im690-a power wave 455/r - lincoln electric...power wave 455/r operator’s manual im690-a feb, 2019...

POWER WAVE 455/R ™

OPERATOR’S MANUAL

IM690-AFeb, 2019

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers: 10675; 10676

Date of Purchase:Serial Number:Code Number:Model:Where Purchased: IEC 60974-1

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2001 Lincoln Global Inc.

R

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE 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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

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

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

2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.

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

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

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

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

POWER WAVE 455/R

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

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

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

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

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

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

POWER WAVE 455/R

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

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

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

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

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

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

POWER WAVE 455/R

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

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

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

POWER WAVE 455/R

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications - Power Wave 455/R ..............................................A-1,A-2Safety Precautions.................................................................................................A-3Select Suitable Location ........................................................................................A-3

Lifting...............................................................................................................A-3Stacking ..........................................................................................................A-3

Machine Grounding ...............................................................................................A-3High Frequency Protection ....................................................................................A-3Input Connection....................................................................................................A-3Input Fuse and Supply Wire Considerations .........................................................A-4Input Voltage Change Over Procedure..................................................................A-4Welding with Multiple Power Waves......................................................................A-5Electrode and Work Cable Connections................................................................A-6Negative Electrode Polarity ..................................................................................A-6Voltage Sensing at the Work Piece .......................................................................A-7Power Wave / Power Feed Wire Feeder Interconnections....................................A-8

Control Cable Specifications ...........................................................................A-8External I/O Connector....................................................................................A-8High Speed Gear Box .....................................................................................A-9Dip Switch Settings and Locations...............................................................A-10Control Board Dip Switch ..............................................................................A-10Feed Head Board Dip Switch........................................................................A-10Devicenet/Gateway Board Dip Switch, Bank (S1) ........................................A-10Bank (S2) ......................................................................................................A-11

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precuations.................................................................................................B-1Graphic Symbols that appear on this machine or in this manual...........................B-2General Description ...............................................................................................B-3Recommended Processes and Equipment ...........................................................B-3Required Equipment ..............................................................................................B-3Limitations..............................................................................................................B-3Duty Cycle and Time Period ..................................................................................B-3

Case Front Controls ........................................................................................B-4Constant Voltage Welding...............................................................................B-5Pulse Welding .................................................................................................B-6STT Welding ...................................................................................................B-7

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Equipment ...............................................................................................C-1Factory Installed..............................................................................................C-1Field Installed..................................................................................................C-1

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Routine Maintenance, Periodic, Calibration Specification .....................................D-1

________________________________________________________________________Troubleshooting ..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1Using the Status LED to Troubleshoot System Problems .....................................E-2Troubleshooting Guide.............................................................................E-3 thru E-6Error Codes for the Power Wave ....................................................................E-7,E-8

________________________________________________________________________Wiring Diagram ....................................................................................Section F-1, F-2Connector Pin Definitions ...........................................................................Section F-3Connection Diagrams...........................................................................Section F-4, F-5Dimension Print............................................................................................Section F-6

________________________________________________________________________Parts Lists .....................................................................................................P377Series

________________________________________________________________________

A-1INSTALLATION

POWER WAVE 455/R

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE 455/R (K1761-1),(K1761-2)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

(K1761-1)208/230/460V - 60HZ.

200/220/440V - 50HZ.

(K1761-2)208/230/460/575V-60HZ.

208/230/460/575V-50HZ.

OPENCIRCUIT

VOLTAGE

75 VDC

INPUTVOLTAGE /

FREQUENCY(HZ)

(K1761-1)

208/50/60230/50/60460/50/60

(K1761-2)

208/50/60230/50/60460/50/60575/50/60

TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)

11011050

1101005040

TYPE 75°CGROUND WIRE IN CON-DUIT AWG[IEC] SIZES

(MM2)

6 (10)6 (10)10 (6)

6 (10)6 (10)10 (6)10 (6)

TYPE 75°CCOPPER WIRE IN CON-DUIT AWG[IEC] SIZES

(MM2)

4 (25)4 (25)8 (10)

4 (25)4 (25)8 (10)10 (6)

PROCESS CURRENT RANGES (DC)

MIG/MAGFCAWSMAWPulseSTT

CURRENT

50-570 Average Amps 40-570 Average Amps30-570 Average Amps5-750 Peak Amps 40-325 Average Amps

PULSEVOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER(CIRCUIT BREAKER

PROTECTED)

40 VDC @10 AMPS115VAC @10 AMPS

PULSE ANDBACKGROUNDTIME RANGE

100 MICRO SEC. -3.3 SEC.

STT PARAMETERS

40-325 AMPS

CURRENTRANGE

5 - 570

PULSEFREQUENCY

0.15 - 1000 Hz

INPUTCURRENT

AMPS

70/65/3587/82/48

72/67/3679/74/41

58/53/25/2282/78/37/31

49/45/23/1867/61/31/25

IDLEPOWER

400 WattsMax.

POWER FACTOR@ RATED OUPUT

.89 MIN.

.95 MIN.

EFFICIENCY@ RATED OUPUT

88%

OUTPUTCONDITIONS

[email protected]%570A@43V. 60%


[email protected]%[email protected]%


A-2INSTALLATION

POWER WAVE 455/R

A-2

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

HEIGHT

26.10 in663 mm

WIDTH

19.86 in505 mm

DEPTH

32.88 in835 mm

WEIGHT(K1761-1) 247 lbs.

112 kg.(K1761-2) 295lbs.

133 kg.

OPERATING TEMPERATURE RANGE-20°C to +40°C

STORAGE TEMPERATURE RANGE-40°C to +40°C

Where there is a combustible surface directly understationary or fixed electrical equipment, that surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not less than5.90”(150mm) beyond the equipment on all sides.

LIFTING

Lift 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 accessories attached to it.

STACKING

Power Wave machines can be stacked to a maximumof 3 high.

The bottom machine must always be placed on afirm, secure, level surface. There is a danger ofmachines toppling over if this precaution is nottaken.

