Lincoln Electric IM691 User Manual

IM691

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POWER WAVE 455/R (CE)

For use with machines having Code Numbers:

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.

10677

™

December, 2000

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

ISO 9001

Designed and Manufactured Under a

Quality Program Certified by
ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

ANSI RAB

QMS

IEC 974-1

Œ

OPERATOR’S MANUAL

Copyright © 2001 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.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.

___________________________________________________

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.

POWER WAVE 455/R (CE)

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.

Mar ‘95

ii

SAFETY

ii

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 Items 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 with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

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

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

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

to

Mar ‘95

POWER WAVE 455/R (CE)

iii

SAFETY

iii

WELDING 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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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
1235 Jefferson Davis Highway, Arlington, VA 22202.

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.

Mar ‘95

POWER WAVE 455/R (CE)

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

POWER WAVE 455/R (CE)

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

vv

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

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

CAUTION

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

TABLE OF CONTENTS

Page

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

Technical Specifications - Power Wave 455/R (CE)..............................................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-2

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

Input Voltage Change Over Procedure..................................................................A-3

Welding with Multiple Power Waves......................................................................A-4

Electrode and Work Cable Connections................................................................A-5

Negative Electrode Polarity ..................................................................................A-5

Voltage Sensing at the Work Piece .......................................................................A-6

Power Wave / Power Feed Wire Feeder Interconnections....................................A-7

Control Cable Specifications ...........................................................................A-7

External I/O Connector....................................................................................A-7

High Speed Gear Box .....................................................................................A-8

Dip Switch Settings and Locations.................................................................A-9

Control Board Dip Switch ................................................................................A-9

Feed Head Board Dip Switch..........................................................................A-9

Devicenet/Gateway Board Dip Switch, Bank (S2) ..........................................A-9

________________________________________________________________________

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

Safety Precuations.................................................................................................B-1

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

General Description...............................................................................................B-3

Recommended Processes and Equipment ...........................................................B-3

Required Equipment..............................................................................................B-3

Limitations..............................................................................................................B-3

Duty Cycle and Time Period..................................................................................B-3

Case Front Controls ........................................................................................B-4

Design Features and Advantages...................................................................B-4

Constant Voltage Welding...............................................................................B-5

Pulse Welding .................................................................................................B-6

STT Welding ...................................................................................................B-7

________________________________________________________________________

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

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

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

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

________________________________________________________________________

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

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

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

________________________________________________________________________

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

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

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

Troubleshooting Guide.............................................................................E-3 thru E-5

________________________________________________________________________

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

Connector Pin Definitions ...........................................................................Section F-2

Connection Diagrams...........................................................................Section F-3, F-4

Dimension Print............................................................................................Section F-5

________________________________________________________________________

Parts Lists ....................................................................................................P375 Series

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455/R CE (K1761-3)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

OUTPUT CONDITIONS

INPUT

CURRENT

IDLE

POWER

POWER FACTOR
@ RATED OUPUT

@ RATED OUPUT

A-1

EFFICIENCY

380V - 50/60HZ.
380V - 50/60HZ.
415V - 50/60HZ.
415V - 50/60HZ.

OPEN

CIRCUIT

VOLTAGE

75 VDC

CURRENT

RANGE

PROCESS CURRENT RANGES (DC)

400A@36V.100%

500A@40V. 60%

400A@36V.100%

500A@40V. 60%

5 - 570

MIG/MAG

FCAW

SMAW

Pulse

PULSE

FREQUENCY

0.15 - 1000 Hz

STT

36
48
33
44

OUTPUT

PULSE

VOLTAGE

RANGE

5 - 55 VDC

400 Watts

Max.

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC.

-

3.3 SEC.

.89 MIN.

STT PARAMETERS

PEAK & BACK-

GROUND CURRENT

40-325 AMPS

CURRENT

50-570 Amps
40-570 Amps
30-570 Amps

5-750 Amps

40-325 Amps

88%

AUXILIARY POWER

(CIRCUIT BREAKER

PROTECTED)

40 VDC AT

10 AMPS

220 VAC AT

5 AMPS

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE /

FREQUENCY

380-50 HZ
415-50 HZ

HEIGHT

26.10 in
663 mm

OPERATING TEMPERATURE RANGE

AMPS/

DUTY

CYCLE

400/100%
400/100%

-20°C to +40°C

INPUT AMPERE

RATING ON

NAMEPLATE

36
33

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG[IEC] SIZES

(MM2)

8 (10)
8 (10)

PHYSICAL DIMENSIONS

WIDTH

19.86 in
505 mm

DEPTH

32.88 in
835 mm

TEMPERATURE RANGES

STORAGE TEMPERATURE RANGE

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG[IEC] SIZES

(MM2)

10 (6)
10 (6)

-40°C to +40°C

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

40
40

WEIGHT

256 lbs.

116 kg.

POWER WAVE 455/R (CE)

A-2

SAFETY PRECAUTIONS

INSTALLATION

LIFTING

A-2

Read this entire installation section before you
start installation.

WARNING

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.

Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.

STACKING

Power Wave machines can be stacked to a maximum
of 3 high.

CAUTION

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

Locate the Power Wave away from radio controlled
machinery.

CAUTION

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 above code 10500 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)

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.

INPUT CONNECTION

WARNING

Only a qualified electrician should connect 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
on the following page.

POWER WAVE 455/R (CE)

A-3

W / L3

V / L2

U / L1

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA

S24190

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

INPUT SUPPLY CONNECTION DIAGRAM

INSTALLATION

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

A-3

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to
do so will result in damage to the machine.

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 recommend-

ed 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

INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)

Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this con­nection to a different input voltage, see the diagram
located on the inside of the input access door. If the
main reconnect switch or link position is placed in the
wrong position, the welder will not produce output
power.

