Multi Process Welders POWER WAVE 455 M Wave455Mb
User Manual: POWER WAVE 455 M
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Power Wave 455M & ® ® Power Wave 455M/STT ® AUTOMATED SOLUTIONS Output Superior Arc Performance. Revolutionary Communication. CC CV DC For welding thicker materials in robotics, hard automation and semiautomatic applications, choose the Power Wave® 455M. For those applications where heat input control, minimal distortion, and reduced spatter are essential, opt for the Power Wave® 455M/STT. Both models feature Waveform Control Technology™ for superior arc performance on a variety of materials, including steel, stainless steel, aluminum and nickel alloys. Both deliver custom control of the arc for a given wire type, size and shielding gas configuration for consistent welds time after time. The Power Wave® 455M and 455M/STT® are designed to be components in a modular, multi-process welding system capable of digital communication with other industrial machines to create a highly integrated and flexible welding cell. Input 3 PHASE 50 60 Hz Processes Stick, TIG, MIG, Pulsed, STT(1), Flux-Cored, Gouging Advantage Lincoln • Lincoln’s Waveform Control Technology® gives you the ability to select the right waveform for each application, enabling patented processes like Pulse-On-Pulse® and Power Mode®. • Utilizes ArcLink® — the leading digital communication protocol for welding, making it the best choice for seamless, time critical integration with the power source. • Choose from over 60 standard welding waveform programs that offer a broad range of electrode size, type and shielding gas combinations to give you optimal appearance, penetration, beadshape and travel speed for each application. • Power Wave® 455M/STT features Lincoln’s Surface Tension Transfer® Process, which controls heat input for great penetration control and reduced spatter and fumes. • Optional communication modules provide networking and Production Monitoring™ capabilities. • Manufactured under a quality system certified to ISO 9001 requirements and ISO 14001 environmental standards. • Three-year warranty on parts and labor. • Push-Pull capability delivers ultimate aluminum welding with the Power Feed™ 10M bench model wire feeder or Power Feed™ 25M portable wire feeder. (1) Power Wave® 455M/STT only. TECHNICAL SPECIFICATIONS Product Name Product Number Input Voltage Rated Output Current/Voltage/Duty Cycle Input Current @Rated Output Output Range Power Wave® 455M K2202-1 208/230/460/575/3/50/60 60Hz: 450A/38V/100% (570A/43V/60%) 60Hz: 58/53/25/22A (82/78/37/31A) 5-570A Power Wave® 455M/STT K2203-1 50Hz: 400A/36V/100% (500A/40V/60%) 50Hz: 49/45/23/18A (67/61/31/25A) Power Wave® 455M CE K2202-2 60Hz: 400A/36V/100% (500A/40V/60%) 60Hz: 36/33A (48/44A) Power Wave® 455M/STT CE K2203-2 50Hz: 400A/36V/100% (500A/40V/60%) 50Hz: 36/33A (48/44A) 380/415/3/50/60 Dimensions HxWxD in (mm) Net Weight lbs (kg) 26.1 x 19.9 x 32.9 (663 x 505 x 835) 286 (130) 293 (133) 5-570A 26.1 x 19.9 x 32.9 (663 x 505 x 835) 280 (127) 340 (154) Publication E5.161 6/07 www.lincolnelectric.com A CLOSER LOOK WHAT IS NEXTWELD®? provide the foundation for Nextweld® innovations like Pulse-On® Pulse™, Power Mode™, STT® and ArcLink®. Look for Nextweld for ultimate arc control, high efficiency/reliability and seamless system integration. Nextweld® integrates Lincoln’s technologies, processes and products to create a comprehensive, flexible, user-friendly welding system that can increase efficiency and reduce fabrication costs. Waveform Control Technology™ and digital communications Waveform Control Technology® Driving Superior Welding Performance Lincoln’s Waveform Control Technology™ controls and shapes the output waveforms (or weld modes) to adapt to virtually any application, material or weld position. In addition, you can have our Application Engineering department add or customize standard waveform programs or request Lincoln Wave Designer™ software to build or customize waveform programs yourself. For more information see Nextweld® Document #NX-1.10 Lincoln Nextweld® Innovations for Challenging Applications Waveform Control Technology makes it possible to take advantage of Lincoln Nextweld® innovations like these patented processes using the Power Wave® 455M and a Power Feed™ 10M wire feeder: TOTAL s2f™ Aluminum Welding Solutions from Lincoln Electric® Providing a complete answer to your