Lincoln Electric IM714 User Manual

IM714

R

RETURN TO MAIN MENU

POWER WAVE 455

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.

10833

™

February, 2005

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

IEC 60974-1

OPERATOR’S MANUAL

Copyright © 2005 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

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.

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.

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.

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

Mar ‘95

to

POWER WAVE 455

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

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.

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
zones où l’on pique le laitier.

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

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

TABLE OF CONTENTS

Page

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

Technical Specifications - POWER WAVE 455 ....................................................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

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-6

System Set-Up.........................................................................................A-7 thru A-9

Welding with Multiple Power Waves....................................................................A-10

Control Cable Specifications................................................................................A-10

I / O Receptacle Specifications............................................................................A-11

Dip Switch Settings and Locations...............................................................A-11

Control Board Dip Switch ..............................................................................A-11

Power Wave Water cooler (Field Installed) .........................................................A-11

Water Flow Sensor ..............................................................................................A-11

________________________________________________________________________

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

Safety Precautions.................................................................................................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

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

Nominal Procedures........................................................................................B-5

Fringe Procedures...........................................................................................B-5

Making a Weld ................................................................................................B-5

Welding Adjustment ........................................................................................B-5

Welding Mode .................................................................................................B-6

Arc Control ......................................................................................................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

________________________________________________________________________

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

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

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

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

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

________________________________________________________________________

vi

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

Troubleshooting Guide.............................................................................E-3 thru E-7

________________________________________________________________________

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

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

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

________________________________________________________________________

Parts Lists ....................................................................................................P394 Series

________________________________________________________________________

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455 (K1517-6)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

OUTPUT

CONDITIONS

INPUT

CURRENT

AMPS

IDLE

POWER

POWER FACTOR

@ RATED OUPUT

A-1

EFFICIENCY

@ RATED

OUPUT

208/230/460/575V - 60HZ.

200/220/440/575V - 50HZ.

450A@38V.100%

570A@43V. 60%

400A@36V.100%

500A@40V. 60%

58/53/25/22
82/78/37/31

49/45/23/18
67/61/31/25

400 Watts

Max.

.95 MIN.

OUTPUT

OPEN

CIRCUIT

VOLTAGE

75 VDC

PROCESS CURRENT RANGES (DC)

CURRENT

RANGE

Amps

5 - 570

PULSE

FREQUENCY

0.15 - 1000 Hz

MIG/MAG

FCAW

SMAW

Pulse

PULSE

VOLTAGE

RANGE

5 - 55 VDC

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC. -

3.3 SEC.

AUXILIARY POWER

(CIRCUIT BREAKER PROTECTED)

40 VDC AT

10 AMPS

115VAC AT

10 AMPS

CURRENT

50-570 Average Amps
40-570 Average Amps
30-570 Average Amps
5-750 Peak Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT

VOLTAGE /

FREQUENCY

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

GROUND WIRE IN CON-

TYPE 75°C

DUIT AWG[IEC] SIZES

(MM2)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

88%

208/50/60HZ
230/50/60HZ
460/50/60HZ
575/50/60HZ

4(25)
4(25)
8(10)
10(6)

PHYSICAL DIMENSIONS

HEIGHT

26.10 in
663 mm

WIDTH

19.86 in
505 mm

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-20°C to +40°C

6(16)
6(16)
10(6)
10(6)

POWER WAVE 455

110
100

50
40

DEPTH

32.88 in
835 mm

STORAGE TEMPERATURE RANGE

-40°C to +40°C

WEIGHT

286 lbs.

130 kg.

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

Do not mount the Power Wave 455 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 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

A-3

INSTALLATION

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

A-3

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

.

Disconnect input power before
inspecting or servicing machine.

.

Do not operate with covers
removed.

ELECTRIC
SHOCK
CAN KILL

.

Do not touch electrically live parts.

.

Only qualified persons should install,
use or service this equipment.