“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.

If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in a
position higher than the applied line voltage, the
welder may not come on at all. If the Auxiliary (A) lead
is placed in a position lower than the applied line volt­age, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this
occurs, turn off the input voltage, properly connect the
(A) lead, reset the breakers, and try again.

POWER WAVE 455/R (CE)

A-4

INSTALLATION

WELDING WITH MULTIPLE POWER
WAVES

A-4

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves.

CAUTION

Special care must be taken when more than one
Power Wave is 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.

FIGURE A.2

TWO POWER WAVES

When these parameters are identical, the pulsing fre­quency will be the same, helping to stabilize the arcs.

Every welding gun requires a seperate shielding gas
regulator for proper flow rate and shielding 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.)

POWERWAVE

-

POWERWAVE

+

-

+

Travel

Direction

Connect All Work
Sense Leads at the End
of the Joint

Connect All Welding
Work Leads at the
Beginning of the Joint

POWER WAVE 455/R (CE)

A-5

INSTALLATION

ELECTRODE AND WORK CABLE
CONNECTIONS

Connect a work lead of sufficient size and length (Per
Table 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 or wire feeder. Avoid
excessive lengths and do not coil excess cable. Do
not tightly bundle the electrode and work cables
together.
Use K1796 Coaxial welding cables wherever possible.
(See Section F-4 Connection Diagram).
Minimum work and electrode cables sizes are as follows:

TABLE 1

(Current (60% Duty Cycle)

400 Amps 2/0 (67 mm2)
500 Amps 3/0 (85 mm2)
600 Amps 3/0 (85 mm2)

When using an inverter type power source like the
Power Waves, use the largest welding (electrode and
ground) cables that are practical. At least 2/0 copper
wire - even if the average output current would not
normally require it.

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)

CAUTION

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.

-----------------------------------------------------------------------­Most welding applications run with the electrode being
positive (+). For those applications, connect one end
of the electrode cable to 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 using the stud, lockwasher,
and nut provided on 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.

A-5

When welding with the STT process, use the positive
output connection labeled (STT) for STT welding. (If
desired, other welding modes can be used on this
stud; however, their average output current will be lim­ited to 325 amps.) For non-STT processes, use the
positive output connection labeled (Power Wave), so
that the full output range of the machine is available.

CAUTION

Do not connect the STT and Power Wave stud
together. Paralleling the studs will bypass STT cir­cuitry and severely deteriorate STT welding perfor­mance. (See Section F-3 Connection Diagram)

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

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as
in some Innershield applications, reverse 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
switch 7 must be set to ON on the Wire Feed Head PC
Board. The default setting of the switch is OFF to rep­resent positive electrode polarity.
Set the Negative Polarity switch on Wire Feed Head
PC board as follows:

WARNING

• 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 wire feed head board is on the right
side of the power source. Locate the 8­position DIP switch and look for switch 7
of the DIP switch.

4. Using a pencil or other small object, slide
the switch right to the ON position for
negative electrode polarity. Conversely,
slide the switch left to the OFF position
for positive electrode polarity.

123456 78

O

N

CAUTION

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

POWER WAVE 455/R (CE)

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

A-6

INSTALLATION

A-6

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 volt­age apparent at the studs of the welder. Voltage
sense leads improve the accuracy of the arc condi­tions and can have a dramatic effect on performance.

CAUTION

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

-----------------------------------------------------------------------­Do not tightly bundle the work sense lead to the work
lead.
The sense leads connect to the Power Wave at the
four pin connector located underneath the output stud
cover. Lead 67 senses electrode voltage. Lead 21
senses work voltage.
Enable the voltage sense leads as follows:

TABLE 2

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional
GMAW-P
FCAW 67 lead required 21 lead optional
STT 67 lead required 21 lead required
GTAW
SAW 67 lead required 21 lead optional
* The electrode voltage 67 sense lead is integral to the

control cable to the wire feeder.

67 lead required 21 lead optional

Voltage sense at studs Voltage sense at studs

Work Voltage Sensing

The Power Waves are shipped from the factory with
the work sense lead enabled.

For processes requiring work voltage sensing, con­nect the (21) work voltage sense lead from the Power
Wave to the work. Attach the sense lead to the work
as close to the weld as practical. Enable the work volt­age sensing in the Power Wave as follows:

WARNING

• 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 left to the ON position if the work sense lead
is present.

123456 78

O

N

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

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead must be connected at the wire
feeder.

POWER WAVE 455/R (CE)

A-7

INSTALLATION

A-7

POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS

Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
robotic Power Waves is located under the spring
loaded output cover, near the bottom of the case front.
The control cable is keyed and polarized to prevent
improper connection.

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.

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. On machines which carry the CE mark, output
connections are made via Twist-Mate receptacles,
that are also located beneath the spring loaded output
cover at the bottom of the case front.

EXTERNAL I/O CONNECTOR

The Power Wave is equipped with a port for making
simple input signal connections. The port is divided
into three groups: Trigger group, Cold Inch Group and
Shutdown Group. Because the Power Wave is a
‘slave’ on the DeviceNet network, the Trigger and
Cold Inch Groups are disabled when the
DeviceNet/Gateway is active.

The shutdown group is always enabled. Shutdown 2
is used for signaling low flow in the water cooler.
Unused shutdowns must be jumpered. Machines from
the factory come with the shutdowns already
jumpered. (See Figure A.3)

FIGURE A.3

A work lead must be run from the negative (-) power
source output connection to the work piece. The work
piece connection must be firm and secure, especially
if pulse welding is planned.

CAUTION

Excessive voltage drops at the work piece con­nection often result in unsatisfactory pulse weld­ing performance.

