Lincoln Electric 455 M General Description, Recommended Processes and Equipment, Limitations

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B-4

OPERATION

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GENERAL DESCRIPTION

The Power Wave 455M (CE) semi-automatic power source is designed to be a part of a modular, multi- process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes.

The Power Wave 455M (CE) power source is designed to be used with the semi automatic family of Power Feed wire feeders, operating as a system. Each component in the system has special circuitry to "talk with" the other system components, so each component (power source, wire feeder, user interface) knows what the other is doing at all times. These com- ponents communicate with ArcLink

The Power Wave 455M (CE) 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 processes. It car- ries an output rating of 400 amps, 36 volts (at 100% duty cycle).

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The Power Wave 455M (CE) can be set up in a num- ber of configurations, some requiring optional equip- ment or welding programs. Each machine is factory preprogrammed with multiple welding procedures, typ- ically including GMAW, GMAW-P, FCAW, GTAW, and CAC for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.

The Power Wave 455M (CE) is recommended for semi-automatic welding with ArcLink compatible equipment like the Power Feed M series of feeders. The Power Wave 455M (CE) can have a number of modules installed that allow the machine to be used in Robotic and hard automation applications.

Wire Drive Interface Module

For Robotic platforms the Wire Drive Control Module is required to drive the Power Feed-10R wire drive. This module can be factory installed through our automation division or field installed for robotic appli- cations.

The Wire Drive Control Module is also be equipped with a terminal strip for making simple input signal connections. It can be used to externally control the basic wire drive function. It is divided into three groups: Trigger group, Cold Inch group, and Shutdown group.

DeviceNet Interface Module

This module can be used for DeviceNet capability. It will be a 5 pin sealed mini connector per ANSI B93.55M-1981.

EtherNet/DeviceNet Module

This module includes the DeviceNet and EtherNet capability. The DeviceNet uses a 5 pin sealed mini connector per ANSI B93.55M-1981. The EtherNet uses a RJ5 connector.

RECOMMENDED EQUIPMENT

Power Wave 455M (CE) – Semi-Automatic Operation

Semi Automatic Power Waves can only be used with ArcLink compatible Power Feed semi-automatic wire feeders and modules. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any mod- els of non-Lincoln wire feeders, cannot be used.

All welding programs and procedures are selected through the Power Feed M semi-automatic user inter- face

REQUIRED EQUIPMENT

Any ArcLink compatible semi-automatic wire feeding equipment. Specifically, the semi-automatic Power Feed M family.

WARNING

LIMITATIONS

•The Power Waves are not to be used in outdoor environments.

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•Only ArcLink compatible Power Feed semi-automat- ic wire feeders and users interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feed- ers cannot be used.

•Power Wave 455M (CE) Output Limitations

The Power Wave 455M (CE) will support maximum average output current of 500 Amps @ 60% duty cycle.

DUTY CYCLE AND TIME PERIOD

The Power Feed wire feeders are capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability. Note that the duty cycle is based upon a ten minute period. A 60% duty cycle repre- sents 6 minutes of welding and 4 minutes of idling in a ten minute period.

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
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