Lincoln Electric Welding System 455M Robotic User Manual

AUTOMATED SOLUTIONS  
Power Wave® 455M Robotic &  
Power Wave® 455M/STT Robotic  
The Next Generation . . .  
The Power Wave 455M Robotic is a high performance, digitally controlled inverter power  
source designed for robotic, hard automation and semiautomatic applications. It is designed  
to be part of a modular, multi-process welding system that can be arranged in a variety of  
ways for optimum, customized performance and easy maintenance. 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. Available as a standard model or with Lincoln’s STT® process  
for applications in which heat input control, minimal distortion, reduced spatter and low  
fumes are essential.  
Processes  
Description  
CC  
CV  
50  
Hz  
3
DC  
MIG  
Pulsed  
STT  
Flux-Cored  
Output  
Input  
60  
PHASE  
Recommended General Options  
Advantage Lincoln  
• 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.  
DeviceNet Interface Module, Ethernet Interface Module, Analog  
Interface Module, Wave Designer™ Software, Dual Cylinder  
Platform Undercarriage, CoolArc® 40 Water Cooler  
Recommended Wire Feeder  
• Modular design enables robotic, hard automation and semiauto-  
matic applications using a single machine platform.  
Power Feed 10R  
Order  
• Optional communication modules provide networking capabilities  
via DeviceNet or Ethernet.  
K2262-1 Power Wave 455M Robotic  
K2263-1 Power Wave 455M/STT Robotic  
• Utilizes ArcLink™ - the leading digital communication protocol  
for welding, making it the best choice for seamless, time critical  
integration to the power source and networked equipment.  
Call the Lincoln Electric Automation Division at 216.383.2667 for  
more information.  
• Software based controls can be upgraded as new features  
become available.  
• Process and production monitoring with access to real time  
(500Hz) feedback such as arc current, 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.  
• A Power Wave inverter operates at a high efficiency (88-90%)  
with a 95% minimum power factor(1) and is capable of operat-  
ing from a universal input voltage (208 to 575 volts).  
• Power Wave 455M/STT features Lincoln’s Surface Tension  
Transfer® Process, which controls heat input for great penetra-  
tion and reduced spatter and fumes.  
TECHNICAL SPECIFICATIONS  
Product  
Name  
Product  
Number  
Input  
Voltage  
Rated Output  
Current/Voltage/Duty Cycle  
Input current  
@Rated Output  
Output  
Range  
Dimensions  
H x W x D  
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) At rated output.  
Publication E10.90 4/03  
 
A CLOSER LOOK  
Key Controls  
5
1. Thermal Light  
1
2. Power Supply Status Light  
3. On/Off Switch  
4. Optional Communication Module Status Light  
(DeviceNet or Ethernet)  
2
3
5. Feeder Status Light  
4
Power Wave 455M Robotic and 455M/STT Robotic Front Panel.  
1. Communication Interface Module -  
DeviceNet or Ethernet/DeviceNet upgrades can  
be field installed.  
1
Power Wave 455M Robotic and 455M/STT Robotic Front Panel.  
1
2
3
4
1. Devicenet or Ethernet/DeviceNet Receptacle (optional)  
2. ArcLink Receptacle  
3. Work Sense Lead Receptacle  
4. RS-232 Diagnostic Receptacle  
5. External Input Connector  
6. STT Stud (not shown)  
5
6
7. Positive Output Stud  
8. CB1 (10A) 40VDC  
11  
7
9. 115VAC Receptacle  
10. CB1 (10A) 40VDC  
11. Negative Output Stud  
10  
8
9
Front Lower Panel  
Power Wave 455M Robotic and Power Wave 455M/STT Robotic  
[3]  
 