VOLTAGE

=

220-230V

200-208V

220-230V

440-460V

550-575V

'A'

W / L 3

V / L2
U / L1

200-208V

220-230V

440-460V
550-575V

CR1

= 440-460V

VOLTAGE

VOLTAGEVOLTAGE

'A'

=

200-208V

200-208V

220-230V

440-460V

550-575V

= 550-575V

200-208V

220-230V

440-460V

550-575V

'A'

'A'

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

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

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 con-

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 and wire feeder. Avoid
excessive lengths and do not coil excess cable.

Minimum work and electrode cables sizes are as follows:

TABLE A.1

(Current (60% Duty Cycle)

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

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)

nection 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.

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.

S25198

XA

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

CAUTION

When using inverter type power sources 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. 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.

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

A-4

INSTALLATION

CABLE INDUCTANCE, AND ITS EFFECTS
ON PULSE WELDING

For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 feet, traditional
welding cables may be used without any effects on
welding performance. For the total welding loop length
greater than 50 feet, 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.2).

FIGURE A.2

POWER
WAVE

A

C

A-4

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.

CAUTION

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, reverse the output
connections at the power source (electrode cable to
the negative (-) stud, and work cable to the positive (+)
stud).

WORK

B

For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length
less than 50 feet. (See Figure A.3.)

POWER
WAVE

K1796 COAXIAL CABLE

MEASURE FROM END
OF OUTER JACKET OF
CABLE

FIGURE A.3

A

WORK

C

B

SLIDING GROUND

A

B

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.

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

C

The best arc performance occurs when the
PowerWaves 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.
Sense Lead Kits (K940 series) are available for this
purpose.

CAUTION

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 455. 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-455 by default.

POWER WAVE 455

A-5

INSTALLATION

A-5

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
GMAW-P
FCAW 67 lead required 21 lead optional
GTAW
GMAW

SAW 67 lead required 21 lead optional

CAC-C
* The electrode voltage 67 sense lead is integral to

the control cable to the wire feeder.

In extremely sensitive applications requiring voltage
sense leads, it may be necessary to route the control
cable (67 lead) and the work voltage sense lead (21
lead) away from the electrode and work welding
cables. For more information regarding the placement
of voltage sense leads, see the section entitled
"Welding with Multiple Power Waves."

Work Voltage Sensing

The standard Power Wave 455’s default to the work
stud (work sense lead disabled)

67 lead required 21 lead optional

Voltage sense at studs Voltage sense at studs
Voltage sense at studs Voltage sense at studs

Voltage sense at studs Voltage sense at studs

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

Electrode Voltage Sensing

Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead is internal to the control cable to
the wire feeder and always connected when a wire
feeder is present.

CAUTION

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 SEMI-AUTOMAT­IC POWER FEED WIRE FEEDER
INTERCONNECTIONS

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:

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.

The Power Wave 455 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
455 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. For specific configuration information, consult
the semi-automatic Power Feed instruction manual.

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.

123456 78

O

N

POWER WAVE 455

A-6

INSTALLATION

A-6

SYSTEM DESCRIPTION

The Power Wave 455 and Power Feed 10/11 family of
products utilize a digital communication system called
Linc-Net. Simply put, Linc-Net 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 power source may be connected to a maximum
of four feeder groups. Each group containing one user
interface (UI), and up to seven Feed Heads (FH). SEE
FIGURE A.4. The UI controls all of the FH’s of that
group. The UI’s and FH’s are assigned to groups by
setting a code on the DIP switches mounted on their
individual control boards. For example all of the FH’s
to be controlled by a given UI must have their "Group
ID" switches set to the same group number as the UI.
In addition, each FH must be assigned a separate FH
number within that group. See the system set-up sec­tion for further details.

From a network perspective, each component in the
system is considered a separate node, regardless of
its physical location. For example, even though a UI
and FH may be physically mounted together, they are
still viewed as separate pieces (nodes) by the net­work, and can only communicate via Linc-Net. The
Linc-Net connection is generally made external
through the Linc-Net Control Cable, but can also be
made internally, as with the PF-10 bench model feed­er.

