set by the Amps control on the Power Feed wire feeder The Volts Trim adjustment has no effect in this mode The Arc Control adjusts the arc force Increasing the Arc Control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force mak ing the arc softer and smoother ARC GOUGING PROCEDURES Arc gouging can be performed by choosing the arc gouging weld mode Doing so automa
19. A 36V 100 duty cycle or 500A 40V 60 duty cycle The duty cycle is based upon a ten minute period For the STT process only the machine is rated at 325 amps 100 duty cycle A 60 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave 1 POWER SWITCH Controls input power to the Power Wave 2 STATUS LIGHT A two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated as follows NOTE The POWER WAVE 455 STT status light will flash green and sometimes red and green for up to one minute when the POWER WAVE 455 STT is first turned on This is a normal situation as the machine goes through a self test at power up Light Steady Green System OK Power source communicating nor mally with wire feeder and its components Nothing connected to Wire Feeder Receptacle Meaning Non recoverable system fault Must turn power source off find source of error and turn power back on to reset See Troubleshooting Section 3 HIGH LIGHT thermal overload yellow light that comes on when an over temper ature situation occurs Output is disabled until the machine cools down When cool the light goes out and output is enabled 4 10 AMP WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder
20. BLE 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 you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine unt
21. E ONLY 450A 38V 100 570A 43V 60 450A 38V 100 570A 43V 60 450A 38V 100 570A 43V 60 450A 38V 100 570A 43V 60 400A 36V 100 500A 40V 60 400A 36V 100 500A 40V 60 400A 36V 100 500A 940V 60 400A 36V 100 500A 40V 60 OUTPUT CONDITIONS OUTPUT CONDITIONS STT PROCESS ALL VOLTAGES STT PROCESS ALL VOLTAGES 325A 33V 100 325A 33V 100 OUTPUT OPEN CURRENT PULSE PULSE PULSE AND AUXILIARY CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND POWER VOLTAGE RANGE TIME RANGE 75 VDC 5 570 0 15 1000 Hz 5 55 VDC 100 MICRO SEC 40 VDC AT 3 3 SEC 10 AMPS 115 VAC AT 10 AMPS PROCESS CURRENT RANGES PROCESS CURRENT RANGES DC CURRENT YO MIG MAG 50 570 Amps FCAW 40 570 Amps SMAW 30 570 Amps Pulse 5 750 Amps STT 40 325 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT OUTPUT AMPS INPUT AMPERE VOLTAGE DUTY RATING ON SUPER LAG FREQUENCY CYCLE NAMEPLATE OR BREAKER 208 60 450 100 230 60 450 100 460 60 450 100 575 60 450 100 200 50 400 100 220 50 400 100 440 50 400 100 550 50 400 100 HEIGHT WEIGHT 26 10 in 86 88 i 250 Ibs 663 mm 114 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 C to 40 C 50 C to 85 C POWER WAVE 455 STT LINCOLN 2 INSTALLATION 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should per
22. ION 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455 STT LINCOLN 8 E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine often noodle welds out put is limited to approximately 100 amps when running a particular procedure Machine won t produce full output For no apparent reason the weld ing characteristics have changed Auxiliary receptacle is dead no auxiliary voltage Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Secondary current limit has been exceeded and the machine has phased back to protect itself Adjust procedure or reduce load to lower current draw from the machine 1 Input voltage may be too low limiting output capability of the power source Make certain that the input voltage is prop er according to the Rating Plate located on the rear of the machine Input may be single phased Make certain the input voltage is proper on all three input lines Check for proper Wire Feed Speed setting In CV MIG and FCAW modes check for proper Voltage setting In the MIG MAG pulse modes check the Trim setting These controls are on
23. O Shipping Costs 77 mm mm mm mme m Name Address Telephone Signature as it appears on Charge Card WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ORBPOBARA ELE het EE OHLMPT APYORAPHRBS NTWSHRELTFSU RREAN 945 CE EC SUE HIER ecran Xe a e sis HIE amp Ju Gu Gi ll el all oh ye eani das ag SONT gh la gS ell All fl Jai P dua aa e Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable
24. RETURN TO MAIN MENU SE IM641 POWER WAVE 455 STT For use with machines having Code Numbers 10552 10554 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful IEC 974 1 OPERATOR S MANUAL ISO 9002 Seen MMe MER LINCOLN World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSI
25. SNVEL NIVW uaonasNvul wa D vier 01 NYI v9 LIN9HI9 VOL 82 F 1 Se gn DN SOHO NIVIN 1 1311238 08 EEN L H3I NHOJSNVH I vex ove wx 01 wen wm HAMHOASNVEL 3INIHOVM 40 1331 ANSYYND H31411934 HAMOd or 31715 0105 037 5 15 1 Sirm in 1 01 vdl LLS SSH 3AVM YAMOd 300419373 01 300812313 E 01 21 ER ar or A009750 2 zer OL 31 emm en wer 01 0 4 031 1115 Ku o 5 95 z1 oL A009 50 19 1937 902 9 m OL ALINDYID VOL zao 3710142034 FS LIN9HI9 VOR HOLO3NNOO zezsy es 319v1d3934 ISN3S 39vV110A 25 wasn 9d 319v1Ld3934 430334 s 3O LNOH3 POWER WAVE 455 STT LINCOLN E N Jequunu zu wd nb y 4 104 SIMS 03 S eu JI LL apisul paysed si Jered e 104 dYIDeds SUL 56 13759 men 3015 LNANOdNOD 32830035 9N3EMDN ALAYI 301934409 100
26. de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 9 fsPBHEICTASESUCFEU e zs SH7IAE S XACE E AAS AH 71 97471 27 amp Qai dul jaa jl arin e os uui BAL al Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas PRE gt DFM TKS e HERES BEER e Meg xp ett AIR Aie Gb pha NM ale Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s
27. e actual voltage for a given wire feed speed is not directly predictable unless the waveform is known In this case it is not practical to preset an actual voltage for the procedure POWER WAVE 455 STT LINCOLN B 6 OPERATION 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 can be adjusted between 0 500 and 1 500 on the control box s Volts Trim display A Trim of 1 000 means that no adjustments will be made to the preset arc lengths A Trim greater than 1 000 increases the preset arc lengths A Trim setting less than 1 000 decreases the preset arc lengths The arc length trim adjustment is factored in at all wire feed speed set tings Increasing the Trim by 10 percent at a given wire feed speed also increases all the other arc length trim settings of the procedure by 10 percent The Power Wave utilizes a control scheme known as adaptive control in all pulse modes Because the Power Wave utilizes adaptive control it can adjust the pulsing parameters based on changes in the arc due to changes in the electrical stickout of the electrode Electrical stickout is the distance from the contact to to the workpiece The Power Wave is optimized for use with a 19 mm 75 stickout The adaptive behavior is programmed to support a stickout range from 1
28. eatures and emm eene B 3 Additional Features B 3 Welding Capability 2 2 rte netten dui B 4 Limitations eor RE ERE UE ERRARE EHI E RR RAE B 4 Compatible Lincoln Equipment B 4 Power Source Operation an arani aae a Eana AEE Eaa AA AE RREA B 4 Duty Cycle and Time 7 B 4 Case Front Controls B 4 Welding Adjustments 3 ca tee date B 5 Detailed Weld Mode Descriptions B 5 5 5 Section C Options ACCESSONIES oie ere ele de p ede ret C 1 Factory Installed eot itr tee te ee Ue aede e td C 1 Field Installed a do tete adde AT C 1 Pt Section D Safety Precaution eee eee eet bee a E ta eue ee cen deua ties D 1 Routine Maintenance D 1 Troubleshooting 2 2 RERET aSk Section Troubleshooting the Power Wave Power Feed System using the Status LED E 1 Safety Precautions nie Rate E 2 How to Use Troubleshooting E 2 Troubleshooting Guide E 3 Wiring Diagram and Dimension Print Section F Parts P335 Series 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS POWER WAVE 455 STT INPUT AT RATED OUTPUT THREE PHAS
29. ectric Company product as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy 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 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Iostallatien ees EENEG Section A Technical Specifications Power Wave 455
30. een the control box and the case front Align the four holes in the back of the control box with the four threaded mounting holes in the case front Secure the control box in place with four of the screws saved from the previous step 6 Reassemble the control box The Power Feed Wire Drive can now be connected to the power source wire feeder connector This con nector is located under the spring loaded output cover near the bottom of the case front The control cable is keyed and polarized so it can be installed in only one way To ensure proper electrode voltage sensing always connect the Wire Drive to the Power Source wire feeder connector Do not connect it to the optional Output Receptacle which may be present on the Power Feed Control Box POWER WAVE 455 STT LINCOLN 8 B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING 0 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 2 dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Z WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have he
