Lincoln Electric Power Wave 455M, 12506 Operator's Manual

Operator’s Manual

Power Wave®455M

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Authorized Service and Distributor Locator:

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IM10302 | Issue D ate July-15

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

12506

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to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

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no later than the following business day.

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Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.

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 thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.

READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.

USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away
from your face.

If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.

WEAR CORRECT EYE, EAR &
BODY PROTECTION

PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare
with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an
electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State
of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a
well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to
www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting ­ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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.

1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.

1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.

3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.

3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage

between the
two can be the total of the open circuit voltage of both
welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS 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. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected
to physical damage.

• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.

FOR ELECTRICALLY
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 Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

v

i

v

i

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications - POWER WAVE®455M ...............................................A-1

Safety Precautions.................................................................................................A-2

Select Suitable Location ........................................................................................A-2

Lifting...............................................................................................................A-2

Stacking ..........................................................................................................A-2

Machine Grounding ...............................................................................................A-2

High Frequency Protection ....................................................................................A-2

Input Connection ...................................................................................................A-3

Input Fuse and Supply Wire Considerations .........................................................A-3

Electrode and Work Cable Connections................................................................A-3

Cable Inductance, and its Effects on Pulse Welding ............................................A-4

Negative Electrode Polarity ...................................................................................A-4

Voltage Sensing .................................................................................................. A-4

Power Wave

®

to Semi-automatic Power Feed®Wire Feeder Interconnections .....A-5

System Description................................................................................................A-5

Configuring the System .........................................................................................A-6

Welding with Multiple Power Waves

®

....................................................................A-8

Control Cable Specifications .................................................................................A-8

Multiple Arc Unsynchronized .................................................................................A-9

I / O Receptacle Specifications............................................................................A-10

Dip Switch Settings and Locations...............................................................A-10

Control Board Dip Switch ..............................................................................A-10

Water Flow Sensor........................................................................................A-10

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1

Graphic Symbols that appear on this machine or in this manual ..........................B-2

Definition of Welding Terms...................................................................................B-3

General Description...............................................................................................B-4

Recommended Processes and Equipment ...........................................................B-4

Required Equipment..............................................................................................B-4

Limitations..............................................................................................................B-4

Duty Cycle and Time Period..................................................................................B-4

Case Front Controls ........................................................................................B-5

Nominal Procedures........................................................................................B-6

Fringe Procedures...........................................................................................B-6

Making a Weld ................................................................................................B-6

Welding Adjustment ........................................................................................B-6

Constant Voltage Welding...............................................................................B-7

Pulse Welding .................................................................................................B-8

________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Factory Installed..............................................................................................C-1

Field Installed..................................................................................................C-1

Compatible Lincoln Equipment .......................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Calibration Specification........................................................................................D-1

________________________________________________________________________

v

ii

vii

TABLE OF CONTENTS

Page

Troubleshooting..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1

Using the Status LED to Troubleshoot System Problems .....................................E-2

Error Codes For Power Waves

®

............................................................................E-3

Troubleshooting Guide ............................................................................E-4 thru E-6

________________________________________________________________________

Wiring Diagram ............................................................................................Section F-1

Connection Diagrams ..................................................................................Section F-2

Dimension Print............................................................................................Section F-3

________________________________________________________________________

Parts List ........................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.

A-1

INSTALLATION

POWER WAVE®455M

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE®455M (K2202-7)

RATED OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

I

NPUT VOLTS­F

REQUENCY

380/415V - 50/60HZ.

INPUT

VOLTAGE /

FREQUENCY

400/50/60HZ

HEIGHT

26.10 in
663 mm

WIDTH

19.86 in
505 mm

DEPTH

32.88 in
835 mm

WEIGHT

286 lbs.

130 kg.

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

40

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

10(6)

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

8(10)

MIG/MAG

FCAW
SMAW
GTAW

Pulse

50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
15-500 Average Amps

5-750 Peak Amps

PULSE

VOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER

(CIRCUIT BREAKER PROTECTED)

40 VDC AT

10 AMPS

220VAC AT

10 AMPS

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC. -

3.3 SEC.

CURRENT

RANGE

AMPS

5 - 570A

PULSE

FREQUENCY

0.15 - 1000 Hz

INPUT

CURRENT

AMPS

4

8/44

36/33

IDLE

POWER

4

00 Watts

Max.

P

OWER FACTOR

@ RATED OUTPUT

.95 MIN.

