AUTOMATED SOLUTIONS
®
Power Wave 455M Robotic &
®
Power Wave 455M/STT Robotic
The Next Generation . . .
The Power Wave 455M Robotic & 455M/STT Robotic are high performance, digitally
controlled inverter welding power sources capable of complex, high-speed waveform
control. The Power Waves are designed to be part of a modular, multi-process welding
system. Optional DeviceNet and Ethernet Communication Modules provide networking
capabilities and allow the power sources to communicate with other industrial machines
to create a highly integrated and flexible welding cell. The Power Wave 455M & 455M/STT
Robotic power sources work exclusively with the Power Feed 10 series wire feeder.
Processes
Stick
TIG
Flux-Cored
Description
MIG
STT(1)
Gouging
Synergic MIG
Pulsed MIG
Output
CC
CV
Input
3
PHASE
50
60
Hz
Advantage Lincoln
Recommended Wire Feeder
• Modular design enables robotic, hard automation and
semiautomatic applications using a single machine platform.
Power Feed 10R
• Optional communication modules provide networking capabilities
via DeviceNet or Ethernet.
Recommended General Options
• Utilizes ArcLink™ - the leading digital communication protocol
making it the best choice for applications requiring seamless,
time critical integration to the power source.
• Software based controls can be upgraded as new features
become available.
DeviceNet Interface Module, Ethernet Interface Module, Analog
Interface Module, Wave Designer Software, Wave Designer Pro
Software, Dual Cylinder Platform Undercarriage, CoolArc 40
Water Cooler
Order
• Process and production monitoring with access to real time
(500Hz) feedback such as arc current and voltage and wire feed
speed. Access to internal Data Acquisition (10KHz) and access
to real time machine status such as fault/alarm conditions and
arc time.
K2262-1 Power Wave 455M Robotic 208/230/460/575/3/50/60
K2263-1 Power Wave 455M/STT Robotic 208/230/460/575/3/50/60
• A Power Wave inverter operates at a high efficiency (88-90%)
with a 95% minimum power factor(2) and is capable of operating from a universal input voltage (208 and 575 volts)
TECHNICAL SPECIFICATIONS
Product
Name
Product
Number
Input
Voltage
Rated Output
Current/Voltage/Duty Cycle
Input current
@Rated Output
Output
Range
Dimensions
HxWxD
in. (mm)
Net
Weight
lbs. (kg)
Power Wave 455M Robotic
K2262-1
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
26.1 x 19.9 x 32.9
(663 x 505 x 835)
286
(130)
Power Wave 455M/STT Robotic
K2263-1
50Hz:
400A/36V/100%
(500A/40V/60%)
50Hz:
49/45/23/18A
(67/61/31/25A)
293
(133)
(1) Power Wave 455M/STT only.
(2) At rated output.
Publication E10.90 12/02
www.lincolnelectric.com
A CLOSER LOOK
PERFORMANCE
• Waveform Control Technology™ uses electronic regulation circuitry
to control and shape the output waveform. Optimizes metal transfer to reduce spatter and improve stability making it the ideal
power source for all types of materials including steel, stainless
steel and aluminum. Simplifies welding process selection and
controls heat input.
• The Power Waves contains a large library of welding programs
or “weld modes”. Each weld mode is a specific software program that defines the output characteristics of the power source
for simple processes like Stick & TIG to more complex processes
like Synergic MIG and Pulse MIG. Weld Modes were developed to
handle a broad range of applications, however they may be tuned
to a specific electrode type, electrode diameter, gas type or
application
• Program your own waveform or 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 Robotic Welding Systems feature Weld Mode
Selection, Preflow, Run-in, Arc Control,Crater, Burnback, Postflow
and Crater that provide the operators full control over the welding
procedure and sequence.
• Synergic Welding eliminates the need to independently set the wire
feed speed and voltage. Synergic welding automatically sets both
voltage and pulse characteristics based on the wire feed speed.
• All Power Waves share a common digital control platform to maximize interoperability, interchangeability and compatible software
tools.
FEATURES
• Welding software is accessible via the Robot’s teach pendant or a
computer via the RS232 serial port.
• Welding software is upgradable via the RS232 serial port or via a
network using the optional Ethernet module.
• Add, customize or replace Lincoln updated welding waveforms for
every application using a lap top and Lincoln’s Wave Designer
Software.
• Simple, reliable input voltage change over.
• Auto device recognition simplifies accessory cable connections.
Robot Teach Pendant
• Select from among the hundreds of welding procedures in the
power source library from the robot’s Teach Pendant.
FANUC Robot Teach Pendant
• Search by process and wire type.
• Full access to all power source details. Examples include:
control loop gains, machine calibration, arc statistics,
unfiltered feedback signals.
• Access to power source diagnostic such as fault/alarm
status/details.
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[2]
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A CLOSER LOOK
Key Controls
1.
2.
3.
4.
1
2
3
Thermal Light
Status Light
On/Off Switch
Optional Communication Module Status Light
(Device Net or Ethernet)
4
Power Wave 455M and 455M/STT Robotic Front Panel.
1. Communication Interface Module DeviceNet or Ethernet
1
Power Wave 455M and 455M/STT Robotic Front Panel.