MACHINE GROUNDINGThe frame of the welder must be grounded. A groundterminal marked with the symbol is located insidethe reconnect/input access door for this purpose. Seeyour local and national electrical codes for propergrounding methods.

HIGH FREQUENCY PROTECTIONLocate the Power Wave away from radio controlledmachinery.

The normal operation of the Power Wave mayadversely affect the operation of RF controlledequipment, which may result in bodily injury ordamage to the equipment.

INPUT CONNECTION

Only a qualified electrician should connect theinput leads to the Power Wave. Connectionsshould be made in accordance with all local andnational electrical codes and the connection dia-gram located on the inside of the reconnect/inputaccess door of the machine. Failure to do so mayresult in bodily injury or death.------------------------------------------------------------------------Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe upper left case back next to the input access door.

SAFETY PRECAUTIONSRead this entire installation section before youstart installation.

ELECTRIC SHOCK can kill.

• Only qualified personnel shouldperform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working onthis equipment. Turn off the input power to anyother equipment connected to the welding systemat the disconnect switch or fuse box before work-ing on the 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.

----------------------------------------------------------

SELECT SUITABLE LOCATIONDo not use Power Waves in outdoor environments.The Power Wave power source should not be subject-ed to falling water, nor should any parts of it be sub-merged in water. Doing so may cause improper opera-tion as well as pose a safety hazard. The best practiceis to keep the machine in a dry, sheltered area.

Place the welder where clean cooling air can freely cir-culate in through the rear louvers and out through thecase sides and bottom. Dirt, dust, or any foreign mater-ial that can be drawn into the welder should be kept ata minimum. Do not use air filters on the air intakebecause the air flow will be restricted. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdowns.

Machines above code 10500 are equipped with F.A.N.(fan as needed) circuitry. The fan runs whenever theoutput is enabled, whether under loaded or open circuitconditions. 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 (causingthe fan to run whenever the power source is on). Todisable F.A.N., connect leads 444 and X3A together atthe output of the solid state fan control relay, locatedon the back of the Control PC board enclosure. (SeeWiring Diagram)

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

A-3INSTALLATION

POWER WAVE 455/R

A-3

WARNING

WARNING

CAUTION

CAUTION

CAUTION

A-4INSTALLATION

POWER WAVE 455/R

A-4

Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on theinside of the input access door or refer to Figure A.1on the following page.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONSRefer to the Technical Specifications at the beginningof this Installation section for recommended fuse andwire 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 tolocal or national electrical codes. Using fuses or circuitbreakers smaller than recommended may result in“nuisance” shut-offs from welder inrush currents, evenif the machine is not being used at high currents.

INPUT VOLTAGE CHANGE OVER(FOR MULTIPLE INPUT VOLTAGEMACHINES ONLY)Welders are shipped connected for the highest inputvoltage listed on the rating plate. To move this con-nection to a different input voltage, see the diagramlocated on the inside of the input access door. If themain reconnect switch or link position is placed in thewrong position, the welder will not produce outputpower.

If the Auxiliary (A) lead is placed in the wrong position,there are two possible results. If the lead is placed in aposition higher than the applied line voltage, thewelder may not come on at all. If the Auxiliary (A) leadis placed in a position lower than the applied line volt-age, the welder will not come on, and the two circuitbreakers in the reconnect area will open. If thisoccurs, turn off the input voltage, properly connect the(A) lead, reset the breakers, and try again.

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure todo so will result in damage to the machine.

(K1761-1) FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

200-208V220-230V440-460V550-575V

200-208V220-230V

VOLTAGE = 220-230V

220-230V200-208V

220-230V440-460V550-575V

200-208V

U / L1

550-575V440-460V

inspecting or servicing machine.Do not operate with coversremoved.Do not touch electrically live parts.Only qualified persons should install,use or service this equipment.

'A'

'A'

VOLTAGE = 440-460V

'A'

S25

198VOLTAGE = 200-208V

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XA

'A'

VOLTAGE = 550-575V

CR1

W / L3

V / L2

440-460V550-575V

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAMWARNING

CAN KILLSHOCK

ELECTRIC

(K1761-2) FIGURE B.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

200-208V

220-230V

380-415V

440-460V

200-208V

220-230V

VOLTAGE=220-230V

220-230V

200-208V

220-230V

380-415V

440-460V

200-208V

U / L1

440-460V

380-415V

.inspecting or servicing machine.

Do not operate with covers.removed.

Do not touch electrically live parts..

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

.

’A’

’A’

VOLTAGE=380-415V

’A’

S2

38

47VOLTAGE=200-208V

TH

E L

INC

OL

N E

LE

CT

RIC

CO

. C

LE

VE

LA

ND

, OH

IO U

.S.A

.

XA

’A’

VOLTAGE=440-460V

CR1

W / L3

V / L2

380-415V

440-460V

Disconnect input power before

11-1

4-97

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC SHOCKCAN KILL

A-5INSTALLATION

POWER WAVE 455/R

A-5

WELDING WITH MULTIPLE POWERWAVES

Special care must be taken when more than onePower Wave is welding simultaneously on a singlepart. Arc blow and arc interference may occur orbe magnified.

Each power source requires a work lead from thework stud to the welding fixture. Do not combine all ofthe work leads into one lead. The welding travel direc-tions should be in the direction moving away from thework lead as shown below. Connect all of the worksense leads from each power source to the workpiece at the end of the weld.

- +

POWERWAVE

- +

POWERWAVE

Connect All WorkSense Leads at the Endof the Joint

Connect All WeldingWork Leads at theBeginning of the Joint

TravelDirection

TWO POWER WAVES

CAUTION

For the best results when pulse welding, set the wiresize and wire feed speed the same for all the PowerWaves.

When these parameters are identical, the pulsing fre-quency will be the same, helping to stabilize the arcs.

Every welding gun requires a seperate shielding gasregulator for proper flow rate and shielding gas cover-age.

Do not attempt to supply shielding gas for two or moreguns from only one regulator.