A CLOSER LOOK  
QUALITY AND RELIABILITY  
Design  
Safety, reliability and service-ability are built into Lincoln’s Inverter  
design.  
• Open construction for preventative maintenance and diagnostics.  
• Thermostatically protected.  
• Electronic output over-current protection and electronic input  
over-voltage protection.  
Open Construction  
Coated Electrical Connections  
• Operating Temperature Range: -20C to +40C.  
• Storage Temperature Range: -40C to +40C.  
• Double insulation and varnish on main transformer.  
• Shielded Heavy Duty Input Contactor in tightly sealed environ-  
mental enclosure.  
• Electrical connections coated with insulating compound for long  
term reliability in harsh environments.  
Automotive Grade Sleeves  
Trayed and Potted PC Board  
• Automotive grade sleeves protect leads from abrasion.  
Tough PC Boards - tray mounted, completely encapsulated,  
double locked harness connectors, environmentally protected  
connectors, electrical silicone grease, high current rating.  
• Efficient Cooling System with Industrial Motor with sealed bear-  
ings 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.  
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.  
Manufacturing & Testing  
Environmental Chamber  
• Three year warranty on parts and labor.  
• Manufactured under a quality system certified to ISO 9001  
requirements.  
WHAT IS POWER ELECTRONICS?  
• Designed to the IECEN 60974-1 standard.  
• Standards - IECEN 60974-1, NEMA EW 3, CSANRTL/C.  
• Environmental rating IP21S.  
Power electronics innovations like lightweight  
inverters and high speed chopper are common,  
but Nextweld’s power electronics provide fabrica-  
tors with a highly efficient system that are reliable  
and can adapt easily to new operations. State-of-  
the-Art Inverter technology provides high power  
efficiency, excellent welding performance and a  
lightweight, compact design. Lincoln inverters  
undergo rigorous environmental, mechanical and  
weld testing in the design/production process to  
ensure ruggedness and reliability.  
Power Wave 455M Robotic and Power Wave 455M/STT Robotic  
[4]  
 
A CLOSER LOOK  
INTERFACE OPTIONS  
• ArcLink is a digital communication protocol designed specifically  
for the arc welding industry. It integrates welding systems and  
networked components to create a flexible welding cell.  
• ArcLink is a Controlled Area Network (CAN) based network with a  
40V supply.  
ArcLink Cable Connector  
• ArcLink is used to connect the welding equipment such as the  
power supply and wire feeder together where reliable, priority-  
based operation is essential.  
• DeviceNet is a network that provides connections between simple  
industrial devices (such as sensors and actuators) and higher-level  
devices (Programmable Logic Controllers [PLC]). The Power Waves  
can be interfaced with DeviceNet using a K2206-1 DeviceNet  
interface module.  
DeviceNet Cables  
• Data is transmitted through wide area network (10 baseT, IEEE  
802.3 Compliant). Monitor/control all equipment from a single  
interfaced desktop computer. The Power Waves can be interfaced  
with Ethernet using a K2207-1 Ethernet/DeviceNet Interface  
Module.  
Ethernet Cables  
• Also includes full DeviceNet capability.  
Hard Automation - DeviceNet  
• Standardized PLC connections enable engineers to connect  
welding systems to other automation devices. Sample application  
templates make it easy to implement typical control features.  
The Power Waves require a K2206-1 or K2207-1 Interface Module.  
Serial  
Allen-Bradley Panelview 600  
All Lincoln digital equipment is configured with a serial interface.  
• All software services are accessible for maintenance.  
• RS-232 serial interfaces are inexpensive and easy to use and  
understand.  
Analog  
• This module provides Analog and Discrete Inputs/Outputs (I/O) for  
trigger controls plus feedbacks.  
RS-232 Cable  
RS-232 Port on the front lower  
panel of the machine.  
WHAT IS DIGITAL COMMUNICATIONS?  
Nextweld’s digital communications offers  
fabricators a fast, reliable, inexpensive way  
to integrate and operate equipment. Large  
amounts of data transmit reliably and accu-  
rately, and wiring costs are relatively low,  
especially when the number of devices on  
the network increase.  
Analog Interface  
Power Wave 455M Robotic and Power Wave 455M/STT Robotic  
[5]  
 