CONTROL CABLE SPECIFICATIONS

It 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.

CAUTION

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

-----------------------------------------------------------------------­Lincoln control cables are copper 22 conductor cable
in a SO-type rubber jacket.

Trigger Input

+15 VDC for Trigger Group

1

2

A

B

4 Step Input

Dual Procedure Input

4

3

Cold Inch Forward

+15 VDC for Cold Inch Group

78

6

5

D

E

C

Gas Purge Input

Cold Inch Reverse

+15 for shutdown group

910

G

F

Shutdown1 input

Shutdown2 input

11

12

H

I

Reserved for future use

POWER WAVE 455/R (CE)

A-8

INSTALLATION

HIGH SPEED GEAR BOX

Changing the ratio requires a gear change and a PC
board switch change. The Power Feed Wire Feeders
are shipped with both high speed and a low speed
gears. As shipped from the factory, the low speed
(high torque) gear is installed on the feeder. For iden­tification purposes, the low speed (high torque) gear
has 20 teeth and is 1.1 inches in diameter. The high
speed gear has 30 teeth and is 1.6 inches in diame­ter.

A-8

6. Remove the small gear from the output shaft.
Lightly cover the output shaft with engine oil or
equivalent. Install gear onto output shaft and secure
with flat washer, lock washer, and Phillips head
screw which were previously removed.

7. Tighten the screw on lower right face of feed plate.

8. Re-attach feed plate to wire feeder if removed in
Step 2.

WARNING

• 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. Pull open the Pressure Door.

3. Remove the Phillips head screw retaining the pinion
gear to be changed and remove the gear. If the
gear is not easily accessible or difficult to remove,
remove the feed plate from the gearbox.

To remove feed plate:

• Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is
accessed from the bottom of the feed plate. It is the
screw which is perpendicular to the feeding direc­tion.

• Loosen the retaining screw, which is also accessed
from bottom of feeder, using a 3/16" Allen wrench.
Continue to loosen the screw until the feed plate
can be easily pulled off of the wire feeder.

9. Feed plate will be rotated out-of-position due to the
gear change. Adjust the angle of the feed plate per
the instructions above.

10. Set the High/Low switch code on Wire Drive PC

board as follows:

• Turn off power to the power source at the discon-

nect switch.

• Remove the front cover from the power source.

• The wire feed head board is on the right

side of the power source. Locate the 8­position DIP switch and look for position
8 of the DIP switch.

• Using a pencil or other small object,

slide the switch right to the OFF posi­tion, when the low speed gear is
installed. Conversely, slide the switch
left to the ON position when the high
speed gear is installed.

• Replace the cover and screws. The PC board will

“read” the switch at power up, automatically

adjusting all control parameters for the speed
range selected.

123456 78

O

N

4. Loosen, but do not remove, the screw on the lower
right face of the feed plate with a 3/16" Allen
wrench.

5. Remove the screw on the left face of the feed plate.
If changing from high speed (larger gear) to low
speed (smaller gear), line the lower hole on the left
face of the feed plate with the threads on the
clamping collar. Line the upper hole with the
threads to install larger gear for high speed feeder.
If feed plate does not rotate to allow holes to line
up, further loosen the screw on right face of feed
plate.

POWER WAVE 455/R (CE)

A-9

C

Left

Right

INSTALLATION

A-9

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.

ontrol Board

Feed Head Board

Bank S1

Bank S2

FEED HEAD BOARD DIP SWITCH:

switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use

switch 7 = negative polarity switch

switch 7

off positive
on negative

switch 8 = high speed gear

switch 8

off low speed gear
on high speed gear

electrode polarity

wire drive gear

DEVICENET/GATEWAY BOARD DIP SWITCH,BANK
(S2):

switch 1,2 = configure the baud rate for DeviceNET

Prior to S24958-6 software

switch 1 switch 2 baud rate

off off ------­on off 125K
off on 250K
on on 500

DeviceNet/Gateway Boa rd

CONTROL BOARD DIP SWITCH:

switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = reserved for future use
switch 4 = reserved for future use
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8 = work sense lead

switch 8

off work sense lead not connected
on work sense lead connected

work sense lead

S24958-6 and later software

switch 1 switch 2 baud rate

off off 125K
off on 250K
on off 500K

on on 500K
programmable value. Consult local Lincoln
Technical representative

switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = reserved for future use
switch 8 = reserved for future use

POWER WAVE 455/R (CE)

B-1

OPERATION

SAFETY PRECUATIONS

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

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when
feeding with gun trigger, the electrode
and drive mechanism are always elec­trically energized and could remain
energized several seconds after the

welding ceases.

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

B-1

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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.

POWER WAVE 455/R (CE)

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

B-2

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

U

U

U

SMAW

GMAW

FCAW

GTAW

OPEN CIRCUIT

0

1

2

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

I

1

I

2

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

POWER WAVE 455/R (CE)

B-3

OPERATION

B-3

GENERAL DESCRIPTION

The Power Wave power source is designed to be a
part of a modular, multi-process welding system.
Depending on configuration, it can support constant
current, constant voltage, Surface Tension Transfer
and pulse welding modes.

The Power Wave power source is designed to be
used with the family of Power Feed wire feeders,
operating as a system. Each component in the system
has special circuitry to "talk with" the other system
components, so each component (power source, wire
feeder, electrical accessories) knows what the other is
doing at all times. The components communicate
using Arc-Link protocol.

Robotic systems can communicate with other industri­al machines via DeviceNET protocol. The result is a
highly intrigated and flexible welding cell.