EFFICIENCY

@RATED OUTPUT

88%

DUTY

C

YCLE

6

0% RATING

100% RATING

OPERATING TEMPERATURE RANGE

-20°C to +40°C

STORAGE TEMPERATURE RANGE

-40°C to +40°C

PROCESS CURRENT RANGE (DC) CURRENT

PROCESS OPEN CIRCUIT VOLTAGE 60% DUTY CYCLE 100% DUTY CYCLE

MIG/MAG AND FCAW 67V 500A @ 39V 400A @ 34V

SMAW 73V 485A @ 39.4V 400A @ 36V

GTAW 33V 485A @ 29.4V 400A @ 26V

LIFTING

Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
t

o lift the Power Wave

®

w

ith accessories attached to it.

STACKING

P

ower Wave

®

m

achines 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 toppling over if this precaution is not

taken.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground
terminal marked with the symbol is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.

HIGH FREQUENCY PROTECTION

This equipment is for industrial use only and it is not
intended for use in residential locations where the
electrical power is provided by the public low-voltage
supply system. There can be potential difficulties in
residential locations due to conducted as well as radi­ated radio-frequency disturbances. The EMC or RF
classification of this equipment is Class A.

Locate the Power Wave®away from radio controlled
machinery.

The normal operation of the Power Wave®may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.

SAFETY PRECAUTIONS Read this

entire installation section before you start
i

nstallation.

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

•Turn the input power OFF at the

disconnect switch or fuse box before

working on this equipment. Turn off
the input power to any other equipment connected
to the welding system at the disconnect switch or
fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave

®

grounding lug
(located inside the reconnect input access door)
to a proper safety (Earth) ground.

----------------------------------------------------------

SELECT SUITABLE LOCATION

Do not use Power Waves®in outdoor environments.
The Power Wave®power source should not be
subjected to falling water, nor should any parts of it be
submerged in water. Doing so may cause improper
operation as well as pose a safety hazard. The best
practice is to keep the machine in a dry, sheltered area.

Do not mount the POWER WAVE®455M over
combustible surfaces. Where there is a combustible
surface directly under stationary or fixed electrical
equipment, that surface shall be covered with a steel plate
at least .060" (1.6mm) thick, which shall extend not less
than 5.90" (150mm) beyond the equipment on all sides.

Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through
the case sides and bottom. Dirt, dust, or any foreign
material that can be drawn into the welder should be
kept at a minimum. Do not use air filters on the air
intake because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.

Machines are equipped with F.A.N. (fan as needed)
circuitry. The fan runs whenever the output is enabled,
whether under loaded or open circuit conditions. The
fan also runs for a period of time (approximately 5
minutes) after the output is disabled, to ensure all
components are properly cooled.

If desired, the F.A.N. feature can be disabled (causing the
fan to run whenever the power source is on). To disable
F.A.N., connect leads 444 and X3A together at the output
of the solid state fan control relay, located on the back of
the Control PC board enclosure. (See Wiring Diagram)

A-2

INSTALLATION

POWER WAVE®455M

A-2

WARNING

CAUTION

CAUTION

A-3

INSTALLATION

POWER WAVE®455M

A-3

INPUT CONNECTION

Only a qualified electrician should
c

onnect the input leads to the Power

Wave

®

. Connections should be made
in accordance with all local and
national electrical codes and the

connection diagram located on the inside of the
reconnect/input access door of the machine.
Failure to do so may result in bodily injury or
death.

-----------------------------------------------------------------------

Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1
below.

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the
recommended super lag fuse or delay type breakers
(also called “inverse time” or “thermal/magnetic” circuit
breakers). Choose an input and grounding wire size
according to local or national electrical codes. Using
fuses or circuit breakers smaller than recommended
may result in “nuisance” shut-offs from welder inrush
currents, even if the machine is not being used at high
currents.

ELECTRODE AND WORK CABLE
CONNECTIONS

Connect a work lead of sufficient size and length (Per
Table A.1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work and wire feeder. Avoid
excessive lengths and do not coil excess cable.

Minimum work and electrode cable sizes are as follows:

TABLE A.1

Current MINIMUM COPPER
(60% Duty Cycle) WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)
400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long cable lengths.
This is especially important when Pulse welding up to
350 amps.

When using inverter type power sources like the
Power Waves®, use the largest welding (electrode
and work) cables that are practical. At least 2/0 (67
mm2) copper wire - even if the average output
current would not normally require it. When
pulsing, the pulse current can reach very high
levels. Voltage drops can become excessive,
leading to poor welding characteristics, if
undersized welding cables are used.

