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Lincoln Electric POWERWAVE IM762-C - page 1
PO WER W A VE 455 M ™ OPERA TOR’S MANUAL IM762-C October, 2006 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READI ...
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Lincoln Electric POWERWAVE IM762-C - page 2
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________ ...
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Lincoln Electric POWERWAVE IM762-C - page 3
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Us e suitable clothing made from durable flame-resistant material to protect your ski ...
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Lincoln Electric POWERWAVE IM762-C - page 4
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric POWERWAVE IM762-C - page 5
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ? ...
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Lincoln Electric POWERWAVE IM762-C - page 6
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay ...
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Lincoln Electric POWERWAVE IM762-C - page 7
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 455M .................................................A-1 Safety Precautions................................................................................ ...
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Lincoln Electric POWERWAVE IM762-C - page 8
vii vii T ABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E How to use Troubleshooting Guide .......................................................................E-1 Using the Status LED to Troubleshoot System Problems ..................................... ...
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Lincoln Electric POWERWAVE IM762-C - page 9
A-1 INST ALLA TION POWER WAVE 455M A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 455M (K2202-1, K2202-3) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RA TED OUTPUT PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS- FREQUENCY 208/230/460/575V - 60HZ. 200/220/440/575V - 50HZ. OPEN CIRCUIT VOLTA ...
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Lincoln Electric POWERWAVE IM762-C - page 10
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. ST ACKING Power Wave machines can be stacked to a maximum of 3 high. The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines ...
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Lincoln Electric POWERWAVE IM762-C - page 11
A-3 INST ALLA TION POWER WAVE 455M A-3 INPUT FUSE AND SUPPL Y WIRE CONSIDERA TIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommend- ed super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circ ...
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Lincoln Electric POWERWAVE IM762-C - page 12
A-4 INST ALLA TION POWER WAVE 455M A-4 CABLE INDUCT ANCE, AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than 50 ft.( 15.24m), tradi- tional welding cables may be used without any effects on welding performance. For the total weldin ...
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Lincoln Electric POWERWAVE IM762-C - page 13
A-5 INST ALLA TION POWER WAVE 455M A-5 Electrode Voltage Sensing Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present. I mportant: The electrode polarity must be config- ured at the feed ...
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Lincoln Electric POWERWAVE IM762-C - page 14
A-6 INST ALLA TION POWER WAVE 455M A-6 CONFIGURING THE SYSTEM For codes below 11100, consult the semi-automatic Power Feed instruction manual for configuration infor- mation about DIP switch settings. For codes above 11100, the power source will “Auto Map” the system eliminating most of the need to set DIP switches to configure the system. If a ...
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Lincoln Electric POWERWAVE IM762-C - page 15
A-7 INST ALLA TION POWER WAVE 455M A-7 In this case the individual feed heads need to be assigned to the dual head control and the PW455 auto mapping disabled and the Equipment Groups set on (See Figure A-6). (See the Feeder documentation for information on setting the feeder DIP switches) System that is NOT "Auto Mappable" POWER WAVE 455 ...
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Lincoln Electric POWERWAVE IM762-C - page 16
A-8 INST ALLA TION POWER WAVE 455M A-8 WELDING WITH MUL TIPLE POWER W A VES Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. ------------------------------------------------------------------------ Each power source requires a work lead from ...
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Lincoln Electric POWERWAVE IM762-C - page 17
A-9 INST ALLA TION POWER WAVE 455M A-9 MUL TIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES ...
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Lincoln Electric POWERWAVE IM762-C - page 18
A-10 INST ALLA TION POWER WAVE 455M A-10 I / O RECEPT ACLE SPECIFICA TIONS TABLE 3 WIRE FEEDER RECEPTACLE S1 PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc E 51 +40vdc TABLE 4 VOLTAGE SENSE RECEPTACLE S2 PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE 5 RS232 RECEPTACLE S3 PIN LEAD# FU ...
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Lincoln Electric POWERWAVE IM762-C - page 19
B-1 OPERA TION B-1 POWER WAVE 455M SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always elec- trically energized and could remain energized several seconds after the ...
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Lincoln Electric POWERWAVE IM762-C - page 20
B-2 OPERA TION B-2 POWER WAVE 455M INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING OR CAUTION GR ...