The most common Linc-Net configuration (called a
simple system) consists of one power source, one
user interface and one feeder. Under these circum­stances the group and feed head ID DIP switches are
ignored and the system will function regardless of
their position. The same is true for the minimum sys­tem consisting of a power source and one UI
(Example: a stick welding system).

System Model

FIGURE A.4

POWER WAVE 455

A-7

INSTALLATION

SYSTEM SET-UP

Basic Rules

• Each group is required to have one user interface.
No group may have more than one user interface.

• Each group can have up to seven Feed Heads.
Exception: Group 3 is limited to a maximum of six
Feed Heads.

• Each system has only one power source. For net­work purposes, the PS belongs to Group 3, which is
why group 3 is only allowed 6 feed heads in addition
it’s user interface.

• No two feed heads can have identical Group and
Feed Head numbers.

• Group and Feed Head ID numbers must be set on
the appropriate dips witches at each node. Consult
the PF-10/11 Instruction Manual for specific details
regarding dip switch settings.

A-7

Simple System

• Feed head “0” not allowed. Exception: Simple sys-
tem ignores all ID numbers, therefore “FH0” will
function.

• Each node must be connected to the Linc-Net com­munication network. The order of connection is not
important, as each node is identified by it’s unique
Group and Feed Head ID number as defined on it’s
dips witches. See Figures A.4 thru A.8.

FIGURE A.5

Group and Feed
Head ID numbers are
ignored in a simple
system.

POWER WAVE 455

A-8

Multiple Group System

INSTALLATION

A-8

FIGURE A.6

No “FH0 Allowed!

Single Group Multi-Head System

FIGURE A.7

No “FH0 Allowed!
The Dual Head

option allows the abil­ity to maintain 2 sets
of procedures. If
more then 2 heads
are used, odd #’s use
FH1 settings, even
#’s use FH2 settings.

POWER WAVE 455

A-9

Single Group Multi-Head System (Alternate Method)

INSTALLATION

FIGURE A.8

A-9

No “FH0 Allowed!
When a standard

User Interface is
used in a group with
multiple Feed Heads,
all of the Feed Heads
use a single set of
procedures.

POWER WAVE 455

A-10

INSTALLATION

A-10

WELDING WITH MULTIPLE 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.

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.

Multiple Arc Sense Lead and Work Lead Placement
Guidelines.

(See Figure A.9)

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(7.6m), 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.

Every welding gun requires a separate 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.

FIGURE A.9

TWO POWER WAVES

POWER WAVE

POWERWAVE

-

-

+

+

Travel

Direction

POWER WAVE

POWERWAVE

-

-

+

+

Connect All Welding
Work Leads at the
Beginning of the Joint

POWER WAVE 455

Connect All Work
Sense Leads at the End
of the Joint

A-11

INSTALLATION

A-11

I / O RECEPTACLE SPECIFICATIONS

TABLE 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 4

VOLTAGE SENSE RECEPTACLE S2

PIN LEAD# FUNCTION

3 21A Work Voltage Sense

TABLE 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

switch 8

off work sense lead not connected
on work sense lead connected

work sense lead
(See Voltage Sensing

Installation Section )

FIGURE A.10

CONTROL BOARD (DIP Switch Location)

POWER WAVE WATER COOLER
(FIELD INSTALLED OPTION)

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 = 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

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. If proper­ly configured, a low flow condition will cause a fault
signal to be sent to the PF-10/11 feed head, and weld­ing output will automatically stop 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 life times without clogging.

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.

POWER WAVE 455

B-1

OPERATION

SAFETY PRECAUTIONS

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

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

B-3

OPERATION

B-3

GENERAL DESCRIPTION

The Power Wave semi-automatic 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, and pulse
welding modes.

The Power Wave power source is designed to be
used with the semi automatic 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, user interface) knows what the
other is doing at all times. These components commu­nicate with Linc-Net.

The Power Wave 455 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, SMAW, GTAW, and CAC-A processes. It car­ries an output rating of either 450 amps, 38 volts; or
400 amps, 36 volts (both at 100% duty cycle),
depending on input voltage and frequency.