------------------------------------------------------------------------

WARNING

FIGURE A.1 - CONNECTION DIAGRAM ON

CONNECTION/INPUT ACCESS DOOR

CAUTION

W / L3

V / L2

U / L1

use or service this equipment.

Do not touch electrically live parts.

removed.

Only qualified persons should install,

Do not operate with covers

inspecting or servicing machine.

Disconnect input power before

.

.

.

.

CR1

WARNING

ELECTRIC

SHOCK

CAN KILL

INPUT SUPPLY CONNECTION DIAGRAM

A-4

INSTALLATION

POWER WAVE®455M

A-4

CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING

For Pulse Welding processes, cable inductance will
c

ause the welding performance to degrade. For the

total welding loop length less than

50 ft.(15.24m),

traditional welding cables may be used without any
effects on welding performance. For the total welding
l

oop length greater than

50 ft.(1

5.24m), the K1796
Coaxial Welding Cables are recommended. The
welding loop length is defined as the total of electrode
cable length (A) + work cable length (B) + work length
(C) (See Figure A.3).

For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length
less than

50 ft.(15.24m). (See Figure A.4.)

Output connections on some Power Waves®are made
via 1/2-13 threaded output studs located beneath the
spring loaded output cover at the bottom of the case
front.

Most welding applications run with the electrode being
positive (+). For those applications, connect the
electrode cable between the wire feeder and the
positive (+) output stud on the power source (located
beneath the spring loaded output cover near the
bottom of the case front). Connect the other end of the
electrode cable to the wire drive feed plate. The
electrode cable lug must be against the feed plate. Be
sure the connection to the feed plate makes tight
metal-to-metal electrical contact. The electrode cable
should be sized according to the specifications given
in the work cable connections section. Connect a work
lead from the negative (-) power source output stud to
the work piece. The work piece connection must be
firm and secure, especially if pulse welding is planned.

For additional Safety information regarding the
electrode and work cable set-up, See the standard
"SAFETY INFORMATION" located in the front of the
Instruction Manuals.

Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.

------------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as
in some Innershield applications, switch the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the
positive (+) stud).

When operating with electrode polarity negative the
"Electrode Sense Polarity" DIP switch must be set to
the "Negative" position on the Wire Drive Feed Head
PC Board. The default setting of the switch is positive
electrode polarity. Consult the Power Feed®instruction
manual for further details.

VOLTAGE SENSING

The best arc performance occurs when the Power
Waves®have accurate data about the arc conditions.
Depending upon the process, inductance within the
electrode and work lead cables can influence the
apparent voltage at the studs of the welder. Voltage
sense leads improve the accuracy of the arc
conditions and can have a dramatic effect on
performance. Sense Lead Kits (K940-10, -25 or -50)
are available for this purpose.

If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
extremely high welding outputs may occur.

------------------------------------------------------------------------

The ELECTRODE sense lead (67) is built into the
control cable, and is automatically enabled for all semi­automatic processes. The WORK sense lead (21)
connects to the Power Wave®at the four pin connector
located underneath the output stud cover. By default
the WORK voltage is monitored at the output stud in
the POWER WAVE®455M. For more information on
the WORK sense lead (21), see "Work Voltage
Sensing” in the following paragraph.

All constant current processes sense the voltage at the
output studs of the POWER WAVE®455M by default.

CAUTION

CAUTION

B

A

C

FIGURE A.3

POWER
WAVE

WORK

A

C

B

POWER
WAVE

F

IGURE A.4

K1796 COAXIAL CABLE

MEASURE FROM END
OF OUTER JACKET OF
CABLE

C

A

B

WORK

SLIDING

WORK

FIGURE A.4

A-5

INSTALLATION

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.

Important: The electrode polarity must be

configured at the feed head for all semi-automatic
processes. Failure to do so may result in
extremely high welding outputs.

------------------------------------------------------------------------

POWER WAVE®TO SEMI­AUTOMATIC POWER FEED®WIRE
FEEDER INTERCONNECTIONS

The POWER WAVE®455M and semi-automatic POWER
FEED

®

family communicate via a 5 conductor control
cable (K1543). The control cable consists of two power
leads, one twisted pair for digital communication, and
one lead for voltage sensing. The cables are designed to
be connected end to end for ease of extension. The
output receptacle on the POWER WAVE

®

455M is

located beneath the spring loaded output cover at the
bottom of the case front. The input receptacle on the
Power Feed

®

is typically located at the back of the

feeder, or on the bottom of the user interface.