If an anti-spatter system is in use then each gun musthave its own anti-spatter system. (See Figure A.2.)

FIGURE A.2

A-6INSTALLATION

POWER WAVE 455/R

A-6

ELECTRODE AND WORK CABLECONNECTIONSConnect a work lead of sufficient size and length (PerTable 1) between the proper output terminal on thepower source and the work. Be sure the connection tothe work makes tight metal-to-metal electrical contact.To avoid interference problems with other equipmentand to achieve the best possible operation, route allcables directly to the work or wire feeder. Avoidexcessive lengths and do not coil excess cable. Donot tightly bundle the electrode and work cablestogether.Use K1796 Coaxial welding cables wherever possible.(See Section F-5 Connection Diagram).Minimum work and electrode cables sizes are as follows:

TABLE 1(Current (60% Duty Cycle) MINIMUM COPPER

WORK CABLE SIZE AWGUp To-100 Ft. Length (30 m)

400 Amps 2/0 (67 mm2)500 Amps 3/0 (85 mm2)600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommendedto reduce the cable inductance in long distance Pulseand STT applications up to 300 amps.

When using an inverter type power source like thePower Waves, use the largest welding (electrode andground) cables that are practical. At least 2/0 copperwire - even if the average output current would notnormally require it.

When pulsing, the pulse current can reach veryhigh levels. Voltage drops can become excessive,leading to poor welding characteristics, if under-sized welding cables are used.------------------------------------------------------------------------Most welding applications run with the electrode beingpositive (+). For those applications, connect one endof the electrode cable to the positive (+) output studon the power source (located beneath the springloaded output cover near the bottom of the casefront). Connect the other end of the electrode cable tothe wire drive feed plate using the stud, lockwasher,and nut provided on the wire drive feed plate. Theelectrode cable lug must be against the feed plate. Besure the connection to the feed plate makes tightmetal-to-metal electrical contact. The electrode cableshould be sized according to the specifications givenin the work cable connections section. Connect a worklead from the negative (-) power source output stud tothe work piece. The work piece connection must befirm and secure, especially if pulse welding is planned.

Excessive voltage drops caused by poor workpiece connections often result in unsatisfactorywelding performance.-------------------------------------------------------------------------When welding with the STT process, use the positiveoutput connection labeled (STT) for STT welding. (Ifdesired, other welding modes can be used on thisstud; however, their average output current will be lim-ited to 325 amps.) For non-STT processes, use thepositive output connection labeled (Power Wave), sothat the full output range of the machine is available.

Do not connect the STT and Power Wave studtogether. Paralleling the studs will bypass STT cir-cuitry and severely deteriorate STT welding perfor-mance. (See Section F-3 Connection Diagram)-------------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITYWhen negative electrode polarity is required, such asin some Innershield applications, reverse the outputconnections at the power source (electrode cable tothe negative (-) stud, and work cable to the positive (+)stud).When operating with electrode polarity negative theswitch 7 must be set to ON on the Wire Feed Head PCBoard. The default setting of the switch is OFF to rep-resent positive electrode polarity.Set the Negative Polarity switch on Wire Feed HeadPC board as follows:


• Do not touch electrically live parts orelectrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

------------------------------------------------------------------1. Turn off power to the power source at the disconnect

switch.

2. Remove the front cover from the power source.

3. The wire feed head board is on the right side ofthe power source. Locate the 8-position DIPswitch and look for switch 7 of the DIP switch.

4. Using a pencil or other small object, slide theswitch right to the OFF position for positiveelectrode polarity. Conversely, slide the switchleft to the ON position for negative electrodepolarity.

WARNING

O N1

23

45

67

8

CAUTION

CAUTION

CAUTION

Work Voltage SensingThe Power Waves are shipped from the factory withthe work sense lead enabled.

For processes requiring work voltage sensing, con-nect the (21) work voltage sense lead from the PowerWave to the work. Attach the sense lead to the workas close to the weld as practical. Enable the work volt-age sensing in the Power Wave as follows:


• Do not touch electrically live parts orelectrodes with your skin or wetclothing.



-----------------------------------------------------------

1. Turn off power to the power source at the discon-nect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side ofthe power source. Locate the 8-positionDIP switch and look for switch 8 of theDIP switch.

4. Using a pencil or other small object,slide the switch right to the OFF positionif the work sense lead is NOT connect-ed. Conversely, slide the switch left tothe ON position if the work sense lead ispresent.

5. Replace the cover and screws. The PC board will“read” the switch at power up, and configure thework voltage sense lead appropriately.

Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead must be connected at the wirefeeder.

A-7INSTALLATION

POWER WAVE 455/R

A-75. Replace the cover and screws. The PC board will

“read” the switch at power up, and configure thework voltage sense lead appropriately.

VOLTAGE SENSINGThe best arc performance occurs when the PowerWaves have accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence the volt-age apparent at the studs of the welder. Voltagesense leads improve the accuracy of the arc condi-tions and can have a dramatic effect on performance.

If the voltage sensing is enabled but the senseleads are missing or improperly connected,extremely high welding outputs may occur.------------------------------------------------------------------------Do not tightly bundle the work sense lead to the worklead.The ELECTRODE sense lead (67) is built into theK1795 control cable. The WORK sense lead (21) con-nects to the Power Wave at the four-pin connectorlocated underneath the output stud cover. Enable thevoltage sense leads as follows:

TABLE 2Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 leadGMAW 67 lead required 21 lead optional**GMAW-P 67 lead required 21 lead optional**FCAW 67 lead required 21 lead optional**STT 67 lead required 21 lead required**GTAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optional*** The electrode voltage 67 sense lead is part of to the

control cable to the wire feeder.

** For consitent weld quality work voltage sensing isrecommended.

WARNING

O N1

23

45

67

8

CAUTION

A-8INSTALLATION

POWER WAVE 455/R

A-8

POWER WAVE / POWER FEED WIREFEEDER INTERCONNECTIONSConnect the control cable between the power sourceand wire feeder. The wire feeder connection on therobotic Power Waves is located under the springloaded output cover, near the bottom of the case front.The control cable is keyed and polarized to preventimproper connection.

