i

SAFETY

i

Diesel engine exhaust and some of its constituents are known to the State of California to cause can- cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.

____________________________________________________

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 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 and tools away from V-belts, gears, fans and all other

moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety 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.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

___________________________________________________

1.g. 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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ???95

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 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 semiautomatic welding gun are also electrically ???hot???.

3.d. 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.

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 and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES 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.

5.d. 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 employer???s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ???95

iii

SAFETY

iii

WELDING SPARKS can 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.

6.b. 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.

6.c. 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.

6.d. 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 Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. 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.

6.g. 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.

6.h. Also see item 1.c.

CYLINDER may explode 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.

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

7.c. Cylinders should be located:

???Away from areas where they may be struck or subjected to physical damage.

???A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically ???hot??? parts to touch a cylinder.

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

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

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,

???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.

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 Code and the manufacturer???s recommendations.

Mar ???95

iv

SAFETY

iv

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 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.

b.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.

c.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.

e.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.

f.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 contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le c??ble-??lectrode autour de n???importe quelle partie du corps.

3.Un coup d???arc peut ??tre plus s??v??re qu???un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant appropri?? ainsi qu???un verre blanc afin de se prot??ger les yeux du ray- onnement de l???arc et des projections quand on soude ou quand on regarde l???arc.

b.Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de

l???arc.

c. Prot??ger l???autre personnel travaillant ?? proximit?? au soudage ?? l???aide d?????crans appropri??s et non-inflammables.

4.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.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les

zones o?? l???on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d???incendie d?? aux ??tincelles.

7.Quand on ne soude pas, poser la pince ?? une endroit isol?? de la masse. Un court-circuit accidental peut provoquer un ??chauffement et un risque d???incendie.

8.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.

9.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.

10.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.

11.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.

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.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.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debranch- er ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

Mar. ???93

v

Thank You

v

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 entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

???Only qualified personnel should perform this installation.

???Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

???Do not touch electrically hot parts.

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

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SELECT SUITABLE 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 (above code 10500 only) 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 prop- erly 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 placed 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 or death.

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Use a three-phase supply line. A 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 or refer to Figure A.1 following.

VOLTAGE=200-208V

200-208V

S24196

.Do not touch electrically live parts.

. Only qualified persons should install, use or service this equipment.

220-230V

380-415V

440-460V

???A???

.Do not touch electrically live parts.

. Only qualified persons should install, use or service this equipment.

CLEVELAND, OHIO U.S.A.

VOLTAGE=440-460V

200-208V

220-230V

380-415V

440-460V

???A???

THE LINCOLN ELECTRIC CO.

A

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 or 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.

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 (???A???) 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.

INPUT VOLTAGE RECONNECT

PROCEDURE

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

OUTPUT CONNECTIONS

Use the largest welding (electrode and ground) 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.

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 may be used if desired.

Sense Lead Kits (K490-10, -25 or -50) are available for this purpose.

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.

3)Locate P26, located on the upper right edge of the Control PC Board. It is a 16 pin connector with only two wires going into it. Unplug P26. It should remain attached to the main harness.

4)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.

POWER WAVE / POWER FEED WIRE

FEEDER INTERCONNECTIONS

ELECTRODE & 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 (located beneath the spring loaded output cover near the bottom of the case front).

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 & 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 cover), and along the channels formed into the base of the Power Wave, out the back of the channels, and then to the wire feeder.

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

U0

U1

U2

I1

I2

SMAW

GMAW

FCAW

GTAW

OPEN CIRCUIT

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE

GROUND

WARNING

GENERAL DESCRIPTION

The Power Wave 455 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 and CAC-A processes.

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.

RECOMMENDED EQUIPMENT

The Power Wave 455 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.

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.)

ADDITIONAL DESIGN FEATURES AND

ADVANTAGES

???Designed to NEMA EW-1, IEC 974-1 and CSA Standards.

???Qualifies for ???S??? mark on nameplate, which means it can be used in areas where there is increased risk of electric shock.

???Multiple process output ranges: 5 - 570 amps.

???Easy access for input connections. Connections are simple strip and clamp (no lugs required).

???F.A.N. (fan as needed). (On codes above 10500 only) Cooling fan runs only when necessary.

???Modular construction for easy servicing.

???Thermostatically protected.

???Electronic over current protection.

???Input over voltage protection.

???Utilizes digital signal processing and microprocessor control.

???Simple, reliable input voltage change over.

???All system components communicate and transfer information.

???Auto device recognition simplifies accessory cable connections.

WELDING CAPABILITY

The POWER WAVE 455 is rated at 60 Hz. 450A@ 38V. 100% duty cycle or 570A@ 43V 60% duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V 60% duty cycle. The machine is capable of higher out- puts at lower duty cycles.

If the duty cycle is exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature.

LIMITATIONS

???The Power Wave is not recommended for process- es other than those listed.

???The Power Wave can only be used with Power Feed wire feeders. Other models of Lincoln feed- ers, or any models of non-Lincoln wire feeders, can- not be used.

COMPATIBLE LINCOLN EQUIPMENT

All Lincoln Power Feed??? Wire Feeders.

POWER SOURCE OPERATION

DUTY CYCLE AND TIME PERIOD

The POWER WAVE 455 is rated at 60 Hz. 450A@ 38V. 100% duty cycle or 570A@ 43V 60% duty cycle - 50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V 60% duty cycle. The duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute peri- od.

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 status light will flash green, and sometimes red and green, for up to one minute when the Power Wave 455 is first turned on. This is a normal situation as the machine goes through a self test at power up.

3.HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temper- ature situation occurs. Output is disabled until 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 power supply.

5.10 AMP AUXILIARY POWER CIRCUIT BREAK- ER: Protects 110 volt AC case front receptacle auxiliary supply.

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) WFS (wire feed speed) is the dominant control parameter, controlling all other variables. 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, out- put current) according to pre-programmed settings contained in the Power Wave. In non-synergic modes, the WFS control changes the wire feed speed according to the desired procedure.

In constant current modes (stick, TIG) 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.

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 the 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. The 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. 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 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 .75??? stickout. The adaptive behavior is programmed to support a stickout range from .5??? to 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 Operator???s 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 automatically 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.

USING THE STATUS LED TO

TROUBLESHOOT SYSTEM PROBLEMS

The Status 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

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.

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.

Step 2. PERFORM EXTERNAL RECOMMEND-

ED TESTS

The second column labeled ???POSSIBLE AREAS OF 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.

455 WAVE POWER

D

G3051-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

1-F

DIAGRAMS

1-F

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