GENERAL DESCRIPTION - POWER WAVE 455/R
(CE)

The POWER WAVE 455/R (CE) is a high perfor­mance, digitally controlled inverter welding power
source capable of complex, high-speed waveform
control. Properly equipped, it can support the GMAW,
GMAW-P, FCAW, GTAW and STT processes. It car­ries an output rating of either 500 amps @ 40 volts
(60% duty cycle); or 400 amps @ 36 volts (100% duty
cycle), depending on input voltage and frequency. The
Surface Tension transfer process (STT) is supported
at currents up to 325 amps, at 100% duty cycle.

If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED EQUIPMENT

• Automatic Operation

All welding programs and procedures are set through
software for the robotic Power Waves. FANUC
robots equipped with RJ-3 controllers may communi­cate directly to the Power Wave. Other pieces of
equipment such as PLC’s or computers can commu­nicate to the Power Wave using DeviceNET. All wire
welding processes require a robotic Power Feed wire
feeder.

REQUIRED EQUIPMENT

• PF-10/R Wire Feeder, K1780-1

• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100

• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 10 ft), K1804-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14
pin, 18 in), K1805-1

• Control Cables (for use on FANUC robot arm, 22 pin to 14
pin, 18 in), K1804-2

LIMITATIONS

• The POWER WAVE 455/R (CE) is not suitable for

SMAW, CAC-A or other processes not listed.

• Power Waves are not to be used in outdoor environ-

ments.

• Only Arc-Link Power Feed wire feeders and user

interfaces may be used. Other Lincoln wire feeders
or non-Lincoln wire feeders cannot be used.

DUTY CYCLE AND TIME PERIOD

The Power Feed wire feeders are capable of welding
at a 100% duty cycle (continuous welding). The power
source will be the limiting factor in determining system
duty cycle capability. Note that the duty cycle is based
upon a ten minute period. A 60% duty cycle repre­sents 6 minutes of welding and 4 minutes of idling in a
ten minute period.

RECOMMENDED PROCESSES

The POWER WAVE 455/R (CE) can be set up in a
number of configurations, some requiring optional
equipment or welding programs. Each machine is fac­tory preprogrammed with multiple welding procedures,
typically including GMAW, GMAW-P, FCAW, GTAW
and STT for a variety of materials, including mild steel,
stainless steel, cored wires, and aluminum. The STT
process supports mild steel and stainless steel weld­ing.

The POWER WAVE 455/R (CE) is recommended only
for automatic or mechanized applications such as

POWER WAVE 455/R (CE)

B-4

OPERATION

CASE FRONT CONTROLS

All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure A.4)

1. POWER SWITCH: Controls input power to the
Power Wave.

2. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated, per table 3.

NOTE: The robotic Power Waves’ status light will
flash green, and sometimes red and green, for up to
one minute when the machine is first turned on. This
is a normal situation as the machine goes through a
self test at power up.

TABLE 3

Light

Condition

Steady Green

Blinking
Green

System OK. Power source communicating nor­mally with wire feeder and its components.

Normal for first 1-10 seconds after power is
turned on.

Meaning

B-4

3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper­ature situation occurs. Output is disabled until the
machine cools down. When cool, the light goes out
and output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.

10 AMP AUXILIARY POWER CIRCUIT BREAKER:

5.
Protects 115 volt AC case front receptacle
auxiliary supply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. 5-PIN ARC LINK S1

8. 5-PIN DEVICENET CONNECTOR S5

9. I / O CONNECTOR

10. NEGATIVE STUD

11. ROBOTIC CONNECTOR

12. STT STUD

Alternating
Green and
Red

Steady Red

6

POWERWAVE

7

8

S5

-

10

Non-recoverable system fault. Must turn
power source off, find source of error, and
turn power back on to reset. See
Troubleshooting Section.

See Troubleshooting Section.

FIGURE A.4

2

3

1

11

S6

+

13

STUD

12

13. POSITIVE STUD

14. AUXILUARY OUTPUT

DESIGN FEATURES AND ADVANTAGES

• Designed to the IEC 974-1 Standard.

• Power Wave 455 multiple process output ranges:

5 - 570 amps

• Easy access for input connections. Connections

are simple strip and clamp (no lugs required).

• F.A.N. (Fan As Needed). Cooling fan runs only

when necessary (above Code 10500 only, and all
STT machines).

• Modular construction for easy servicing.

• Thermostatically protected.

• Electronic over-current protection.

• Input over-voltage protection.

• Utilizes digital signal processing and microproces-

sor control.

• Simple, reliable input voltage change over.

• All system components communicate and transfer

information.

• Auto device recognition simplifies accessory cable

connections.

9

14

54

Case Front Layout

Power Wave 455/R (CE Version)

POWER WAVE 455/R (CE)

B-5

OPERATION

CONSTANT VOLTAGE WELDING

For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft­ware at the factory. The preprogrammed voltage is the
best average voltage for a given wire feed speed.
With synergic programs, when the wire feed speed
changes the Power Wave will automatically adjust the
voltage correspondingly.

Wave control adjusts the inductance of the wave­shape. (This adjustment is often referred to as "pinch".
Inductance is inversely proportional pinch.) Increasing
wave control greater than 0 results in a harsher, cold­er arc while decreasing the wave control to less than 0
provides a softer, hotter arc. (See Figure A.5)

FIGURE A.5

B-5

Current

Time

Wave Control +10.0

ave Control 0.00

ave Control -10.0

POWER WAVE 455/R (CE)

B-6

PULSE WELDING

OPERATION

B-6

Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes
impractical, and instead the arc length is set by
adjusting "trim".

Trim adjusts the arc length and ranges from 0.50 to

1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.

Most pulse welding programs are syngeric. As the
wire feed speed is adjusted, the Power Wave will
automatically recalculate the waveform parameters to
maintain similar arc properties.