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Lincoln Electric POWERWAVE IM762-C - page 21
B-3 OPERA TION B-3 POWER WAVE 455M DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage based ...
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Lincoln Electric POWERWAVE IM762-C - page 22
DeviceNet Interface Module This module can be used for DeviceNet capability. It will has 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 EQU ...
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Lincoln Electric POWERWAVE IM762-C - page 23
B-5 OPERA TION POWER WAVE 455M B-5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1 . POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indic ...
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Lincoln Electric POWERWAVE IM762-C - page 24
B-6 OPERA TION B-6 NOMINAL PROCEDURES The Power Wave is designed to operate with 3/4" electrode stick-out for CV and Pulse processes. FRINGE PROCEDURES Excessively short or long electrode stick-outs may function only on a limited basis, if at all. MAKING A WELD The serviceability of a product or structure utiliz- ing the welding programs is an ...
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Lincoln Electric POWERWAVE IM762-C - page 25
Current Ti m e CURRENT W A VE FORM (CV) B-7 OPERA TION B-7 • WELDING MODE May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characteristics of the Power Wave power source. For a more complete description of the w ...
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Lincoln Electric POWERWAVE IM762-C - page 26
B-8 OPERA TION B-8 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed ...
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Lincoln Electric POWERWAVE IM762-C - page 27
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED Wire Drive Interface Module, K2205-1 FIELD INST ALLED Work Voltage Sense Lead Kit, K940 Dual Cylinder Undercarriage, K1570-1. Gas Guard Regulator, K659-1 Coaxial welding Cable, K1796 Cool Arc 40 K1813-1 (115VAC) Water Flow Sensor, K1536-1 Wire Drive Interface Module, K2205-1 DeviceNet inte ...
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Lincoln Electric POWERWAVE IM762-C - page 28
D-1 MAINTENANCE D-1 POWER WAVE 455M SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE Routine maintenance consists of periodically bl ...
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Lincoln Electric POWERWAVE IM762-C - page 29
E-1 TROUBLESHOOTING E-1 POWER WAVE 455M If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair ...
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Lincoln Electric POWERWAVE IM762-C - page 30
E-2 TROUBLESHOOTING E-2 POWER WAVE 455M USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on the us ...
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Lincoln Electric POWERWAVE IM762-C - page 31
E-3 TROUBLESHOOTING E-3 POWER WAVE 455M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ERROR C ...
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Lincoln Electric POWERWAVE IM762-C - page 32
E-4 TROUBLESHOOTING E-4 POWER WAVE 455M Observe all Safety Guidelines detailed throughout this manual CAUTION If 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 CA ...
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Lincoln Electric POWERWAVE IM762-C - page 33
E-5 TROUBLESHOOTING E-5 POWER WAVE 455M Observe all Safety Guidelines detailed throughout this manual CAUTION If 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 CA ...
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Lincoln Electric POWERWAVE IM762-C - page 34
E-6 TROUBLESHOOTING E-6 POWER WAVE 455M Observe all Safety Guidelines detailed throughout this manual CAUTION If 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 CA ...
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Lincoln Electric POWERWAVE IM762-C - page 35
F-1 DIAGRAMS F-1 POWER WAVE 455M NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code num ...
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Lincoln Electric POWERWAVE IM762-C - page 36
F-2 DIAGRAMS F-2 POWER WAVE 455M NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code num ...
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Lincoln Electric POWERWAVE IM762-C - page 37
F-3 CONNECTION DIAGRAM F-3 POWER WAVE 455M Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK ...
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Lincoln Electric POWERWAVE IM762-C - page 38
F-4 DIAGRAMS F-4 POWER WAVE 455M 32.88 26.10 22.63 12.35 19.00 19.90 19.16 9.48 14.62 23.12 23.51 1 1-14-97 M18241 DIMENSION PRINT - PO WER W A VE 455M ...
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Lincoln Electric POWERWAVE IM762-C - page 39
NOTES POWER WAVE 455M ...
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Lincoln Electric POWERWAVE IM762-C - page 40
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL U ...
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Lincoln Electric POWERWAVE IM762-C - page 41
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro ...
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Lincoln Electric POWERWAVE IM762-C - page 42
• 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 • ...
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