For convenience sake, the electrode and control cables
can be routed behind the left or right strain reliefs (under
the spring loaded output cover), and along the channels
formed into the base of the Power Wave

®

, out the back of

the channels, and then to the wire feeder.

Due to the flexibility of the platform the configuration may
vary. The following is a general description of the
system.

SYSTEM DESCRIPTION

The POWER WAVE®455M and Power Feed®M family
of products utilize a digital communication system called
ArcLink. Simply put, ArcLink allows large amounts of
information to be passed at very high speeds between
components (nodes) in the system. The system
requires only two wires for communication, and because
of its bus-like structure, the components may be
connected to the network in any order, thus simplifying
the system set-up.

Each "system" must contain only one power source.
The number of wire feeders is determined by the type
of wire feeder. Refer to the wire feeder instruction
manual for details

Enable the voltage sense leads as follows:

TABLE A.2

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional
G

MAW-P67 lead required 21 lead optional
FCAW 67 lead required 21 lead optional
GTAW

Voltage sense at studs Voltage sense at studs

GMAW

Voltage sense at studs Voltage sense at studs

S

AW 67 lead required 21 lead optional

CAC

Voltage sense at studs Voltage sense at studs

* The electrode voltage 67 sense lead is integral to

the control cable to the wire feeder.

Work Voltage Sensing
The standard POWER WAVE

®

455M’s default to the

work stud (work sense lead disabled)

For processes requiring work voltage sensing,
connect the (21) work voltage sense lead (K940) from
the Power Wave®work sense lead receptacle to the
work piece. Attach the sense lead to the work piece
as close to the weld as practical, but not in the return
current path. Enable the work voltage sensing in the
Power Wave®as follows:

• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.

• Insulate yourself from the work
and ground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

1. Turn off power to the power source at the
disconnect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side of
the power source. Locate the 8-position
DIP switch and look for switch 8 of the
DIP switch.

4. Using a pencil or other small object,
slide the switch right to the OFF
position if the work sense lead is NOT
connected. Conversely, slide the switch
to the ON position if the work sense
lead is present.

5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the
work voltage sense lead appropriately.

O

N

1 2 3 4 5 6 7 8

CAUTION

WARNING

A-6

INSTALLATION

POWER WAVE®455M

A-6

CONFIGURING THE SYSTEM

The power source will “Auto Map” the system
eliminating most of the need to set DIP switches to
configure the system.

I

f a system can not be “Auto Mapped” then the status
light on the power source will blink green fast and the
w

elder output will be disabled. If a system is not
“Auto-mappable”, then consult the instruction manual
for the accessory being used for configuration
information about DIP switch settings, or consult your
l

ocal Lincoln sales representative.

POWER WAVE

®

4

55M

ROBOT

PLC CONTROLLER

ANALOG INTERFACE

etc.

POWER WAVE®455M

POWER WAVE

®

455M

P

OWER WAVE

®

455M

FEED HEAD

SINGLE HEAD FEEDER DUAL HEAD FEEDER

SINGLE HEAD BOOM FEEDER

FH 1

PF-10R

SINGLE HEAD BOOM FEEDER

UP TO 4 FEEDERS
ALLOWED

UP TO 4 FEED HEADS
ALLOWED

WIRE
DRIVE
MODULE

A-7

INSTALLATION

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®455M

POWER WAVE®455M

POWER WAVE

®

455M

D

UAL HEAD

DUAL HEAD

ALTERNATE HARD AUTOMATIC APPLICATION
(using a UI, WD Module, and PF-10R)

COMBINATION HARD AUTOMATION APPLICATION
(w/ Semi-Auto, WD Module, and PF-10R)

DUAL HEAD BOOM FEEDER
(using two single heads)

PF-10R

FH-1

FH-2

PF-10R

WIRE
DRIVE
M

ODULE

(FH1)

WIRE
D

RIVE

M

ODULE

(FH1)

A-8

INSTALLATION

POWER WAVE®455M

A-8

WELDING WITH MULTIPLE POWER
WAVES

®

Special care must be taken when more than one
P

ower Wave

®

i

s welding simultaneously on a
single part. Arc blow and arc interference may
occur or be magnified.

------------------------------------------------------------------------

Each power source requires a work lead from the
work stud to the welding fixture. Do not combine all of
the work leads into one lead. The welding travel
directions should be in the direction moving away from
the work lead as shown below. Connect all of the work
sense leads from each power source to the work
piece at the end of the weld.

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves®. When these parameters are identical, the
pulsing frequency will be the same, helping to stabilize
the arcs.