FIGURE A.6

The Power Wave utilizes "adaptive control" to
compensate for changes in electrical stick-out while
welding. (Electrical stick-out is the distance from the
contact tip to the work piece.) The Power Wave
waveforms are optimized for a 0.75" (19mm) stick-out.
The adaptive behavior supports a range of stickouts
from 0.50" (13mm) to 1.25" (32mm). At very low or
high wire feed speeds, the adaptive range may be
less due to reaching physical limitations of the welding
process.

Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave control
values less than 0 decrease the pulse frequency while
increasing the background current, for a soft arc good
for out-of-position welding. (See Figure A.6)

Current

Time

Wave Control -10.0

Wave Control 0.0

Wave Control +10.0

POWER WAVE 455/R (CE)

B-7

W

STT WELDING

OPERATION

B-7

The pictures illustrate the waveshape of current for
the process. They are not drawn to scale, and are
intended only for the purpose of showing how the
variables effect the waveform.

FIGURE A.7

Current

Time

Trim in the STT mode adjusts the tailout and background
portion of the waveform. Trim values greater than 1.0
add more energy to the weld and make the weld puddle
hotter; trim values less than 1.0 reduce energy to weld
A nominal value of 1.0 will work for most applications.
(See Figure A.7)

rim 1.50

rim 1.00

Trim 0.50

For most programs, peak current is adjusted by wave
control values. A value of +10.0 maximizes the peak
current, while a wave control of -10.0 minimizes peak
current. In general, the peak current is proportional
torch arc length. (See Figure A.8)

FIGURE A.8

Current

Wave Control +10.0

Wave Control 0.0

ave Control -10.0

Time

POWER WAVE 455/R (CE)

C-1

ACCESSORIES

C-1

OPTIONAL EQUIPMENT

FACTORY INSTALLED

There are no factory installed options available for the
Power Wave 455/R (CE).

FIELD INSTALLED

• Gas Guard Regulator (K659-1)

The Gas Guard regulator is available as an optional
accessory for Power Feed Robotic wire drive unit.
Install the 5/8-18 male outlet on the regulator to the
proper 5/8-18 female gas inlet on the back panel of
the wire drive. Secure fitting with flow adjuster key at

top.

* Voltage Sense Leads (K940-10, -25 or -50)

The voltage sense leads connect at the front of the
machine. (See Section A-6 for use and Section F-3
Connection Diagram).

• Power Wave Water Cooler (K1767-1)*

(See Section F-3 Connection Diagram)
The K1767-1 is the recommended water cooler for
the Power Waves. Incorporated into the cooler is an
automatic flow sensor to detect low coolant flow. In
the event of a low flow condition, a fault signal is
sent to the Power Wave and welding output auto­matically stops to protect the torch.

The water coolers are designed to cool only one
welding gun and should be not used to cool multiple
guns or other devices.

Water cooler manufacturers often specify additives
to the coolant such as fungicides or alkalides. Follow
manufacturers recommendations to achieve proper
operation and long lifetimes without clogging.

* Water Flow Sensor (K1536-1)

Water cooled guns can be damaged very quickly if
they are used even momentarily without water flow­ing. Recommend practice is to install a water flow
sensor such as 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.

• Dual Cylinder Undercarriage, K1570-1*

• Coaxial welding Cable, K1796

(See Section F-4 Connection Diagram)

*The Dual Cylinder Undercarriage, K1570-1 is not

compatible in combination with the Power Wave
Water Cooler K1767-1.

POWER WAVE 455/R (CE)

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only Qualified personnel should
perform this maintenance.

• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.

D-1

POWER WAVE 455/R (CE)

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE 455/R (CE)

E-2

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

E-2

The Status LED on the power source case front
can help diagnose problems down to the system
component (power source, wire feeder, wire drive,
etc.) level. If, for any reason, the system does not
appear to be working properly, always check the

Status LED is solid green (no blinking).
Status LED is blinking green.

Status LED is blinking red and green.

color of the Status LED, and refer to the following
chart to help you determine which system compo­nent (power source, wire feeder, wire drive, etc.)
may be faulty. Replace the components identified
as potentially faulty with known good components,
and the system should operate normally.

System operating normally.

1. Normal condition for the first few seconds after the
power is turned on.

1. If the Thermal LED is also lit, see “Yellow Thermal
LED Lit” in the Main Troubleshooting Chart.

2. Input voltage is too high or too low. Make certain
that input voltage is proper, according to the
Rating Plate located on the rear of the machine.

3. Power source is having trouble communicating
with wire feeder or its components. Turn machine
off. Disconnect control cable from the Wire
Feeder Receptacle. Turn power back on. If
Status LED then blinks green, the problem is with
the wire feeder. If light is still blinking red and
green, contact an authorized Lincoln Field Service
facility.

Status LED is blinking red.

1. Error code display. Contact an authroized Lincoln
Field Service Shop.

POWER WAVE 455/R (CE)

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Major physical or electrical damage
is evident when the sheet metal
covers are removed.

Input fuses keep blowing, or input
breaker keeps tripping.

Machine will not power up (no
lights, no fan, etc.)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local authorized
Lincoln Electric Field Service
facility for technical assis­tance.

1. Make certain that fuses or
breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.

2. Welding procedure is drawing
too much output current, or
duty cycle is too high.
Reduce output current, duty
cycle, or both.

3. There is internal damage to
the power source. Contact an
authorized Lincoln Electric
Service facility.

1. Make certain that the Power
Switch (SW1) is in the “ON”
position.

2. Circuit breaker CB4 (in recon­nect area) may have opened.
Reset. Also, check input volt­age selection, below.

3. Input voltage selection made
improperly. Power down,
check input voltage reconnect
according to diagram on
reconnect cover.