For convenience sake, the electrode and controlcables can be routed behind the left or right strainreliefs (under the spring loaded output cover), andalong the channels formed into the base of the PowerWave, out the back of the channels, and then to thewire feeder.

Output connections on some Power Waves are madevia 1/2-13 threaded output studs located beneath thespring loaded output cover at the bottom of the casefront. On machines which carry the CE mark, outputconnections are made via Twist-Mate receptacles,that are also located beneath the spring loaded outputcover at the bottom of the case front.

A work lead must be run from the negative (-) powersource output connection to the work piece. The workpiece connection must be firm and secure, especiallyif pulse welding is planned.

Excessive voltage drops at the work piece con-nection often result in unsatisfactory pulse weld-ing performance.------------------------------------------------------------------------

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave / Power Feed system.

The use of non-standard cables, especially inlengths greater than 25 feet, can lead to communi-cation problems (system shutdowns), poor motoracceleration (poor arc starting) and low wire dri-ving force (wire feeding problems).------------------------------------------------------------------------Lincoln control cables are copper 22 conductor cablein a SO-type rubber jacket.

EXTERNAL I/O CONNECTOR

The Power Wave is equipped with a port for making simple input signal connections. The port is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group. Because the Power Wave is a ‘slave’ on the DeviceNet network, the Trigger and Cold Inch Groups are disabled when the DeviceNet/Gateway is active.

The shutdown group is always enabled. Shutdown 2 is used for signaling low flow in the water cooler. Unused shutdowns must be jumpered. Machines from the factory come with the shutdowns already jumpered. (See Figure A.3)

Shutdown 1 and shutdown 2 inputs are for weld sys-tem faults and should not be used as emergency or safety shutdowns.

D

E

F

1 2 3 4 5 6 7 8 9 10 11 12

G

H

I

A

B

C

+15

VD

C fo

r T

rigge

r G

roup

Trig

ger

Inpu

t

Dua

l Pro

cedu

re In

put

4 S

tep

Inpu

t

+15

VD

C fo

r C

old

Inch

Gro

up

Col

d In

ch F

orw

ard

Col

d In

ch R

ever

se

Gas

Pur

ge In

put

+15

for

shut

dow

n gr

oup

Shu

tdow

n1 in

put

Shu

tdow

n2 in

put (

Wat

er F

ault)

Res

erve

d fo

r fu

ture

use

CAUTION

CAUTION

FIGURE A.3

A-9INSTALLATION

POWER WAVE 455/R

A-9

HIGH SPEED GEAR BOXChanging the ratio requires a gear change and a PCboard switch change. The Power Feed Wire Feedersare shipped with both high speed and a low speedgears. As shipped from the factory, the low speed(high torque) gear is installed on the feeder. Tochange Gear ratio see Power Feed 10/R InstructionManual.


• Do not touch electrically live partsor electrodes with your skin or wetclothing.



-----------------------------------------------------------

1. Set the High/Low switch code on Wire Drive PCboard as follows:

• Turn off power to the power source at the discon-nect switch.

• Remove the front cover from the power source.

• The wire feed head board is on the rightside of the power source. Locate the 8-position DIP switch and look for position8 of the DIP switch.

• Using a pencil or other small object,slide the switch right to the OFF position,when the low speed gear is installed.Conversely, slide the switch left to theON position when the high speed gear isinstalled.

• Replace the cover and screws. The PC board will“read” the switch at power up, automaticallyadjusting all control parameters for the speedrange selected.

O N1

23

45

67

8

WARNING

A-10INSTALLATION

POWER WAVE 455/R

A-10

DIP Switch Settings and LocationsDIP switches on the P.C. Boards allow for customconfiguration of the Power Wave. To access the DIPswitches:

• Turn off power at the disconnect switch.------------------------------------------------------------------------• Remove the top four screws securing the front

access panel.• Loosen, but do not completely remove, the bottom

two screws holding the access panel.• Open the access panel, allowing the weight of the

panel to be carried by the bottom two screws. Makesure to prevent the weight of the access panel fromhanging on the harness.

• Adjust the DIP switches as necessary.• Replace the panel and screws, and restore power.

Control Board DIP Switch:switch 1 = Object Instance LSB1 (see table 1)

switch 2 = Object Instance MSB2 (see table 1)switch 3 = Equipment Group 1 Selectswitch 4 = Equipment Group 2 Selectswitch 5 = Equipment Group 3 Selectswitch 6 = Equipment Group 4 Selectswitch 7 = reserved for future useswitch 8 = work sense lead1 LEASE SIGNIFICANT BIT2 MOST SIGNIFICANT BIT

switch 8 work sense leadoff work sense lead not connectedon work sense lead connected

Feed Head Board DIP Switch:switch 1 = Object Instance LSB (see table 1)switch 2 = Object Instance MSB (see table 1)switch 3 = Equipment Group 1 Selectswitch 4 = Equipment Group 2 Selectswitch 5 = Equipment Group 3 Selectswitch 6 = Equipment Group 4 Selectswitch 7 = negative polarity switch

switch 7 electrode polarityoff positive (default)on negative

switch 8 = high speed gearswitch 8 wire drive gearoff low speed gear (default)on high speed gear

DeviceNET/Gateway Board DIP Switch:

Bank (S1):switch 1 = Object Instance LSB (see table1)switch 2 = Object Instance MSB (see table 1)switch 3 = Equipment Group 1 Selectswitch 4 = Equipment Group 2 Selectswitch 5 = Equipment Group 3 Selectswitch 6 = Equipment Group 4 Selectswitch 7 = Reserved for future useswitch 8 = Reserved for future use

TABLE 1Object Instanceswitch 2 switch 1 Instanceoff off 0 (default)off on 1on off 2on on 3

