Lincoln Electric 455 M Machine Grounding, High Frequency Protection, Lifting, Stacking, Falling

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SAFETY PRECAUTIONS Read

A-2

INSTALLATION

A-2

 

 

 

this entire installation section before you start installa- tion.

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. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

Do not touch electrically hot parts.

Always connect the Power Wave 455M (CE) grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

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SELECT SUITABLE LOCATION

Do not use Power Wave 455M (CE) in outdoor envi- ronments. The Power Wave 455M (CE) power source 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.

Do not mount the Power Wave 455M (CE) over com- bustible surfaces. Where there is a combustible sur- face directly under stationary or fixed electrical equip- ment, that surface shall be covered with a steel plate at least .060" (1.6mm) thick, which shall extend not less than 5.90" (150mm) beyond the equipment on all sides.

Place the welder where clean cooling air can freely cir- culate in through the rear louvers and out through the case sides and bottom. Dirt, dust, or any foreign mater- ial that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

Machines are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 min- utes) after the output is disabled, to ensure all compo- nents 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, located on the back of the Control PC board enclosure. (See Wiring Diagram)

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.

STACKING

Power Wave machines can be stacked to a maximum of 3 high.

WARNING

 

• Lift only with equipment of

 

adequate lifting capacity.

 

• Be sure machine is stable

 

when lifting.

 

• Do not lift this machine using

 

lift bail if it is equipped with a

 

heavy accessory such as trail-

 

er or gas cylinder.

FALLING

• Do not lift machine if lift bail is

EQUIPMENT can

damaged.

cause injury.

• Do not operate machine while

 

suspended from lift bail.

Do not stack the Power Wave 455M (CE) on top of any other machine.

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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.

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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

Locate the Power Wave away from radio controlled machinery.

CAUTION

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.

POWER WAVE 455M (CE)

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Contents Power Wave 455 M Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Safety Thank You Table of Contents Section E Thru E-6Section F-1 Section F-2Installation Technical Specifications Power Wave 455M CE K2202-2Machine Grounding High Frequency ProtectionLifting StackingInput Fuse and Supply Wire Considerations Input ConnectionTable A.1 Negative Electrode Polarity Voltage SensingCable INDUCTANCE, and ITS Affect on Pulse Welding System Description Table A.2Electrode Voltage Sensing Configuring the System Single Head FeederSingle Head Boom Feeder UP to 4 Feeders AllowedDual Head Boom Feeder using two single heads Welding with Multiple Power Waves Control Cable SpecificationsInstallation Receptacle Specifications DIP Switch Settings and LocationsControl Board DIP Switch Water Flow SensorSafety Precautions 1OPERATIONB-1Power Wave 455M CE Operation Definition of Welding TermsGeneral Description Recommended Processes and EquipmentRequired Equipment LimitationsCase Front Controls Figure B.1Nominal Procedures Fringe ProceduresWelding Adjustments Making a WeldWelding Mode Constant Voltage WeldingARC Control Pulse Welding Figure A.6 Current Wave Form PulseAccessories Factory InstalledField Installed Optional EquipmentMaintenance Routine MaintenanceTroubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Error code before the machine is turned offError Codes for the Power Wave Error Code # IndicationAuthorized Field Service Facility Contact your local LincolnPower Feed System Using Status LED section of this text Cabling, etc Verify weld mode is correct for Power Wave 455M CE Wiring Diagram Connection Diagram Connection Diagram Semi-automatic Simple SystemDiagrams Dimension Print Power Wave 455MPrecaucion Warnung