31. en necessary e Modular construction for easy servicing e Thermostatically protected Electronic over current protection Input over voltage protection Utilizes digital signal processing and microprocessor control Simple reliable input voltage change over All system components communicate and transfer information Auto device recognition simplifies accessory cable connections POWER WAVE 455 STT LINCOLN B 4 OPERATION B 4 WELDING CAPABILITY 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 duty cycle If the duty cycle is exceeded a thermostat will shut off the output until the machine cools to a reasonable operating temperature LIMITATIONS e The Power Wave is not recommended for process es other than those listed Power Wave only be used with Power Feed wire feeders Other models of Lincoln feed ers any models of non Lincoln wire feeders not be used COMPATIBLE LINCOLN EQUIPMENT All Lincoln Power Feed Wire Feeders POWER SOURCE OPERATION DUTY CYCLE AND TIME PERIOD The POWER WAVE 455 STT is rated at 60 Hz 450A 38V 100 duty cycle or 570A 43V 60 duty cycle 50 Hz 400
32. ess STT for mild steel and stainless steel RECOMMENDED EQUIPMENT The POWER WAVE 455 STT must be used with the Power Feed family of wire feeders These feeders are required to access and make use of the many of the welding features contained in the POWER WAVE 455 STT DESIGN FEATURES AND ADVANTAGES A unique feature of the Power Wave is the ability to function without any controls when used with Power Feed wire feeders All power source control informa tion comes to the Power Wave from a Power Feed wire feeder The following chart lists the power source parameters that can be changed from the Power Feed wire feed er and gives examples of each Optional equipment may be required to access some of the following para meters Parameter Examples Welding Stick Crisp Stick Soft Flux Cored with Gas Flux Cored without Gas CV Synergic CV 035 Stainless Pulse 045 Steel Pulse 5356 Aluminum Pulse STT Synergic Current CC modes Voltage CV modes Wire Feed Speed synergic modes ADDITIONAL DESIGN FEATURES AND ADVANTAGES e Designed to NEMA EW 1 and IEC 974 1 Standards e Qualifies for 5 mark on nameplate which means it can be used in areas where there is increased risk of electric shock e Multiple process output ranges 5 570 amps e Easy access for input connections Connections are simple strip and clamp no lugs required e F A N fan as needed Cooling fan runs only wh
33. f UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry C O D Orders Please Invoice only if order is over 50 PI Invoi ly if order i 50 00 Check or Money Order Enclosed U S Funds only Check or M Order Enclosed U S Funds Credit Card p s v 111 1111111111 Ge pes Mal LL Le THIS FORM TO ORDER sooks OR FREE INFORMATIVE CATALOGS li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 5 00 L Seminar Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H Educational Video Information Incentive Management 5 00 IM ED 93 New Approach to Industrial Economics 5 00 NA Lames F Lincoln Arc Welding American Century of John C Lincoln 55 00 AC Foundation Book Information JFLF 515 Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Welding Preheat Calculator 300 wcs Pipe Welding Chats 950 eo so A
34. form this installation TN Turn the input power OFF at the disconnect switch or fuse box before working on this equipment not touch electrically hot parts Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bottom Dirt dust or any foreign material that can be drawn into the welder should be kept at a minimum Using filters on the air intake to prevent dirt from building up restricts air flow Do not use such filters Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdowns This machine is equipped with F A N fan as needed circuitry The fan runs whenever the output is enabled whether under loaded or open circuit conditions The fan also runs for a period of time approximately 5 minutes after the output is disabled to ensure all components are properly cooled If desired the F A N feature can be disabled causing the fan to run whenever the power source is on To disable F A N connect leads 444 and X3A together at the output of the solid state fan control relay locat ed on the back of the Control PC board enclosure STACKING Power Wave machines can be stacked to a maximum of 3 high The bottom machine must always be p
35. g Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c LINCOLN 8 CYLINDER may explode 22 B s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operat
36. he machine through special soft wares at the factory This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed If the wire feed speed is changed on the wire feeder the voltage automatically changes with it In some cases the operator may want to change the preprogrammed voltages for example to compensate for cable and fixture voltage drops The preset volt ages can be adjusted on the wire feeder s Voltage display When a change is made to the voltage at one wire feed speed this change is applied to all other wire feed speed settings For example if the operator turns up the voltage by 10 percent the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent The preset voltage programmed at the factory may be changed with the wire feeder VOLTS adjustment The Arc Control adjusts the inductance This adjust ment is often referred to as pinch Inductance is inversely proportional to pinch Increasing the Arc Control setting decreases the inductance which results in the arc getting colder and pinched tighter Decreasing the Arc Control setting increases the inductance which results in the arc getting wider reduced pinch GMAW PULSE PROCEDURES In these procedures the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual voltage Th
37. hemselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES 4 can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your em
38. il fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Sai Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 6 In some cases it may be necessary to remove safety LZ 2b minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan ke Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and
39. ions and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 i SAFETY i PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la
40. laced on a firm secure level surface There is a danger of machines toppling over if this precaution is not taken ENVIRONMENTAL PROTECTION The Power Wave power source is rated IP21S and should not be subjected to falling water nor should 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 it MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PROTECTION If possible locate the Power Wave away from radio controlled machinery 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 INPUT CONNECTION WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electri cal codes and the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury
41. ld com bustibles ARC RAYS can burn Ge 2 Wear eye body protection Observe additional Safety Guidelines detailed in the beginning of this manual POWER WAVE 455 STT LINCOLN O O O O O O OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER ON OFF HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER po INPUT POWER THREE PHASE DIRECT CURRENT POWER WAVE 455 STT B 2 SMAW GMAW FCAW GTAW OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING B 3 OPERATION 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 PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave can be set up in a number of config urations some requiring optional equipment Each machine is factory preprogrammed with multiple weld ing procedures typically including GMAW GMAW P FCAW SMAW GTAW and CAC A for a variety of materials including mild steel stainless steel cored wires and aluminum Additionally it supports the Surface Tension transfer proc
42. ocedure 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 contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related
43. or death Use a three phase supply line 1 75 inch 45 mm diameter access hole for the input supply is located on the upper left case back next to the input access door Connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door refer to Figure 1 following POWER WAVE 455 STT LINCOLN 3 INSTALLATION 3 FIGURE A 1 CONECTION DIAGRAM ON REN ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM 1 A INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE 200 208V WARNING dote ec W 13 2 2 Disconnect input power before WARNING vis Gene 206 2087 BS inspecting or servicing machine S 2 Disconnect input power before 220 230 Do not operate with covers inspecting or servicing machine U L1 2 2 IN removed Do not operate with covers 380 415V SHOCK Do not touch electrically live parts BD O 440 460V Only qualified persons should install 5156145194 Do not touch electrically live parts Tc e use or service this equipment Only qualified persons should install Z d i nt EIE use or service this equipme VOLTAGE 220 230V VOLTAGE 380 415V
44. patter An Arc Control setting of 0 0 is a good starting point for most conditions The Trim is a fine adjustment of the heat input to the weld It can be varied from 0 500 to 1 500 A Trim setting of 1 000 is a good starting point for most condi tions POWER WAVE 455 STT LINCOLN C 1 ACCESSORIES OPTIONS ACCESSORIES FACTORY INCLUDED ACCESSORIES K940 10 amp 25 Voltage Sense Lead Kits used for voltage sensing at the workpiece See the INSTALLA TION section for more details on proper use FIELD INSTALLED The following options accessories are available for your Power Wave from your local Lincoln Distributor K1570 1 Dual Cylinder Undercarriage K940 50 Voltage Sense Lead Kit 50 foot voltage sense lead kit if additional length is required POWER WAVE 455 STT LINCOLN 8 C 1 D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING 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 blowing out the machine using a low pressure airstream to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine POWER WAVE 455 STT LINCOLN 8 D 1 E 1 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The S
45. pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 6 zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut pro
46. ployer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 LINCOLN 8 SAFETY 7 WELDING SPARKS lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Weldin
47. power supply 5 10 AMP AUXILIARY POWER CIRCUIT BREAK ER Protects 110 volt AC case front receptacle auxiliary supply POWER WAVE 455 STT LINCOLN 8 B 5 OPERATION 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 feeder itself or mounted separately as might be done in a welding boom installation Because the control box can be configured with many different options your system may not have all of the following adjustments Regardless of availability all controls are described below For further information consult the Power Feed wire feeder instruction manual 1 WFS AMPS In synergic welding modes synergic CV pulse GMAW STT WFS wire feed speed is the domi nant control parameter controlling all other vari ables The user adjusts WFS according to factors such as weld size penetration requirements heat input etc The Power Wave then uses the WFS setting to adjust its output characteristics output voltage output current according to pre pro grammed settings contained in the Power Wave In non synergic modes the WFS control changes the wire feed speed according to the desired proce dure In constant current modes stick TIG
48. r cir cuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE A WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electri cal codes and the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Welders are shipped connected for the highest input voltage listed on the rating plate To move this con nection to a different input voltage refer to reconnect instructions located on the inside of the input access door or in Figure A 1 If the main reconnect switch is placed in the wrong position the welder will not pro duce output power If the Auxiliary A lead is placed in the wrong position there are two possible results If the lead is placed in a position higher than the applied line voltage the welder may not come on at all If the Auxiliary lead is placed in a position lower than the applied line voltage the welder will not come on and the two circuit breakers in the reconnect area will open If this occurs turn off the input volt age properly connect the A lead reset the breakers and try again OUTPUT CONNECTIONS Use the largest welding electrode and ground
49. subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 950 00 amp credit card orders i
50. tatus LED on the power source case front can help diagnose problems down to the system component power source wire feeder wire drive etc level If for any reason the system does not appear to be working properly always check the Status LED is solid green no blinking Status LED is blinking green Status LED is solid red no blinking Status LED is blinking red and green Status LED is blinking red TROUBLESHOOTING E 1 color of the Status LED and refer to the following chart to help you determine which system compo nent power source wire feeder wire drive etc may be faulty Replace the components identified as potentially faulty with known good compo nents and the system should operate normally System operating normally Normal condition for the first few seconds after the power is turned on Wire feeder and or its components are not prop erly configured and or connected together Refer to wire feeder instruction manual s for wire feeder configuration information Indicates that nothing is connected to the Wire Feeder Receptacle Connect a Power Feed Wire Feeder to the wire feeder receptacle Power source cannot communicate with the wire feeder and or its components due to a problem within the power source Contact an authorized Lincoln Electric Service facility If the Thermal LED is also lit see Yellow Thermal LED Lit in the Main Troubleshooting Chart Input voltage is too high or
51. the wire feed er Check for proper shielding gas mix and flow Check for loose or faulty weld cables and cable connections Circuit breaker CB2 on case front may have opened Reset Circuit breaker CB4 in recon nect area may have opened Reset RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 455 STT LINCOLN 8 Jequunu epoo zu wd nb SAID 104 JUBLUIeEd G au JO euo uo LL paysed si seyno Med 104 2u12ade Jenueuu siy Aq seulu2eui 104 93e1n2552e jou 1 Aqjuo 40 SI SIUL 3LON LIP 30 3015 LN3NOdNO2 32830035 ONUIGANN ALAYI 501534405 O 0 29 M012V1N02 01 82 0L 2 o 3 8 65000000 0099999 500000 00000 69 9 9 oooooooo 000000 1 9 ezr lever SLIVM SWHO SUO1SIS3Y 110 03