Feed Head BoardControl Board

DeviceNET/Gateway Board

Left Right

WARNING

A-11INSTALLATION

POWER WAVE 455/R

A-11

Bank (S2):switch Description

1 Devicenet Baud Rate2 (see table 2)

TABLE 2Prior to S24958-6 softwareswitch 1 switch 2 baud rate

off off Programmable valueon off 125Koff on 250Kon on 500K

S24958-6 and later softwareswitch 1 switch 2 baud rate

off off 125Koff on 250Kon off 500Kon on Programmable value

Bank (S2):switch Description

3 Devicenet Mac IDthru (see table 3)

8

TABLE 3

0 0 0 0 0 0 01 0 0 0 0 0 12 0 0 0 0 1 03 0 0 0 0 1 14 0 0 0 1 0 05 0 0 0 1 0 16 0 0 0 1 1 07 0 0 0 1 1 18 0 0 1 0 0 09 0 0 1 0 0 110 0 0 1 0 1 011 0 0 1 0 1 112 0 0 1 1 0 013 0 0 1 1 0 114 0 0 1 1 1 015 0 0 1 1 1 116 0 1 0 0 0 017 0 1 0 0 0 1

18 0 1 0 0 1 019 0 1 0 0 1 120 0 1 0 1 0 021 0 1 0 1 0 122 0 1 0 1 1 023 0 1 0 1 1 124 0 1 1 0 0 025 0 1 1 0 0 126 0 1 1 0 1 027 0 1 1 0 1 128 0 1 1 1 0 029 0 1 1 1 0 130 0 1 1 1 1 031 0 1 1 1 1 132 1 0 0 0 0 033 1 0 0 0 0 134 1 0 0 0 1 035 1 0 0 0 1 136 1 0 0 1 0 037 1 0 0 1 0 138 1 0 0 1 1 039 1 0 0 1 1 140 1 0 1 0 0 041 1 0 1 0 0 142 1 0 1 0 1 043 1 0 1 0 1 144 1 0 1 1 0 045 1 0 1 1 0 146 1 0 1 1 1 047 1 0 1 1 1 148 1 1 0 0 0 049 1 1 0 0 0 150 1 1 0 0 1 051 1 1 0 0 1 152 1 1 0 1 0 053 1 1 0 1 0 154 1 1 0 1 1 055 1 1 0 1 1 156 1 1 1 0 0 057 1 1 1 0 0 158 1 1 1 0 1 059 1 1 1 0 1 160 1 1 1 1 0 061 1 1 1 1 0 162 1 1 1 1 1 0*Software Selectable (Line 0)**Default Setting (Line 62)

SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3SWITCH 8

SWITCH 7 SWITCH 6 SWITCH 5 SWITCH 4 SWITCH 3SWITCH 8

*

**

B-1OPERATIONB-1

POWER WAVE 455/R

SAFETY PRECUATIONSRead this entire section of operating instructionsbefore operating the machine.


• Unless using cold feed feature, whenfeeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and could remainenergized several seconds after thewelding ceases.

• Do not touch electrically live parts or electrodeswith your skin or wet clothing.

• Insulate yourself from the work and ground.


FUMES AND GASES can be dan-gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fireor explosion.

• Keep flammable material away.

• Do not weld on containers that haveheld combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the begin-ning of this manual.

WARNING

B-2OPERATIONB-2

POWER WAVE 455/R

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

GMAW

FCAW

GTAW

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVEGROUND

WARNING ORCAUTION

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

SMAW

RECOMMENDED EQUIPMENT• Automatic OperationAll welding programs and procedures are set throughsoftware for the robotic Power Waves. FANUCrobots equipped with RJ-3 controllers may communi-cate directly to the Power Wave. Other pieces ofequipment such as PLC’s or computers can commu-nicate to the Power Wave using DeviceNET. All wirewelding processes require a robotic Power Feed wirefeeder.

REQUIRED EQUIPMENT• PF-10/R Wire Feeder, K1780-1• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 10 ft), K1804-1 • Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 18 in), K1805-1• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 18 in), K1804-2

LIMITATIONS• The Power Wave 455/R is not suitable for SMAW,

CAC-A or other processes not listed.• Power Waves are not to be used in outdoor environ-

ments.• Only Arc-Link Power Feed wire feeders and user

interfaces may be used. Other Lincoln wire feedersor non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIODThe Power Feed wire feeders are capable of weldingat a 100% duty cycle (continuous welding). The powersource will be the limiting factor in determining systemduty cycle capability. Note that the duty cycle is basedupon a ten minute period. A 60% duty cycle repre-sents 6 minutes of welding and 4 minutes of idling in aten minute period.

B-3OPERATIONB-3

GENERAL DESCRIPTIONThe Power Wave power source is designed to be apart of a modular, multi-process welding system.Depending on configuration, it can support constantcurrent, constant voltage, Surface Tension Transferand pulse welding modes.

The Power Wave power source is designed to beused with the family of Power Feed wire feeders,operating as a system. Each component in the systemhas special circuitry to "talk with" the other systemcomponents, so each component (power source, wirefeeder, electrical accessories) knows what the other isdoing at all times. The components communicateusing Arc-Link protocol.

Robotic systems can communicate with other industri-al machines via DeviceNET protocol. The result is ahighly intrigated and flexible welding cell.

GENERAL DESCRIPTION - POWER WAVE 455/RThe Power Wave 455/R is a high performance, digital-ly controlled inverter welding power source capable ofcomplex, high-speed waveform control. Properlyequipped, it can support the GMAW, GMAW-P,FCAW, GTAW and STT processes. It carries an out-put rating of either 450 amps, 38 volts; or 400 amps,36 volts (both at 100% duty cycle), depending on inputvoltage and frequency. The Surface Tension transferprocess (STT) is supported at currents up to 325amps, at 100% duty cycle.

If the duty cycle is exceeded, a thermostat will shut offthe output until the machine cools to a reasonableoperating temperature.

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSESThe Power Wave 455/R can be set up in a number ofconfigurations, some requiring optional equipment orwelding programs. Each machine is factory prepro-grammed with multiple welding procedures, typicallyincluding GMAW, GMAW-P, FCAW, GTAW and STTfor a variety of materials, including mild steel, stain-less steel, cored wires, and aluminum. The STTprocess supports mild steel and stainless steel weld-ing.