A CLOSER LOOK  
Seamless Integration  
Power Wave power sources are compatible with Ethernet and DeviceNet  
systems for seamless integration and efficiency.  
ArcLink allows welding systems and networked equipment to communi-  
cate with each other for high speed data transfer and full integration of  
systems.  
Power Wave  
Optional Modules  
Computer  
RS-232 Serial Port  
Ethernet/  
DeviceNet  
Gateway  
Module  
DeviceNet  
Gateway  
Module  
Robot Controller  
Computer  
Internet  
Robot Teach Pendant  
Power Feed 10R  
Process  
Monitoring  
Power Wave  
FANUC Robot  
PLC  
Computer  
Analog Interface  
Non-FANUC Robot  
Power Wave 455M Robotic and Power Wave 455M/STT Robotic  
[6]  
 
RECOMMENDED OPTIONS  
GENERAL OPTIONS  
GENERAL OPTIONS CONT.  
DeviceNet Interface Module  
This module provides Networking  
capabilities for Output Control,  
Weld Settings, Weld Mode  
Selection and Data Logging.  
Order K2206-1  
Dual Cylinder  
Platform Undercarriage  
Platform undercarriage for mount-  
ing two gas cylinders at rear of  
welder.  
Order K1570-1  
Ethernet/DeviceNet Interface  
Module  
Cool Arc 40 Water Cooler  
Energy-efficient long life cooler for  
water-cooled welding applications.  
Order K1813-1 for 115V  
This module provides all DeviceNet  
functionality, networking capabilities  
for Weld Development, Data  
Logging, Systems Updates,  
Diagnostics, Weld Settings and  
Weld Mode Selection.  
Order K2187-1 for 230V  
WIRE FEEDER OPTION  
Power Feed 10R  
Order K2207-1  
The Power Feed 10R is a high  
performance, digitally controlled  
wire feeder designed to be a part  
of a modular, multi-process weld-  
ing system. It is specifically  
designed to mount to a robot arm  
or to use in hard automation  
applications.  
Analog Interface Module  
This module provides Analogs  
and Discrete Inputs/Outputs (I/O)  
for trigger controls plus feedbacks.  
Contact Lincoln Automation at  
216.383.2667 for information.  
Order K1780-2  
Wave Designer Software  
This software allows you to pro-  
gram your own waveforms. Custom  
parameters include PEAK and  
BACKGROUND CURRENT,  
FREQUENCY, PULSE WIDTHS  
and others.  
Contact Lincoln Automation at  
216.383.2667 for information.  
Power Wave 455M Robotic and Power Wave 455M/STT Robotic  
[7]  
 
POWER WAVE 455M ROBOTIC & POWER WAVE 455M/STT ROBOTIC ORDER FORM  
PRODUCT DESCRIPTION  
ORDER NUMBER  
QUANTITY  
PRICE  
POWER WAVE 455M ROBOTIC  
POWER WAVE 455M/STT ROBOTIC  
K2262-1  
K2263-1  
RECOMMENDED GENERAL OPTIONS  
DeviceNet Interface Module  
K2206-1  
K2207-1  
Ethernet Interface Module  
Analog Interface Module  
Contact Lincoln Automation at 216.383.2667  
Wave Designer Software  
Contact Lincoln Automation at 216.383.2667  
Dual Cylinder Platform Undercarriage  
Cool Arc® 40 Water Cooler - 115V  
Cool Arc® 40 Water Cooler - 230V  
K1570-1  
K1813-1  
K2187-1  
RECOMMENDED WIRE FEEDER  
Power Feed 10R  
K1780-2  
TOTAL:  
C U S T O M E R A S S I S T A 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.  
THE LINCOLN ELECTRIC COMPANY  
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com  
 

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