Lincoln-electric IM905 POWER WAVE 455M User Manual

POWER WAVE 455 M™OPERATOR’S MANUALIM905January, 2007Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in

x x TABLE OF CONTENTSPageTroubleshooting...Section EHow to

A-1INSTALLATION POWER WAVE 455M (CE)A-1TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-5)OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZESPHYSICAL

LIFTINGLift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave with acces

A-3INSTALLATION A-3INPUT CONNECTIONOnly a qualified electrician shouldco nn e c t t h e i n pu t le a ds t o t h ePow e r Wa ve 455M

A-4INSTALLATION POWER WAVE 455M (CE)A-4CABLE INDUCTANCE, AND ITS AFFECTON PULSE WELDINGFor Pulse Welding processes, cable inductance willcause the w

A-5INSTALLATION POWER WAVE 455M (CE)A-5Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured through s

A-6INSTALLATION POWER WAVE 455M (CE)A-6CONFIGURING THE SYSTEMFor codes below 11100, consult the semi-automaticPower Feed instruction manual for conf

A-7INSTALLATION POWER WAVE 455M (CE)A-7In this case the individual feed heads need to be assigned to the dual head control and the PW455M auto map-p

A-8INSTALLATION POWER WAVE 455M (CE)A-8WELDING WITH MULTIPLE POWERWAVESSpecial care must be taken when more than onePower Wave is welding simultaneo

A-9INSTALLATION POWER WAVE 455M (CE)A-9 MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

A-10INSTALLATION POWER WAVE 455M (CE)A-10I / O RECEPTACLE SPECIFICATIONSTABLE 3WIRE FEEDER RECEPTACLE S1PIN LEAD# FUNCTIONA 53 Communication Bus L

B-1OPERATIONB-1POWER WAVE 455M (CE)SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHO

B-2OPERATIONB-2POWER WAVE 455M (CE)INPUT POWERONOFFHIGH TEMPERATUREMACHINE STATUSCIRCUIT BREAKERWIRE FEEDERPOSITIVE OUTPUTNEGATIVE OUTPUT3 PHASE INVER

B-3OPERATIONB-3POWER WAVE 455M (CE)DEFINITION OF WELDING TERMSNON-SYNERGIC WELDING MODES• A Non-synergic welding mode requires all weldingprocess vari

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

B-5OPERATIONPOWER WAVE 455M (CE)B-5CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave 455m (CE).

B-6OPERATIONB-6NOMINAL PROCEDURESThe Power Wave 455M (CE) is designed to operatewith 19.1mm (3/4") electrode stick-out for CV andPulse processes.

CurrentTimeCURRENT WAVE FORM (CV)B-7OPERATIONB-7• WELDING MODEMay be selected by name (CV/MIG, CC/Stick Crisp,Gouge, etc.) or by a mode number (10, 24

B-8OPERATIONB-8PULSE WELDINGPulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc volt

C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDNone Available.FIELD INSTALLED Work Voltage Sense Lead Kit, K940Dual Cylinder Undercarriage, K1570

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

D-1MAINTENANCED-1POWER WAVE 455M (CE)SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn the

E-1TROUBLESHOOTINGE-1POWER WAVE 455M (CE)If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely

E-2TROUBLESHOOTINGE-2POWER WAVE 455M (CE)USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe Power Wave / Power Feed are best diagnosed asa system.

E-3TROUBLESHOOTINGE-3POWER WAVE 455M (CE)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-4TROUBLESHOOTINGE-4POWER WAVE 455M (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand t

E-5TROUBLESHOOTINGE-5POWER WAVE 455M (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand t

E-6TROUBLESHOOTINGE-6POWER WAVE 455M (CE)Observe all Safety Guidelines detailed throughout this manualCAUTIONIf for any reason you do not understand t

F-1DIAGRAMSF-1POWER WAVE 455M (CE)NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The sp

F-2CONNECTION DIAGRAMF-2POWER WAVE 455M (CE)Connection Diagram Semi-automatic "Simple System"(Electrode Positive, CV/Pulse Configuration sho

F-3DIAGRAMSF-3POWER WAVE 455M (CE)32.8826.1022.6312.3519.0019.9019.169.48 14.6223.1223.5111-14-97M18241DIMENSION PRINT - POWER WAVE 455M

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

NOTES POWER WAVE 455M (CE)

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

vSAFETYv

viSAFETYvi

viiviiThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

ixix TABLE OF CONTENTSPageInstallation ..........................Section