aluminum MIG welding needs from "start to finish". • Power Wave® welding systems provide the best equipment for light and industrial aluminum welding needs. • Super Glaze® aluminum consumables deliver consistent wire com position, smooth feeding, and a stable arc. • Nextweld® welding processes beat all of the challenges you face with aluminum welding. Superior Arc Performance For more information see Nextweld® Document #NX-2.90 Power Mode™ uses high-speed regulation of output power to deliver extremely fast response to changes in the arc, for example, when using a whip technique. The result is improved MIG welding performance, including low spatter, very uniform, consistent bead wetting and controlled penetration. Power Mode™ benefits are especially apparent on low voltage applications on thin steel and stainless steel material less than 20 gauge (0.7 mm). It also delivers excellent arc characteristics on aluminum and other alloys such as silicone bronze and nickel alloys. For more information see Nextweld® Document #NX-2.60 Power Mode™ reduces spatter and improves bead appearance, even for low voltage procedures on stainless. Power Mode™ aids bead wetting and penetration on aluminum. Power Wave® 455M and Power Wave® 455M/STT® [2] www.lincolnelectric.com A CLOSER LOOK WELDING CURRENT PULSE CYCLE Peak Ramp Up Pulsed MIG varies weld current between peak (high heat) and background (low heat) current to provide better control of heat input, which reduces warping and burnthrough on thin materials. Pulsed MIG also enables in-the-flat, horizontal, vertical up, or overhead welding without a slag system. It can be used in hard automation, robotic, and high production semiautomatic applications. Optimized GMAW-P waveforms are readily available to use on aluminum, carbon steel, high strength low alloy steel, stainless steel, and nickel alloys. Tail Out Background Step Off TIME For more information see Nextweld® Document #NX-2.70 Low Heat (Background) High Heat (Peak) STT® (Surface Tension Transfer®) is a controlled GMAW short circuit transfer process that uses current controls to adjust the heat independent of wire feed speed, resulting in superior arc performance, good penetration, low heat input control, and reduced spatter and fumes. For more information see Nextweld® Document #NX-2.20 Conventional CV short circuit transfer using CO2 and .045” solid wire. STT® using CO2 and .045” solid wire. Note reduced spatter and fume. Digital Communications Fast, Reliable, System-Wide ® ArcLink is the leading digital communications protocol for the arc welding industry. It integrates all welding components for seamless, time-critical data transfer. The strength of ArcLink® lies in the ability to communicate with each system component in a pre-defined welding language. In addition, ArcLink® is an open communications protocol, meaning that Lincoln Electric publishes how it works and encourages other companies to adopt it. DeviceNet™ is a communications protocol widely used throughout the automotive, semiconductor, and packaging industries. In its typical application, DeviceNet™ works in conjunction with a programmable Logic Controller (PLC) and several system devices to provide a framework for data trafficking and monitoring. ® Ethernet is a specification for networking that provides the ability to pull large amounts of information into monitoring and supervisory applications. For more information see Nextweld® Document #NX-1.30 Power Wave® 455M and Power Wave® 455M/STT® [3] www.lincolnelectric.com A CLOSER LOOK Digital Communications, Cont. Seamless Integration Power Wave® Power Source Optional Gateway Modules RS-232 Serial Port ® Ethernet/DeviceNet™ Gateway Module Power Feed™ 10M Power Feed™ 10R FANUC R-J3 or R-J3iB Robot Controller DeviceNet Gateway Module ® Robot Teach Pendant Process Monitoring Internet Computer Additional Networked Power Wave® Power Sources FANUC Robot • Production Monitoring • Machine Management • Advanced Diagnostics PLC or Hard Automation Interface DeviceNet Compatible Robot Key Controls 4 5 6 7 1. Thermal Light 2. Power Supply Status Light 3. On/Off Switch 4. Communication Module Status Light (DeviceNet or Ethernet/DeviceNet™) (Optional) 1 5. Feeder Status Light (for Power Feed® 10R) (Optional) 2 6. Communication Interface Module – DeviceNet™ or Ethernet/DeviceNet upgrades can be field installed. 