Every welding gun requires a separate shielding gas
re gulator for prop er flow rate an d s hieldin g gas
coverage.

Do not attempt to supply shielding gas for two or more
guns from only one regulator.

If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.2)

FIGURE A.2

-

+

POWERWAVE

Connect All Work
Sense Leads at the End
of the Joint

Connect All Welding
Work Leads at the
Beginning of the Joint

Travel

Direction

-

+

POWER WAVE®

-

+

POWERWAVE

-

+

POWER WAVE®

TWO POWER WAVES

®

CONTROL CABLE SPECIFICATIONS

I

t is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave

®

/ Power Feed®system.

The use of non-standard cables, especially in
lengths greater than 25 ft.(7.62), can lead to
communication problems (system shutdowns),
poor motor acceleration (poor arc starting) and
low wire driving force (wire feeding problems).

------------------------------------------------------------------------

The K1543 series of control cables can be connected
end to end for ease of extension. Do not exceed more
than 100 feet (30.5 m) total control cable length.

CAUTION

CAUTION

A-9

INSTALLATION

POWER WAVE®455M

A-9

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

A-10

INSTALLATION

POWER WAVE®455M

A-10

I / O RECEPTACLE SPECIFICATIONS

TABLE A.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 A.4

VOLTAGE SENSE RECEPTACLE S2

PIN LEAD# FUNCTION

3 21A Work Voltage Sense

TABLE A.5

RS232 RECEPTACLE S3

PIN LEAD# FUNCTION

2 253 RS232 Receive
3 254 RS232 Transmit
4#S3 Pin5
5#S3 Pin4
6 # # S3 Pin20
20 # # S3 Pin6
7 251 RS232 Common

DIP SWITCH SETTINGS AND LOCATIONS

DIP switches on the P.C. Boards allow for custom
configuration of the Power Wave®. To access the DIP
switches:

• Turn off power at the disconnect switch.

• Remove the top four screws securing the front
access panel.

• Loosen, but do not completely remove, the bottom
two screws holding the access panel.

• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.

• Adjust the DIP switches as necessary.

• Replace the panel and screws, and restore power.

CONTROL BOARD DIP SWITCH:

switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = equipment group 1 selcted (default=off)
switch 4 = equipment group 2 selcted (default=off)
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = auto mapping
switch 8 = work sense lead

(See Figure A.6 for Dual Head Boom Feeder)

switch 7

auto mapping

off(default) auto mapping enable

on auto mapping disabled

switch 8

work sense lead

*off(default) work sense lead not connected

on work sense lead connected

*

The POWER WAVE®455M does not come supplied with a
work sense lead.

WATER FLOW SENSOR

Water cooled guns can be damaged very quickly if
they are used even momentarily without water flowing.
A water flow sensor is recommended for those water
coolers that do not have an integral flow sensor.
Recommended practice is to install a water flow
sensor such as K1536-1 on the water return line of the
torch. When fully integrated into the welding system,
the sensor will prevent welding if no water flow is
present.

CONTROL BOARD (DIP Switch Location)

FIGURE A.5

FIGURE A.6

B-1

OPERATION

B-1

POWER WAVE®455M

SAFETY PRECAUTIONS

Read this entire section of operating instructions
before operating the machine.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

• Do not operate with covers, panels or guards
removed or open.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire
or explosion.

• Keep flammable material away.

• Do not weld on containers that have
held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the
beginning of this manual.

WARNING

B-2

OPERATION

B-2

POWER WAVE®455M

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

GMAW

FCAW

GTAW

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

U

0

U

1

U

2

I

1

I

2

SMAW

B-3

OPERATION

B-3

POWER WAVE®455M

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDINGMODES

• A Non-synergic welding mode requires all welding

p

rocess 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
correct voltage and amperage based on the wire
feed speed (WFS) set by the operator.

455M

•455 Modular

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

GMAW

• Gas Metal Arc welding

GMAW-P

• Gas Metal Arc welding-(Pulse Arc)

GMAW-S

• Gas Metal Arc welding-(Short Circuiting Arc)

GTAW

• Gas Tungsten Arc welding

GTAW-P

• Gas Tungsten Arc welding-(Pulse Arc)

PAW

• Plasma Arc welding

SMAW

•

Shielded Metal Arc welding

SW

• Stud Arc Welding

SAW

• Submerged Arc Welding

S

AW-S

• Submerged Arc Welding-(Series)

FCAW

• Flux Core Arc Welding

CAC

• Carbon Arc Cutting