RECOMMENDED EQUIPMENT

Power Wave 455 – Semi-Automatic Operation

Semi Automatic Power Waves can only be used with
Linc-Net compatible Power Feed semi-automatic wire
feeders. In addition, the Power Feed semi-automatic
wire feeders may require optional equipment to
access certain weld modes in the Power Wave. Other
models of Lincoln feeders, or any models of non­Lincoln wire feeders, cannot be used.

All welding programs and procedures are selected
through the Power Feed semi-automatic user inter­face

REQUIRED EQUIPMENT

Any Linc-Net compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF-10, PF-10X2, PF-11).

LIMITATIONS

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED PROCESSES

The Power Wave 455 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
CAC-A for a variety of materials, including mild steel,
stainless steel, cored wires, and aluminum.

The Power Wave 455 is recommended for semi-auto­matic welding, and may also be suitable for basic hard
automation applications.

• This Power Wave is not recommended for processes
other than those listed.

WARNING

• The Power Waves are not to be used in outdoor
environments.

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

• Only Linc-Net compatible Power Feed semi-auto­matic wire feeders and users interfaces may be
used. Other Lincoln wire feeders or non-Lincoln wire
feeders cannot be used.

• Power Wave 455 Output Limitations
The Power Wave 455 will support maximum average
output current of 570 Amps (@ 60% duty cycle) on
the standard Power Wave stud.

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.

POWER WAVE 455

B-4

OPERATION

CASE FRONT CONTROLS

All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)

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 Power Wave 455 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

Alternating
Green and
Red

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

Occurs during a reset, and indicates the
Power Wave 455 is mapping (identifying)
each component in the system. Normal for
first 1-10 seconds after power is turned on,
or if the system configuration is changed
during operation

Non-recoverable system fault. If the PS
Status light is flashing any combination of
red and green, errors are present in the
Power Wave 455. Read the error code

before the machine is turned off.

Meaning

B-4

FIGURE B.1

2

3

1

7

8

9

4

11

5

6

10

CASE FRONT LAYOUT

POWER WAVE 455 (NORTH AMERICAN)

4.

10 AMP AUXILIARY POWER CIRCUIT BREAKER:
Protects 115 volt AC case front receptacle
auxiliary supply.

5. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.

6. LEAD CONNECTOR S2 (SENSE LEAD)

7. DIAGNOSTIC CONNECTOR (RS-232)

Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with
a long pause between digits. If more than
one code is present, the codes will be sepa­rated by a green light.

To clear the error, turn power source off,
and back on to reset. See Troubleshooting
Section.

Steady Red

Blinking Red

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

Non recoverable hardware fault. Generally
indicates nothing is connected to the Power
Wave 455 wire feeder receptacle. See
Trouble Shooting Section.

Not applicable.

8. WIRE FEEDER RECEPTACLE (S1 5-PIN)

9. NEGATIVE STUD

10. POSITIVE STUD

11. AUXILIARY OUTPUT

POWER WAVE 455

B-5

OPERATION

B-5

NOMINAL PROCEDURES

The Power Wave is designed to operate with 3/4"
electrode stick-out for CV and Pulse processes.

FRINGE PROCEDURES

Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.

MAKING A WELD

WARNING

The serviceability of a product or structure utiliz­ing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable
for all applications, and the build/user is and must
be solely responsible for welding program selec­tion.

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

The steps for operating the Power Wave will vary
depending upon the options installed in the user inter­face (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.

First, consider the desired welding process and the
part to be welded. Choose an electrode material,
diameter, shielding gas and process (GMAW, GMAW­P, etc.)

Second, find the program in the welding software that
best matches the desired welding process. The stan­dard software shipped with the Power Waves encom­passes a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales repre­sentative.

WELDING ADJUSTMENTS

All adjustments are made on the system component
known as the User Interface (Control Box), which con­tains the switches, knobs, and digital displays neces­sary to control both the Power Wave and a Power
Feed wire feeder. Typically, the Control Box is sup­plied as part of the wire feeder. It can be mounted
directly on the wire feeder itself, the front of the power
source, or mounted separately, as might be done in a
welding boom installation.

