Multi Process Welders POWER WAVE 455 M Wave455Mb
User Manual: POWER WAVE 455 M
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Publication E5.161 6/07
www.lincolnelectric.com
Power Wave®455M &
Power Wave®455M/STT®
AUTOMATED SOLUTIONS
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.
CV
CC
3
PHASE
60
50
Hz
DC
Superior Arc Performance.
Revolutionary Communication.
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®.
• 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.
• Optional communication modules provide networking and Production
Monitoring™ capabilities.
• Push-Pull capability delivers ultimate aluminum welding with the
Power Feed™ 10M bench model wire feeder or Power Feed™ 25M
portable wire feeder.
• Utilizes ArcLink®— the leading digital communication protocol for
welding, making it the best choice for seamless, time critical integration
with the power source.
• Power Wave®455M/STT features Lincoln’s Surface Tension Transfer®
Process, which controls heat input for great penetration control and
reduced spatter and fumes.
• Manufactured under a quality system certified to ISO 9001 requirements
and ISO 14001 environmental standards.
• Three-year warranty on parts and labor.
Stick, TIG, MIG, Pulsed, STT(1), Flux-Cored, Gouging
Processes
Output
Input
TECHNICAL SPECIFICATIONS
(1) Power Wave®455M/STT only.
Dimensions Net
Product Product Input Rated Output Input Current Output H x W x D Weight
Name Number Voltage Current/Voltage/Duty Cycle @Rated Output Range in (mm) lbs (kg)
Power Wave®455M K2202-1 208/230/460/575/3/50/60 60Hz: 60Hz: 5-570A 26.1 x 19.9 x 32.9 286
450A/38V/100% 58/53/25/22A (663 x 505 x 835) (130)
(570A/43V/60%) (82/78/37/31A)
Power Wave®455M/STT K2203-1 50Hz: 50Hz: 293
400A/36V/100% 49/45/23/18A (133)
(500A/40V/60%) (67/61/31/25A)
Power Wave®455M CE K2202-2 380/415/3/50/60 60Hz: 60Hz: 5-570A 26.1 x 19.9 x 32.9 280
400A/36V/100% 36/33A (663 x 505 x 835) (127)
(500A/40V/60%) (48/44A)
Power Wave®455M/STT CE K2203-2 50Hz: 50Hz: 340
400A/36V/100% 36/33A (154)
(500A/40V/60%) (48/44A)
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:
Power Wave
®
455M and Power Wave
®
455M/STT
®
www.lincolnelectric.com
[2]
A CLOSER LOOK
WHAT IS NEXTWELD®?
Nextweld®integrates Lincoln’s technologies, process-
es 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
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.
Power Mode™ reduces spatter and
improves bead appearance, even for low
voltage procedures on stainless.
Superior Arc Performance
Power Mode™ aids bead wetting
and penetration on aluminum.
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.
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 perform-
ance, 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 Wave
®
455M and Power Wave
®
455M/STT
®
[3]
A CLOSER LOOK
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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
®
SSTTTT®®((SSuurrffaaccee TTeennssiioonn TTrraannssffeerr®®))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.
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 applica-
tions. Optimized GMAW-P waveforms are readily available to use
on aluminum, carbon steel, high strength low alloy steel, stainless
steel, and nickel alloys.
For more information see Nextweld®Document #NX-2.70
®
TIME
WELDING CURRENT
Background
Peak
Ramp Up Tail Out
Step Off
PULSE CYCLE
Low Heat
(Background) High Heat
(Peak)
Power Wave
®
455M and Power Wave
®
455M/STT
®
www.lincolnelectric.com
[ 4]
A CLOSER LOOK
Key Controls
Power Wave®455M and 455M/STT®Front Panel
1. Thermal Light
2. Power Supply Status Light
3. On/Off Switch
4. Communication Module Status Light
(DeviceNet or Ethernet/DeviceNet™) (Optional)
5. Feeder Status Light (for Power Feed®10R)
(Optional)
6. Communication Interface Module – DeviceNet™ or
Ethernet/DeviceNet upgrades can be field installed.
7. Robotic wire drive module upgrade can be field
installed.
4
1
2
3
567
RS-232 Serial Port
Optional Gateway Modules
FANUC Robot
Power Feed™ 10R
Internet Computer
Additional
Networked
Power Wave®
Power Sources
• Production
Monitoring
• Machine
Management
• Advanced
Diagnostics
®
Power Wave®Power Source
Robot Teach Pendant
PLC or Hard Automation Interface
DeviceNet Compatible Robot
DeviceNet
Gateway Module
Ethernet/DeviceNet™
Gateway Module
®
Power Feed™ 10M
Process
Monitoring
FANUC R-J3 or R-J3iB
Robot Controller
Digital Communications, Cont.
Seamless Integration
Power Wave
®
455M and Power Wave
®
455M/STT
®
www.lincolnelectric.com
[ 5]
A CLOSER LOOK
Key Controls, Cont.
Power Wave®455M and 455M/STT®Front Panel
Easy Modular Expansion
Front Lower Panel
1. DeviceNet™ or Ethernet/DeviceNet™ Receptacle (optional)
2. ArcLink Receptacle
3. Work Sense Lead Receptacle
4. RS-232 Serial Communication Port
5. 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
10
987
6
1234
5
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
Ethernet Module Shown
Open Spot for Robotic
Wire Drive Module
Power Wave
®
455M and Power Wave
®
455M/STT
®
[ 6]
A CLOSER LOOK
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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.
• 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.
Environmental Chamber
Manufacturing and Testing
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 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.
• 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.
• 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.
Open Construction
Coated Electrical Connections
Trayed and Potted
PC Board
Automotive Grade Sleeves
Cooling System
Power Wave
®
455M and Power Wave
®
455M/STT
®
[ 7]
RECOMMENDED OPTIONS
GENERAL OPTIONS
DeviceNet Interface Module
This module provides Networking
capabilities for Output Control,
Weld Settings, Weld Mode
Selection and Data Logging.
Order K2206-1
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
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
WIRE FEEDER OPTIONS
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
WIRE FEEDER OPTIONS CONT.
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 code-
quality 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
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.
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
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
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
www.lincolnelectric.com
POWER WAVE®455M K2202-1
POWER WAVE®455M/STT®K2203-1
POWER WAVE®455M/POWER FEED™ 10M READY-PAK®K2375-1
RECOMMENDED GENERAL OPTIONS
DeviceNet Interface Module K2206-1
Ethernet Interface Module K2207-1
Analog Interface Module Contact Lincoln Automation
Dual Cylinder Platform Undercarriage K1570-1
Cool Arc® 40 Water Cooler - 115V K1813-1
Cool Arc® 40 Water Cooler - 230V K2187-1
RECOMMENDED WIRE FEEDER OPTIONS
Power Feed™ 10M Bench Model K2230-1
Power Feed™ 10M Dual Bench Model K2234-1
Power Feed™ 10M Boom Model K2314-1
Power Feed™ 10M Dual Boom Model K2316-1
Power Feed™ 10R K1780-2
Power Feed™ 25M K2536-1
RECOMMENDED STICK OPTIONS
Accessory Kit K704
RECOMMENDED TIG OPTIONS
PTA-17V TIG Torch (12.5 ft., 2-piece) K1782-7
PTA-26V TIG Torch (12.5 ft., 2-piece) K1783-7
TOTAL:
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
POWER WAVE®455M & POWER WAVE®455M/STT®ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
CUSTOMER ASSISTANCE POLICY
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.