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE 455/R (CE)

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Thermal LED is lit.

Machine won’t weld, can’t get any
output. (CR1 will not pull in.)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Fan thermostat has opened.
Check for proper fan opera­tion. (Fan should run whenev­er main power is on.) Check
for material blocking intake or
exhaust louvers, or for exces­sive dirt clogging cooing chan­nels in machine.

2. Secondary rectifier thermostat
has opened. After machine
has cooled, reduce load, duty
cycle, or both. Check for
material blocking intake or
exhaust louvers.

1. Input voltage is too low or too
high. Make certain that input
voltage is proper, according to
the Rating Plate located on
the rear of the machine.

2. If the Thermal LED is also lit,
see “Yellow Thermal LED is
Lit” section.

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE 455/R (CE)

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Machine often “noodle welds” (out­put is limited to approximately 100
amps) when running a particular
procedure

Machine won’t produce full output.

For no apparent reason, the weld-

ing characteristics have changed.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Secondary current limit has
been exceeded, and the
machine has phased back to
protect itself. Adjust proce­dure or reduce load to lower
current draw from the
machine.

1. Input voltage may be too low,
limiting output capability of the
power source. Make certain
that the input voltage is prop­er, according to the Rating
Plate located on the rear of
the machine.

2. Input may be “single phased”.
Make certain the input voltage
is proper on all three input
lines.

1. Check for proper Wire Feed
Speed setting. In CV MIG
and FCAW modes, check for
proper Voltage setting. In the
MIG/MAG pulse modes,
check the Trim setting. These
controls are on the wire feed­er.

2. Check for proper shielding
gas mix and flow.

3. Check for loose or faulty weld
cables and cable connections.

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,

contact your local Lincoln
Authorized Field Service Facility.

Auxiliary receptacle is “dead”— no
auxiliary voltage .

1. Circuit breaker CB2 (on case
front) may have opened.
Reset.

2. Circuit breaker CB4 (in recon­nect area) may have opened.
Reset.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE 455/R (CE)

F-1

TM

POWER WAVE 455 / R WIRING DIAGRAM

LEFT SIDE OF MACHINE

TO TP6

AUXILI ARY TRA N SF O RM E R #3

CONTROL BOARD

TO J9

202

TO SW1

TO AUX#1

X3B

(115V)

(18V)

345

TO

J10CH

TO3WJ7

3R

SUPPLY BOARD

DIGITAL POWER

BOARD

FEED HEAD

2

BOARD

GATEWAY

DEVI CE N ET

TO

CB1

J47

TO TP 3

DIAGRAMS

H1A
1

(200 -208)

P52

TO

OPERATION.

STT SNUBBER

400V

289A

289E288E

2

+

TO TP3

206A

+

TO A SYSTE M GROUND PER

NATIONAL ELECTRICAL CODE.

AUXILIARY TRANSFORMER #2

S4

CB2

CAPACITOR BANK

289C

R3

STT

(TOP)

A

TO RECONNECT PANEL

ELECTRODE

8

J87

J1,J6,J7

J10,J7 0,J85

1
7

1
6

J4,J13,

J43,J71

11
5

J3,

J61,J86

4

J8,

J84

J47,J6 0

11

3

1

J14,J40J42,

J50,J75,J83

J1VS,J9,J10CH,

2

J82

J2,J5,J11,

J41,J46,J72

J73,J76,J81

1

J10,J2VS

J74

COMPONENT VALUES:

G=GREEN

B=BLACK

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537

RIGHT SIDE OF MACHINE

C10

20uF

400V

288E

289D

288D

288C

288B

289C

289B

289F

R4

2

2

RESISTOR BANK

STT SNUBBE R

288F

L3A

TO CONTACTOR

LOAD LINE

H1D

TO J61

SW1

POWER

WATER

COOLER

3

2

RECEPTACLE

352

TO

MAIN TRANSFORMER

19C

TO REC ONNECT SWIT CH

20C

12
11
16

15

14

LEFT)

F3

F3

D3

TO D5

TO C8

TO C1 0

287

289A

289B

J10

4

5

1

3

2

6

4R

4W

346

345

7

1

2

9

10

J20

J21

J60

238

405

604

503

406

5054506

10

J6

TO

ELECTRODE

WORK

TP3

S7

X

W

REAR OF MACHINE

TO

SWITCH

RECONNECT

TO

CR1

J6

AUX #1

231

238

232

X3

601

604

1

8

765

432

J60

INPUT BOARD

TO J6, J10B

2.7 10W

404

TO

852

.022

7

1

WORK

TP6

RECEPTACLE

853

3

TO

SWITCH

BD #2

PRI

RIGHT)

(BOTTOM

SEC

800V

TO

ROBO T

9

10

J87

1W

3456789

2

STT

TO

854

855

42156

RIGHT)

(BOTTOM

D2

POWER BD

RECTIFIER

IFACE

1112131415

TO

SSR

J10CH

1B

32

31

J85

856

857

858

8

7

17

F2

F2

C3

TO

X2

POS

AC

AC

16

2B

2W

10

J7

SELECT

VOLTAGE SENSE

TO

CB2

J81

859

860

861

862

9

11

10

12

15

EMITTER

6

5

348

403

15

1411121316

S4

110V

851

12 PIN

CONNECTOR

AUX. #1

D6TOJ11

BOARD

AC

1

POS

POS

AC

2

INPUT

AC

3

NEG

RECTIFIER

NEG

TO J61

TO

CR1

SW1

CB4

T1T2612

T3

H1D

1

3

2

567

4

8

9

10

J61

18

17

6

506

5

505

4

504

503

3
2

518
514

1

+

J50

#2

SWITCH BOARD

11

13

TO

BD #1

SWITCH

PRI

(TOP

RIGHT)

SEC

(TOP

2.7 10W

TP7

X1

NEG

S1

J47

TO

TO

SSR, J10 CHOPPER BD.