3 7. Robotic wire drive module upgrade can be field installed. Power Wave® 455M and 455M/STT® Front Panel Power Wave® 455M and Power Wave® 455M/STT® [ 4] www.lincolnelectric.com A CLOSER LOOK Key Controls, Cont. Easy Modular Expansion Ethernet Module Shown Open Spot for Robotic Wire Drive Module Power Wave® 455M and 455M/STT® Front Panel 1 3 2 4 1. 2. 3. 4. 5. 5 10 6 9 8 DeviceNet™ or Ethernet/DeviceNet™ Receptacle (optional) ArcLink Receptacle Work Sense Lead Receptacle RS-232 Serial Communication Port STT® Stud (not shown) 6. Positive Output Stud 7. CB1 (10A) 40VDC 8. 115 VAC Duplex Receptacle 9. CB1 (10A) 40VDC 10. Negative Output Stud 7 Front Lower Panel Power Wave® 455M/Power Feed™ 10M Ready-Pak™ Take the hassle out of ordering — Order a Ready-Pak™ pre-assembled welding package. Includes: • Power Wave® 455M Power Source • Power Feed™ 10M Single Bench Model Wire Feeder • .040-.045” (1.0-1.1 mm) Drive Roll and Guide Tube Kit • Magnum® 400 Gun and Cable Kit • Work Lead Package • Harris® Flowmeter Regulator (includes adapter and 10 ft. hose) Order K2375-1 Power Wave® 455M and Power Wave® 455M/STT® [ 5] www.lincolnelectric.com A CLOSER LOOK QUALITY AND RELIABILITY Design Safety, reliability and serviceability are built into Lincoln’s inverter design. • A Power Wave® inverter operates at a high efficiency (88-90%) with a 95% minimum power factor at rated output (K2202-1 and K2203-1) and is capable of operating from a universal input voltage (208 to 575 volts). Open Construction • Open construction for preventative maintenance and diagnostics. • Thermostatically protected. • Electronic output over-current protection and electronic input over-voltage protection. • Operating Temperature Range: -20ºC to +40ºC. • Storage Temperature Range: -40ºC to +40ºC. • Double insulation and varnish on main transformer. Coated Electrical Connections • Shielded heavy duty input contactor in tightly sealed environmental enclosure. • Electrical connections coated with insulating compound for long term reliability in harsh environments. • Automotive grade sleeves protect leads from abrasion. • Tough PC Boards — potted and trayed, filed with epoxy, double locked harness connectors, environmentally protected connectors, electrical silicone grease, high current rating. Extra attention to detail provides excellent protection from dirt, dust and the environment. • Efficient Cooling System with industrial motor with sealed bearings and metal fan blade. Automotive Grade Sleeves • Fan-As-Needed™ — reduces power consumption and the amount of debris that gets drawn into the machine by shutting the fan down when it is not needed. Trayed and Potted PC Board Cooling System Testing and Reliability All Lincoln inverters are fully tested for reliability before and after assembly. • Each machine undergoes a functional weld test to ensure performance. • Lincoln inverters are operated in an environmental chamber under extreme conditions of temperature and humidity. • Mechanical testing, including vibration and drop testing, is performed • Extensive temperature testing is performed to ensure that all components are running within allowable range. • Three-year warranty on parts and labor. Environmental Chamber • Manufactured under a quality system certified to ISO 9001 requirements and ISO 14001 environmental standards. • Designed to the IEC/EN 60974-1 standard. Meets tough NEMA EW 1, CSA NRTL/C standards. • Meets rigorous IP21S environmental rating. Manufacturing and Testing Power Wave® 455M and Power Wave® 455M/STT® [ 6] www.lincolnelectric.com RECOMMENDED OPTIONS GENERAL OPTIONS WIRE FEEDER OPTIONS CONT. DeviceNet Interface Module This module provides Networking capabilities for Output Control, Weld Settings, Weld Mode Selection and Data Logging. Order K2206-1 Power Feed™ 10M Boom & Dual Boom Choose the Power Feed™ 10M Boom Models for boom arm applications in automotive manufacturing, shipbuilding, pressure vessels/heavy plate, oil, gas and pipeline construction, particularly where codequality work is required. The Power Feed™ 10M Dual Boom has all the features of the Power Feed™ 10M Boom, plus a second wire reel for twice the productivity. Order K2314-1 Boom Order K2316-1 Dual Boom Ethernet/DeviceNet Interface Module This module provides all DeviceNet functionality as well as networking capabilities for Weld Development, Data Logging, Systems Updates, Diagnostics, Weld Settings and Weld Mode Selection. Order K2207-1 Power