52. tically ener gizes the output terminals on the Power Wave mak ing the power source immediately ready to weld The output current is set by the Amps control on the Power Weld wire feeder The Volts Trim adjustment has no effect in this mode The Arc Control adjusts the arc force Increasing the Arc Control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force mak ing the arc softer and smoother SURFACE TENSION PROCEDURES TRANSFER STT The STT process is neither a constant current CC nor a constant voltage CV process It is a current controlled process where the electrode current changes quickly in response to the instantaneous requirements of the arc In the Power Wave 455 STT the ideal STT wave forms and current control alogorithms are pro grammed into the power source These waveforms are automatically adjusted as the wire feed speed is varied on the Power Feed wire feeder This is known as synergic control of the STT process Some adjust ments are available to the user so that the arc can be adjusted to meet the actual weld conditions The Arc Control setting is a coarse adjustment of the heat input to the weld It can be varied from 10 0 to 10 0 with a nominal setting nof 0 0 Reducing the Arc Control too far may cause electrode stubbing Raising the Arc Control too high may cause the electrode to be too fluid increasing s
53. too low Make certain that input voltage is proper according to the Rating Plate located on the rear of the machine Power source is having trouble communicating with wire feeder or its components Turn machine off Disconnect control cable from the Wire Feeder Receptacle Turn power back on If Status LED then blinks green the problem is with the wire feeder If light is still blinking red and green contact an authorized Lincoln Field Service facility Error code display Contact an authroized Lincoln Field Service Shop POWER WAVE 455 STT LINCOLN E 2 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment This Troubleshooting Guide is provided to help you locate and correct possible machine misad justments Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting
54. ver and along the channels formed into the base of the Power Wave out the back of the channels and then to the wire feeder POWER WAVE 455 STT LINCOLN 8 5 INSTALLATION POWER FEED CONTROL BOX 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 Complete details for separating the con trol box from the wire drive are contained in the Power Feed Instruction Manual Once separated mounting instructions are as follows 1 Disconnect the input power from the Power Wave 2 Separate the control box from the wire drive on the Power Feed wire feeder and remove the control panels see the Power Feed Instruction Manual for details 3 Remove the front nameplate from the Power Wave by removing six screws from the metal nameplate Save the screws for re use 4 Connect the 6 pin connector that comes out the back of the control box to the 6 pin receptacle that is tie wrapped to the harnessing inside the rectan gular opening in the power source It will be nec essary to remove one or two of the wire ties in order to give enough slack to the power source connector and leads 5 Position the control box over the rectangular hole in the Power Wave case front being careful not to pinch any leads betw
55. voquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie dico LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR
56. wever their average output current will be lim ited to 325 amps For non STT processes the use of the positive output connection labeled Power Wave is recommended so that the full output range of the machine is available Do not connect the Positive STT connection directly to the Positive Power Wave connection Unpredictable welding perfor mance will result A work lead must be run from the negative power source output stud to the work piece The work piece connection must be firm and secure especially if pulse welding is planned Excessive voltage drops at the work piece connection often result in unsatisfacto ry pulse welding performance ELECTRODE amp WORK LEADS ELECTRODE NEGATIVE APPLICATIONS When negative electrode polarity is required such as in some Innershield applications install as above except reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud CONTROL CABLE CONNECTIONS Connect the control cable between the wire feeder and power source The power source wire feeder connection is located under the spring loaded output cover near the bottom of the case front The control cable is keyed and polarized so it can be installed in only one way For neatness and convenience sake both the elec trode and control cables can be routed behind the left or right strain reliefs under the spring loaded output co

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