3R3R

3W

4R

1415111213

16

TO

J9

J85

511

67

512

1

5

2

4

3

J1

TO

202A

855

855A

RIGHT SIDE

RIGHT)

F1

F1

.022

800V

+

-

D1

287

TO J46

POS

POS

POS

POWER BD RECT

NEG

NEG

NEG

C3

+

J73

WORK

ELECTRODE

TO J1 VOLTAG E SENSE

TO

P90

P91

212

213

813

811

216

202

206

211

812

816

1

456

3

2

7

8

2

3

J8

TO

S1

S6

67A

67B

D6

216

DIODE

+40VDC

J2

S4

TO

J81

WORK

ELECTRODE

206A

31

33

R

1

50

CB2

BREAKER

10A CIRCUIT

L1

T1

T2

T3

CR1

601

TO J60

19D

C5

20D

15 16

DIOD E D5

STT SNUBBER

TO C10

288B

TO C8

288A

U

G

L1A

TO SW1

L2

V

TO SUPPLY LIN ES

L3

W

L3A

TO SW1

X4

TO AUX #1

TO

CB3

AUX #1

H4A

H2A

H5A

H3A

H6A

2

6

3

4

5

P50

TO

H5

H4H3H1

H2

H6

(220-230)

(440 -460)

(380-415)

(550 -575)

SWITCH

RECONNECT

R

W

(115V)

1

4

6

(220V)

1

2

P51

33

352

32

350

TO

MAIN

TRANSFORMER

NOTES:

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

ALIGNS WITH BLACK LEAD OF LED SOCKET.

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT

OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR

VOLTAGE. CONNECTION SHOWN IS FOR 380-460V

++

234

1

P90

813

812

811

816

TO J8

TRANSDUCER

STT CURRENT

C8

20uF

TO D5

288C

TO

J40,J50

S2

TO

67

J9

J43

21A

418

5141273

274

154

153

5182414

1

1

5

621

2

3

4

J11

J10A

J10B

TO

J83

886

880

AC

AC

N.A.

THERMAL LED (Y)

TO J7

N.A.

STATUS LED (R/G)

TO J7

2W

1W

2B

1B

288A

J88

289D

R2

288D

TO TP6

C6

.05/600V

TP5

C2

.05/600V

TP2

TO R1

206

TO J9

FRONT OF MACHINE

S8

200-208V

220-230V

380-415V

10A

CB3

BREAKER

CIRCUIT

CB4

CB3

TO J61

H1A

612B

612A

TO CB4

TO AUX #2

FAN

6A

BREAKER

CIRCUIT

X5

X5A

444

TO AUX#1

TO AUX#3

H1

612

612A

TO SOLID STATE RELAY

TO AUX #1

440-460V

TO SW 1

'A

N.C.

H2

H3

TO AUX #1

RECONNECT

PANEL

N.B.

19C

TO

SWI T CH B D #1

TO

SWITCH BD #1

1

350

'

H5

H4

20C

NEG

TO

INPUT RECT

REAR OF MACHINE

THIS A R EA VIEWED FROM

19D

RECONNECT SWITCH

TO

TRANSDUCER

1

212

267

11

846

6

567

J3

X3B

12

TO AUX#3

TO J5

847

8

7

TO J6,J10B

MAIN

TRANSFORMER

OUTPUT

224

224A

DC BUSS

852

851

1

2

8

91234

10

743

123

98765

10

SWI T CH B D #2

14

13

406
405
404
403
418
414

16

LEFT SIDE

220

RECT

RECT

POS

POS

TO C3

1

2

BOARD

J46

856

855

854

853

6

5

3

4

228

267

266

268

5

S1

TO

TO

J81

53

54

800

840

741

1

2

4

J72

CB4

TOX3AUX #2X5RECONNECT PANEL

H3A

H2A

H5A

H6A

H4A

H4

H2

H3

H5

H6

H5

H6

(550-575)

W

(51V )

AUXILIARY TRANSFORMER #1

X1

X2

TO FAN

X5A

346

H1

TO FAN

H1

(380-415)

H4

(440-460)

(200-208)H2(220-230)

X3A

U

N

W H3

(24V)

X3

TO POWER BD.

RECTIFIER

224A

TO SOLI D STATE RELAY

R

(115V)

X4

TO

J60

CR1

CHOKE

THERMTO RECT

291

CURRENT

THERM

++

3

2

4-

3
+

413

X3A

1

TP4

2

444

SOLID

STATE

RELAY

TO

J47

TO

J4

223

221

225

477

476

222

227

475

1

1

3

65432

2

J41

J42

TO

TO

J11

J47

J72

741

743

154

153

500

540

800

840

4

3

4

3

2

1

2

1

J82

J81

9137

865

13

12

14

10

J1

1

5

987

6

4

3

2

10

J70

4

P91

TO AUX#1

L1

216

211

TO FAN

478

1

4

TO

541

539

1

2

15

16

12

11

213

MAIN CHOKE

TO J8

TOJ4J11

2733228

274

226

266

268

765

4

2

8

9

10

J43

J6

D6

S6

TO

845

844

843

842

841

880

886

522

521

6

5

3

4

5

3

4

1

2

J84

J83

S3

TO

251

253

254

1

1

2

3

4

234

J2

1

4

3

2

16

15

14

J71

20D

POS

TO

INPUT RECT

TO

SWI T CH B D #2

6
5
4
3
2

1

BD #2

TO

SWITCH

PRI

(TOP

LEFT)

SEC

(TOP

LEFT)