The Power Wave 455/R is recommended only forautomatic or mechanized applications such as roboticwelding.

POWER WAVE 455/R

B-4OPERATION

POWER WAVE 455/R

B-4CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave. (See Figure A.4)

1. POWER SWITCH: Controls input power to thePower Wave.

2. STATUS LIGHT: A two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated, per table 4.

NOTE: The robotic Power Waves’ status light willflash green, and sometimes red and green, for up toone minute when the machine is first turned on. Thisis a normal situation as the machine goes through aself test at power up.

TABLE 4

3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled until themachine cools down. When cool, the light goes outand output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.

5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER:Protects 115 volt AC case front receptacleauxiliary supply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. 5-PIN ARC LINK S1

8. 5-PIN DEVICENET CONNECTOR S5

9. I / O CONNECTOR

10. NEGATIVE STUD

11. INTERFACE CONNECTOR S6

12. STT STUD

13. POSITIVE STUD

14. AUXILIARY OUTPUT

- +

POWERWAVE

Case Front LayoutPower Wave 455/R (Domestic/Canadian Version)

SAFETY INSTRUCTIONS

2 3

11

12

14

1310

9

8

7

6

5 4

1

FIGURE A.4

LightCondition

Steady Green

BlinkingGreen

A l t e r n a t i n gGreen andRed

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-ly with wire feeder and its components.

Occurs during a reset, and indicates the PW-455/R is mapping (identifying) each componentin the system. Normal for first 1-10 secondsafter power is turned on, or if the system con-figuration is changed during operation.

Non-recoverable system fault. If the PSStatus light is flashing any combination ofred and green, errors are present in the PW-455/R. Read the error code before themachine is turned off.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red witha long pause between digits. If more thanone code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, andback on to reset. See TroubleshootingSection.

Not applicable.

Not applicable.

B-5OPERATIONB-5

CONSTANT VOLTAGE WELDING

For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The preprogrammed voltage is thebest average voltage for a given wire feed speed.With synergic programs, when the wire feed speedchanges the Power Wave will automatically adjust thevoltage correspondingly.

Wave control adjusts the inductance of the wave-shape. (This adjustment is often referred to as "pinch".Inductance is inversely proportional pinch.) Increasingwave control greater than 0 results in a harsher, cold-er arc while decreasing the wave control to less than 0provides a softer, hotter arc. (See Figure A.5)

POWER WAVE 455/R

Wave Control 0.00

Wave Control +10.0

Wave Control -10.0

FIGURE A.5

Current

Time

B-6OPERATIONB-6

PULSE WELDING

Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. Theexact voltage for a given wire feed speed can only bepredicted when all the pulsing waveform parametersare known. Using a preset voltage becomesimpractical, and instead the arc length is set byadjusting "trim".

Trim adjusts the arc length and ranges from 0.50 to1.50, with a nominal value of 1.00. Trim values greaterthan 1.00 increase the arc length, while values lessthan 1.00 decrease the arc length.

Most pulse welding programs are syngeric. As thewire feed speed is adjusted, the Power Wave willautomatically recalculate the waveform parameters tomaintain similar arc properties.

POWER WAVE 455/R

The Power Wave uti l izes "adaptive control" tocompensate for changes in electrical stick-out whilewelding. (Electrical stick-out is the distance from thecontact tip to the work piece.) The Power Wavewaveforms are optimized for a 0.75" (19mm) stick-out.The adaptive behavior supports a range of stickoutsfrom 0.50" (13mm) to 1.25" (32mm). At very low orhigh wire feed speeds, the adaptive range may beless due to reaching physical limitations of the weldingprocess.

Wave control in pulse programs usually adjusts thefocus or shape of the arc. Wave control values greaterthan 0 increase the pulse frequency while decreasingthe background current, resulting in a tight, stiff arcbest for high speed sheet metal welding. Wave controlvalues less than 0 decrease the pulse frequency whileincreasing the background current, for a soft arc goodfor out-of-position welding. (See Figure A.6)

Wave Control 0.0Wave Control +10.0

Wave Control -10.0

FIGURE A.6

Current

Time

B-7OPERATIONB-7

STT WELDING

The pictures illustrate the waveshape of current forthe process. They are not drawn to scale, and areintended only for the purpose of showing how thevariables effect the waveform.

For most programs, peak current is adjusted by wavecontrol values. A value of +10.0 maximizes the peakcurrent, while a wave control of -10.0 minimizes peakcurrent. In general, the peak current is proportionaltorch arc length. (See Figure A.8)

POWER WAVE 455/R

Trim 1.00

Trim 1.50

Trim 0.50

Wave Control 0.0

Wave Control +10.0

Wave Control -10.0

Trim in the STT mode adjusts the tailout and backgroundportion of the waveform. Trim values greater than 1.0add more energy to the weld and make the weld puddlehotter; trim values less than 1.0 reduce energy to weldA nominal value of 1.0 will work for most applications. (See Figure A.7)

Current

Current

Time

Time

FIGURE A.7

FIGURE A.8

NOTE: The ranges on Wave Control and Trim aredependent on the weld programs. The values shownare typical ranges.

C-1ACCESSORIESC-1

OPTIONAL EQUIPMENT

FACTORY INSTALLEDThere are no factory installed options available for thePower Wave 455R.

FIELD INSTALLED• Gas Guard Regulator (K659-1)The Gas Guard regulator is available as an optionalaccessory for the Power Feed Robotic wire driveunit. Install the 5/8-18 male outlet on the regulatorto the proper 5/8-18 female gas inlet on the backpanel of the wire drive. Secure fitting with flowadjuster key at top.