1
3
2
4
1. Devicenet Receptacle (optional)
2. ArcLink Receptacle
3. RS-232 Diagnostic Receptacle
4. Work Sense Lead Receptacle
5. External Input Connector
6. STT Stud (not shown)
7. Positive Output Stud
8. CB1 (10A) 40VDC
9. 115VAC Receptacle
10. CB1 (10A) 40VDC
11. Negative Output Stud
12. Ethernet Receptacle - Not Installed (optional)
5
6
11
7
10
9
8
Front Lower Panel
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[3]
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A CLOSER LOOK
QUALITY AND RELIABILITY
• Optimal positioning in the air flow.
• 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.
• Tough PC Board - Tray Mounted,Completely Encapsulated,
Double Locked Harness Connectors,Environmentally Protected
Connectors, Electrical Silicone Grease, High current rating
• Three year warranty on parts and labor.
• Manufactured under a quality system certified to ISO 9001
requirements.
• Lincoln’s design philosophy adds an extra factor of safety in all
components and construction to maximize reliability and service.
• Open construction for preventative maintenance.
• Manufactured with the latest surface mount technology in a clean
room environment.
• Fully tested and inspected before and after assembling in the
power source.
• Thermostatically protected.
• Electronic output over-current protection.
• Electronic input over-voltage protection.
• Designed to the IEC 60974-1 standard.
• Operating Temperature Range: -20C to +40C.
• Storage Temperature Range: -40C to +40C./
• Efficient Cooling System with Industrial Motor with sealed bearings and metal fan blade.
• Double Insulation on main transformer.
• Tinned and soldered lugs on all high power leads to eliminate
mechanical/electrical connection problems.
• Double varnish coating for extra environmental protection
• Shielded Heavy Duty Input Contactor in tightly sealed environmental enclosure.
• Electrical connections coated with insulating compound for long
term reliability in harsh environments.
• Lincoln inverters are subjected to environmental testing which
consist of operating the equipment in an environmental chamber.
under extreme conditions of temperature and humidity.
• Large capacity heatsinks insure lower temperatures for longer
component life.
• Optimal positioning in the air flow.
• Large capacity heatsinks insure lower temperatures for longer
component life
• Automotive grade sleeves protect leads from abrasion.
• Mechanical testing including vibration and drop testing is performed
• In depth temperature testing is performed to insure that all components are running within allowable range.
• Standards - IEC 60974-1, NEMA EW 3, CSANRTL/C, C TICK,
CE.
• Environmental rating IP21-S.
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[4]
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A CLOSER LOOK
INTERFACE OPTIONS
Arc LInk
• ArcLink is an open protocol designed specifically for the arc welding industry. It addresses industry specific requirements.
• ArcLink is a CAN based network with a 40V supply.
• ArcLink is used for low-level connections such as the power supply and wire feeder where reliable and deterministic operation is
essential.
DeviceNet
• The DeviceNetTM network is a low-level network that provides
connections between simple industrial devices (such as sensors
and actuators) and higher-level devices (such as PLC controllers
and computers).
Ethernet
• Data may be passed to wide area network (10 baseT, IEEE 802.3
Compliant). Monitor/control all equipment from a single desktop
computer.
Hard Automation
• Standardized PLC connections enable engineers to connect
welding systems to other automation devices. Sample application
templates make it easy to implement typical control features.
Serial
• All Lincoln digital equipment is configured with a serial interface.
• All software services are accessible.
• RS 232 serial interfaces are simple and inexpensive.
Analog
• Analog/Discrete Inputs/Outputs for trigger/level controls plus
feedbacks. Front Panel and/or Observer required as well as the
DeviceNet Interface Module
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[5]
www.lincolnelectric.com
PAGE TITLE
Seamless Integration
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[6]
www.lincolnelectric.com
RECOMMENDED OPTIONS
WIRE FEEDER OPTION
GENERAL OPTIONS CONT.
Power Feed 10R
Description.
Order K1780-2
Wave Designer Pro Software
Description.
Order K1705-2
GENERAL OPTIONS
Dual Cylinder
Platform Undercarriage
Description.
Order K
DeviceNet Interface Module
Description.
Order K2206-1
Cool Arc 40 Water Cooler
Description.
Order K
Ethernet Interface Module
Description.
Order K2207-1
Analog Interface Module
Description.
Order K
Wave Designer Software
Description
Order K1705-1
Power Wave 455M Robotic and Power Wave 455M/STT Robotic
[7]
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POWER WAVE 455M ROBOTIC & POWER WAVE 455M/STT ROBOTIC ORDER FORM
PRODUCT DESCRIPTION
ORDER NUMBER
QUANTITY
POWER WAVE 455M ROBOTIC
POWER WAVE 455M/STT ROBOTIC
K2262-1
K2263-1
RECOMMENDED WIRE FEEDER
Power Wave 10R
K1780-2
RECOMMENDED GENERAL OPTIONS
DeviceNet Interface Module
Ethernet Interface Module
Analog Interface Module (requires DeviceNet)
Coolarc 40 Water Cooler
Wave Designer Software
Wave Designer Pro Software
K2206-1
K2207-1
Contact Lincoln Automation at 216.383.2667
Kxxxx
K1705-1
K1705-2
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 responsive 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