Feed™ 10R The Power Feed™ 10R is a high performance, digitally controlled wire feeder designed to be part of a modular, multi-process welding system. It is specifically designed to mount to a robot arm or to use in hard automation applications. Order K1780-2 Contact Lincoln Automation at (216) 383-2667 for Power Wave® Robotic upgrade. Analog Interface Module This module provides Analog and Discrete Inputs/Outputs (I/O) for trigger controls plus feedbacks. Contact Lincoln Automation at (216) 383-2667 for information. Dual Cylinder Platform Undercarriage Platform undercarriage for mounting two gas cylinders at rear of welder. Order K1570-1 Cool Arc® 40 Water Cooler Energy-efficient long life cooler for water-cooled welding applications. Order K1813-1 for 115V Order K2187-1 for 230V Power Feed™ 25M Designed for aluminum fabrication, high-alloy construction and pipeline welding environments. Designed exclusively for use with Power Wave® power sources. Order K2536-1 WIRE FEEDER OPTIONS STICK OPTIONS Accessory Kit For stick welding. Includes 35 ft. (10.7m) 2/0 electrode cable with lug, 30 ft. (9.1m) 2/0 work cable with lugs, headshield, filter plate, work clamp and electrode holder. 400 amp capacity. Order K704 Power Feed™ 10M Bench & Dual Bench Choose the Power Feed™ 10M Bench Models for automotive manufacturing, shipbuilding, pressure vessels/heavy plate, oil, gas and pipeline construction, particularly where code-quality work is required. The Power Feed™ 10M Dual Bench has all the features of the Power Feed™ 10M Bench, plus a second wire reel for twice the productivity. Order K2230-1 Bench Order K2234-1 Dual Bench TIG OPTIONS PTA-17V TIG Torch (12.5 ft. 2 pc) Air-cooled TIG torch, rated 150 amps at 60% duty cycle. Equipped with a valve for gas flow control. Order K1782-7 PTA-26V TIG Torch (12.5 ft. 2 pc) Air-cooled TIG torch, rated 200 amps at 60% duty cycle. Equipped with a valve for gas flow control. Order K1783-7 Power Wave® 455M and Power Wave® 455M/STT® [ 7] www.lincolnelectric.com POWER WAVE® 455M & POWER WAVE® 455M/STT® ORDER FORM PRODUCT DESCRIPTION ORDER NUMBER POWER WAVE® 455M POWER WAVE® 455M/STT® POWER WAVE® 455M/POWER FEED™ 10M READY-PAK® K2202-1 K2203-1 K2375-1 RECOMMENDED GENERAL OPTIONS DeviceNet Interface Module Ethernet Interface Module Analog Interface Module Dual Cylinder Platform Undercarriage Cool Arc® 40 Water Cooler - 115V Cool Arc® 40 Water Cooler - 230V K2206-1 K2207-1 Contact Lincoln Automation K1570-1 K1813-1 K2187-1 RECOMMENDED WIRE FEEDER OPTIONS Power Feed™ 10M Bench Model Power Feed™ 10M Dual Bench Model Power Feed™ 10M Boom Model Power Feed™ 10M Dual Boom Model Power Feed™ 10R Power Feed™ 25M K2230-1 K2234-1 K2314-1 K2316-1 K1780-2 K2536-1 RECOMMENDED STICK OPTIONS Accessory Kit K704 RECOMMENDED TIG OPTIONS PTA-17V TIG Torch (12.5 ft., 2-piece) PTA-26V TIG Torch (12.5 ft., 2-piece) K1782-7 K1783-7 QUANTITY PRICE TOTAL: C U S T O M E R A S S I S TA N C E P O L I C Y The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsible manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change — This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information. T H E L I N C O L N E L E C T R I C C O M PA N Y 22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.3 Linearized : No XMP Toolkit : 3.1-702 Producer : QuarkXPress(R) 7.1 Keywords : E5.161; multi-process welders; MIG welder; TIG welder; stick welder; flux-cored welder; arc gouging; Power Wave; Nextweld; STT X Press Private : %%DocumentProcessColors: Cyan Magenta Yellow Black.%%EndComments Create Date : 2007:06:07 15:07:13Z Creator Tool : QuarkXPress(R) 7.1 Modify Date : 2007:06:08 11:54:13-04:00 Metadata Date : 2007:06:08 11:54:13-04:00 Document ID : uuid:83d2dcc7-2d2f-e542-a704-d10ea78f464e Instance ID : uuid:900a5b2b-c414-4e76-ad90-224aa070dfe7 Format : application/pdf Title : Multi-Process Welders: Power Wave 455M and 455M/STT Description : For welding thicker materials in robotics, hard automation and semiautomatic applications, choose the Power Wave 455M. For applications where heat input control, minimal distortion, and reduced spatter are essential, opt for the Power Wave 455M/STT. Subject : E5.161, multi-process welders, MIG welder, TIG welder, stick welder, flux-cored welder, arc gouging, Power Wave, Nextweld, STT Page Count : 8 Creator : QuarkXPress(R) 7.1 Warning : [Minor] Ignored duplicate Info dictionaryEXIF Metadata provided by EXIF.tools