* Voltage Sense Leads (K940-10, -25 or -50)The voltage sense leads connect at the front of themachine. (See Section A-6)

• Power Wave Water Cooler (K1767-1)*(See Section F-4 Connection Diagram)The K1767-1 is the recommended water cooler forthe Power Waves. Incorporated into the cooler is anautomatic flow sensor to detect low coolant flow. Inthe event of a low flow condition, a fault signal issent to the Power Wave and welding output auto-matically stops to protect the torch.

POWER WAVE 455/R

The water coolers are designed to cool only onewelding gun and should be not used to cool multipleguns or other devices.

Water cooler manufacturers often specify additivesto the coolant such as fungicides or alkalides. Followmanufacturers recommendations to achieve properoperation and long lifetimes without clogging.

* Water Flow Sensor (K1536-1)Water cooled guns can be damaged very quickly ifthey are used even momentarily without water flow-ing. Recommend practice is to install a water flowsensor such as on the water return line of the torch.When fully integrated into the welding system, thesensor will prevent welding if no water flow is pre-sent.

• Dual Cylinder Undercarriage, K1570-1*

• Coaxial welding Cable, K1796(See Section F-5 Connection Diagram)

*The Dual Cylinder Undercarriage, K1570-1 is notcompatible in combination with the Power WaveWater Cooler K1767-1.

D-1MAINTENANCED-1

POWER WAVE 455/R

SAFETY PRECAUTIONS


• Only Qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE Routine maintenance consists of periodically blowingout the machine, using a low pressure airstream, toremove accumulated dust and dirt from the intake andoutlet louvers, and the cooling channels in themachine.

PERIODIC MAINTENANCECalibration of the Power Wave-455/R is critical toits operation. Generally speaking the calibrationwill not need adjustment. However, neglected orimproperly calibrated machines may not yield sat-isfactory weld performance. To ensure optimalperformance, the calibration of output Voltage andCurrent should be checked yearly.

CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at thefactory. Generally speaking the machine calibrationwill not need adjustment. However, if the weld per-formance changes, or the yearly calibration checkreveals a problem, contact the Lincoln ElectricCompany for the calibration software utility.

The calibration procedure itself requires the useof a grid, and certified actual meters for voltageand current. The accuracy of the calibration willbe directly affected by the accuracy of the mea-suring equipment you use. Detailed instructionsare available with the utility.

WARNING

E-1TROUBLESHOOTINGE-1

POWER WAVE 455/R

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


POWER WAVE 455/R

USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS

The Status LED on the power source case frontcan help diagnose problems down to the systemcomponent (power source, wire feeder, wiredrive, etc.) level. If, for any reason, the systemdoes not appear to be working properly,

always check the color of the Status LED, andrefer to the following chart to help you determinewhich system component (power source, wirefeeder, wire drive, etc.) may be faulty. Replacethe components identified as potentially faultywith known good components, and the systemshould operate normally.

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

Blinking Red.

System OK. Power source communicating normallywith wire feeder and its components.

Occurs during a reset, and indicates the Power Waveis mapping (identifying) each component in the system.Normal for first 1-10 seconds after power is turned on,or if the system configuration is changed during opera-tion

Non-recoverable system fault. If the PS Status light isflashing any combination of red and green, errors arepresent in the Power Wave. Read the error codebefore the machine is turned off.

Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, and back onto reset.

Not applicable.

Not applicable.


POWER WAVE 455/R

Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTIONIf 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.

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.

Input fuses keep blowing, or inputbreaker keeps tripping.

Machine will not power up (nolights, no fan, etc.)

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assis-tance.

1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.

2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.

3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.

1. Make certain that the PowerSwitch (SW1) is in the “ON”position.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset. Also, check input volt-age selection, below.

3. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.

If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.


POWER WAVE 455/R




PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMS

Thermal LED is lit.

Machine won’t weld, can’t get anyoutput. (CR1 will not pull in.)

1. Fan thermostat has opened.Check for proper fan opera-tion. (Fan should run whenev-er main power is on.) Checkfor material blocking intake orexhaust louvers, or for exces-sive dirt clogging coolingchannels in machine.

2. Secondary rectifier thermostathas opened. After machinehas cooled, reduce load, dutycycle, or both. Check formaterial blocking intake orexhaust louvers.

1. Input voltage is too low or toohigh. Make certain that inputvoltage is proper, according tothe Rating Plate located onthe rear of the machine.

2. If the Thermal LED is also lit,see “Yellow Thermal LED isLit” section.



POWER WAVE 455/R




PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure

Machine won’t produce full output.

For no apparent reason, the weld-ing characteristics have changed.

Auxiliary receptacle is “dead” — noauxiliary voltage .

1. Secondary current limit hasbeen exceeded, and themachine has phased back toprotect itself. Adjust proce-dure or reduce load to lowercurrent draw from themachine.

1. Input voltage may be too low,limiting output capability of thepower source. Make certainthat the input voltage is prop-er, according to the RatingPlate located on the rear ofthe machine.

2. Input may be “single phased”.Make certain the input voltageis proper on all three inputlines.

1. Check for proper Wire FeedSpeed setting. In CV MIGand FCAW modes, check forproper Voltage setting. In theMIG/MAG pulse modes,check the Trim setting. Thesecontrols are on the wire feed-er.

2. Check for proper shieldinggas mix and flow.

3. Check for loose or faulty weldcables and cable connections.

1. Circuit breaker CB2 (on casefront) may have opened.Reset.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.



POWER WAVE 455/R

Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)


The PowerWave is triggered to weld,but there is no output.

In the STT mode, the arc is exces-sively long and erratic.

In the STT mode, the spatter is high-er than normal and the arc is incon-sistent.

The feeder will not cold inch wire

Arc loss fault on robot

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow/ water flowturned off.

1. Check that the (21) work senselead is connected.

1. Check that the (21) work senselead is connected.

2. Verify that the electrode lead isconnected to the STT stud andnot the "POWERWAVE" stud.

3. Check that the "POWERWAVE"stud is not electrically connectedto the STT stud.

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow/ water coolerturned off.

1. Possibly caused by wire feedingproblem.

2 Problem - Conduit leading to thewire feeder has bends or twists,which can reduce the wire feedspeed.Solution - Remove bends andtwists from conduit.