291

THERM

TO

CHOKE

THERM

5002

511

NEG

NEG

3

4

S7

TO

857

861

860

8599

858

8

7

10

J85

TO

J42

J43

226

221

227

8

7

6

9

J4

3

1

2

4

J74

J73

+

C4

J40

#1

11 12

SWITCH BOARD

12

18

TO

BD #1

SWITCH

PRI

LEFT)

(BOTTOM

SEC

F4

D4

J41

CB1

TO

503

5404

4755

4766

J47

TO

J1VS

511

512

862

141311

223

222

225

12

10

11

S5

TO

892

893

1

234

J75

(BOTTOM

F4

.022

800V

2.7 10W

J88

4777

4788

BD

COLLECTOR

CHOPPER

6

5

348

1

2

151216

J86

TO

THERM

THERM

TO

224

220

504

231

232

1

1

3

4

2

3

56879

2

4

J5

891

894

6

5

34W2

1

4

J76

L2

J2

J9

21A

842

C

4

SENSE

843

D

TO

254

253

1

4

5

2

3

S3

RECEPTACLE

3 CONDUCTOR

TWISTED/SHIELDED

SHIELD GROUND TO CASE

845

846

847

539

541

67B

I

E

F

JKL

H

G

251

7

6

20

RS232

CONNECTOR

521

NPRSTUV

M

BUSS BD

TO

L2

50

52

CB1

BREAKER

10A CIRCUIT

522

855A

TO

J13

J47

CB1

J1VS

67A

54E53

C

B11A

S1

WIRE

C1

.05/600V

202A

TO R1

-

WORK

FEEDER

TO

J75

TP1

892

893

894

1

423

DEVICENET

S5

CONNECTOR

CAN_H

+24V

+24V GND

S1

TO

TO

52

D

L2

1

2513

S2

RECEPTACLE

891

5

S6

CAN_L

VOLTAGE

841

844

ROBOTIC/

A

B

WIREDRIVE

INTERFACE

RECEPTACLE

F-1

16

B-U F

G3792

9
14

8
12

710

6

(VIEWED FROM COMPONENT SIDE OF BOARD)

8

564

3 4

CONNECTOR CAVITY NUMBERING SEQUENCE

2

RESISTORS=O HMS/WATTS

CAPA CITOR S=MFD/ VOLT S

W=WHITE

U=BLUE

R=RED

N=BROWN

289E

L1A

TO CONTACTOR

612B

TO CB3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

POWER WAVE 455/R (CE)

F-2

DIAGRAMS

F-2

TABLE 1 INTERFACE CONNECTOR S6

Pin Lead # Function

A 841 +15vdc T ach voltage
B 844 Tach common
C 842 Tach 1A differential signal
D 843 Tach 1B differential signal
E 845 Tach 2A differential signal
F 846 Tach 2B differential signal
G 847 Single Tach Input
H Reserved for future use
I 67B Voltage sense lead
J 539 Motor "+"
K 541 Motor "-"
L Reserved for future use
M Reserved for future use
N 521 +40vdc for solenoid
P 522 Solenoid input
R Reserved for future use
S Reserved for future use

T 855A Shield ground to case

U Reserved for future use

V Reserved for future use

W Reserved for future use
X Reserved for future use

TABLE 2 WIRE FEEDER RECEPTACLE S1

Pin Lead # Function

A 53 Arclink L
B 54 Arclink H
C 67A Electrode Voltage Sense
D 52 Ground(0v)
E 51 +40vdc

TABLE 3 VOLTAGE SENSE RECEPTACLE S2

TABLE 4 RS232 CONNECTOR 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

TABLE 5 DEVICENET CONNECTOR S5

Pin Lead # Function

2 894 +24vdc Devicenet
3 893 Commom Devicenet+
4 892 Devicenet H
5 891 Devicenet L

TABLE 6 EXTERNAL I/O S7

Pin Lead # Function

1 851 +15vdc for Trigger group
2 852 Trigger input
3 853 Dual procedure input
4 854 4 Step input
5 855 +15vdc for cold inch group
6 856 cold inch forward
7 857 cold inch reverse
8 858 gas purge input
9 859 +15vdc for shutdown group
10 860 shutdown1 input
11 861 shutdown2 input
12 862 input B

Pin Lead # Function

3 21A Work Voltage Sense

POWER WAVE 455/R (CE)

F-3

- +

WORK
SENSE
LEAD
K940

WATERCOOLED
TORCH

ELECTRODE LEAD

CONTROL CABLE K1795

WATER COOLER
POWER
CONNECTION

SHIELDING GA S

TO SHIELDING GAS DEVICENET CA BLE

TO PLC/CONTROLLER

DIAGRAMS

Hard Automation, Electrode Positive, STT
Configuration

DEVICENET CABLE
TO PLC/CONTROLLER

CONTROL CABLE K1795

F-3

ELECTRODE LEAD

WATER COOLER
POWER CONNECTION

POWER WAVE 455/R (CE)

F-4

K1796 COAXIAL WELD CABLE

User supplied
work lead

User supplied
electrode lead

-

+

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE OR
K1804-2 AND ANY K1795 CONTROL CABLE

User supplied
work lead

User s uppl ied
elect rod e lea d

CONTROL CABLE K1805- 1

DIAGRAMS

Robotic Set Up, Electrode Positive, CV/Pulse
Configuration

F-4

POWER WAVE 455/R (CE)

F-5

DIAGRAMS

32.88

11-97

M18241

F-5

DIMENSION PRINT - POWER WAVE 455

19.90

19.16

9.48 14.62

22.63

26.10

23.51

23.12

12.35

19.00

POWER WAVE 455/R (CE)

NOTES

POWER WAVE 455/R (CE)

NOTES

POWER WAVE 455/R (CE)

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com