3. Problem – Conduit leading up tothe wire feeder from the wire reelis too long.Solution – Use a shorter length ofconduit.

WELDING PROBLEMS



POWER WAVE 455/R



CAUTION

ERROR CODES FOR THE POWERWAVEThe following is a list of possible error codes that the PW-455 can output via the status light (see"Troubleshooting the PowerWave / Power Feed System Using the Status LED").

Error Code #

11 CAN communication bus off.

12 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage (Left side facing machine)

33 Capacitor "B" under voltage (Right side facing machine)

34 Capacitor "A" over voltage (Left side facing machine)

35 Capacitor "B" over voltage (Right side facing machine)

36 Thermal error

37 Softstart error

Indication

Probably due to excessive number of communication errors.

User Interface is no longer responding to the Power Source. The mostlikely cause is a fault/bad connection in the communication leads orcontrol cable.Contact the Service Department for instructions on reloading theWelding Software.

Contact the Service Department for instructions on reloading theWelding Software.

Contact the Service Department for instructions on reloading theWelding Software.

Excessive Primary current present. May be related to a switch board oroutput rectifier failure.

Low voltage on the main capacitors. May be caused by improper inputconfiguration.When accompanied by an overvoltage error on the same side, it indi-cates no capacitor voltage present on that side, and is usually the resultof an open or short in the primary side of the machine.

Excess voltage on the main capacitors. May be caused by improperinput configuration. When accompanied by an undervoltage error on the same side, it indi-cates no capacitor voltage present on that side, and is usually the resultof an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cycle limitof the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.


POWER WAVE 455/R



CAUTION

Error Code #

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indication

The secondary (weld) current limit has been exceeded. When thisoccurs the machine output will phase back to 100 amps, typically result-ing in a condition referred to as "noodle welding" NOTE: For the Power Wave 455/R the secondary limit is 570 amps forthe standard stud, and 325 amps for the STT stud and all single phaseoperation.

The maximum voltage difference between the main capacitors has beenexceeded. May be accompanied by errors 32-35.

Indicates machine is running on single phase input power. Usuallycaused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal errors.These codes generally indicate internal errors on the PS Control Board.If cycling the input power on the machine does not clear the error, tryreloading the operating system. If this fails, replace the control board.

F-1DIAGRAMSF-1

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TTH

ERM

DC

BU

STH

ERM

L5

TO AUX

#2

S1

TO J83

J84

J2VS

100V

2400

μF

500V

3500

μF

500V

3500

μF

1920

HA

RM

ON

ICFI

LTE

R

FILT

ER

FILT

ER

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

TABLE 5 DEVICENET CONNECTOR S5

Pin Lead # Function2 894 +24vdc Devicenet3 893 Commom Devicenet+4 892 Devicenet H5 891 Devicenet L

F-3CONNECTOR PIN DEFINITIONSF-3

POWER WAVE 455/R

TABLE 1 INTERFACE CONNECTOR S6

Pin Lead # FunctionA 841 +15vdc Tach voltageB 844 Tach commonC 842 Tach 1A differential signalD 843 Tach 1B differential signal E 845 Tach 2A differential signal F 846 Tach 2B differential signalG 847 Single Tach InputH Reserved for future useI 67B Voltage sense leadJ 539 Motor "+"K 541 Motor "-"L Reserved for future useM Reserved for future useN 521 +40vdc for solenoidP 522 Solenoid inputR Reserved for future useS Reserved for future useT 855A Shield ground to caseU Reserved for future useV Reserved for future useW Reserved for future useX Reserved for future use

TABLE 2 WIRE FEEDER RECEPTACLE S1

Pin Lead # FunctionA 53 Arclink LB 54 Arclink HC 67A Electrode Voltage SenseD 52 Ground(0v)E 51 +40vdc

TABLE 6 EXTERNAL I/O S7

Pin Lead # Function1 851 +15vdc for Trigger group2 852 Trigger input3 853 Dual procedure input4 854 4 Step input5 855 +15vdc for cold inch group6 856 cold inch forward7 857 cold inch reverse8 858 gas purge input9 859 +15vdc for shutdown group10 860 shutdown1 input11 861 shutdown2 input12 862 input B

TABLE 4 RS232 CONNECTOR S3

Pin Lead # Function2 253 RS232 Receive3 254 RS232 Transmit4 # S3 Pin55 # S3 Pin46 ## S3 Pin2020 ## S3 Pin67 251 RS232 Common

TABLE 3 VOLTAGE SENSE RECEPTACLE S2

Pin Lead # Function3 21A Work Voltage Sense

F-4CONNECTION DIAGRAMF-4

POWER WAVE 455/R

Hard Automation, Electrode Positive, STTConfiguration

- +

WORKSENSELEADK940

WATERCOOLEDTORCH

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLERPOWERCONNECTION

SHIELDING GAS

TO SHIELDING GAS DEVICENET CABLETO PLC/CONTROLLER

DEVICENET CABLETO PLC/CONTROLLER

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLERPOWER CONNECTION

WATERLINES

F-5CONNECTION DIAGRAMF-5

POWER WAVE 455/R

K1796 COAXIAL WELD CABLE

User suppliedwork lead

User suppliedelectrode lead

- +

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE ORK1804-2 AND ANY K1795 CONTROL CABLE

Robotic Set Up, Electrode Positive, CV/PulseConfiguration

User suppliedwork lead

User suppliedelectrode lead

CONTROL CABLE K1805-1

F-6DIAGRAMSF-6

POWER WAVE 455/R

32

.88

26

.10

22

.63

12

.35

19

.00

19

.90

19

.16

9.4

81

4.6

2

23

.12

23

.51

11-1

4-97

M18

241

DIM

EN

SIO

N P

RIN

T -

PO

WE

R W

AV

E 4

55

NOTES

POWER WAVE 455/R

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

im690-a power wave 455/r - lincoln electric...power wave 455/r operator’s manual im690-a feb, 2019...

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