Because the Control Box can be configured with many
different options, your system may not have all of the
following adjustments. Regardless of availability, all
controls are described below. For further information,
consult the Power Feed wire feeder instruction manu­al.

• WFS / AMPS:
In synergic welding modes (synergic CV, pulse
GMAW) WFS (wire feed speed) is the dominant con­trol parameter, controlling all other variables. The user
adjusts WFS according to factors such as weld size,
penetration requirements, heat input, etc. The Power
Wave then uses the WFS setting to adjust its output
characteristics (output voltage, output current) accord­ing to pre-programmed settings contained in the
Power Wave. In non-synergic modes, the WFS con­trol behaves more like a conventional CV power
source where WFS and voltage are independent
adjustments. Therefore to maintain the arc character­istics, the operator must adjust the voltage to compen­sate for any changes made to the WFS.

In constant current modes (stick, TIG) this control
adjusts the output current, in amps.

• VOLTS / TRIM:

In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only)
the user can change the Trim setting to adjust the arc
length. It is adjustable from 0.500 to 1.500. A Trim set­ting of 1.000 is a good starting point for most condi­tions.

To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicat­ed digitally via the control cable.

POWER WAVE 455

B-6

• WELDING MODE

May be selected by name (CV/MIG, CC/Stick Crisp,
Gouge, etc.) or by a mode number (10, 24, 71, etc.)
depending on the Control Box options. Selecting a
welding mode determines the output characteristics of
the Power Wave power source. For a more complete
description of the welding modes available in the
Power Wave, see the explanation below.

• ARC CONTROL

Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0 to
+10.0, with a nominal setting of 00.0 (The nominal set­ting of 00.0 may be displayed as OFF on some Power
Feed wire feeder control panels). See the Welding
Mode descriptions, below, for detailed explanations of
how the Arc Control affects each mode.

OPERATION

B-6

POWER WAVE 455

B-7

OPERATION

CONSTANT VOLTAGE WELDING

Synergic CV:

For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft­ware at the factory. The nominal preprogrammed volt­age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automati­cally adjusts the voltage level correspondingly to
maintain similar arc characteristics throughout the
WFS range.

Non Synergic CV:

This type of CV mode behaves more like a conven­tional CV power source. Voltage and WFS are inde­pendent adjustments. Therefore to maintain the arc
characteristics, the operator must adjust the voltage to
compensate for any changes made to the WFS.

FIGURE B.2

B-7

All CV Modes:

Arc Control, often referred to as wave control, adjusts
the inductance of the wave shape. The wave control
adjustment is similar to the "pinch" function in that it is
inversely proportional to inductance. Therefore,
increasing wave control greater than 0.0 results in a
harsher, colder arc while decreasing the wave control
to less than 0.0 provides a softer, hotter arc.
(See Figure B.2)

Current

CURRENT WAVE FORM (CV)

Wave Control +10.0

ave Control 0.00

ave Control -10.0

Time

POWER WAVE 455

B-8

OPERATION

B-8

PULSE WELDING

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 synergic. As the
wire feed speed is adjusted, the Power Wave will
automatically recalculate the waveform parameters to
maintain similar arc properties.

FIGURE B.3

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 wave
forms 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.

Arc Control, often referred to as wave control, in pulse
programs usually adjusts the focus or shape of the
arc. Wave control values greater than 0.0 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

0.0 decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-posi­tion welding.
(See Figure B.3)

Current

Time

CURRENT WAVE FORM (PULSE)

Wave Control -10.0

Wave Control 0.0

Wave Control +10.0

POWER WAVE 455

C-1

ACCESSORIES

OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED

Work Voltage Sense Lead Kit, K940
Dual Cylinder Undercarriage, K1570-1. *
Gas Guard Regulator, K659-1
Coaxial welding Cable, K1796
PowerWave Water Cooler, K1767-1 *
Water Flow Sensor, K1536-1

*The Dual Cylinder Undercarriage, K1570-1 is not
compatible in combination with the Power Wave
Water Cooler K1767-1.

COMPATIBLE LINCOLN EQUIPMENT

Any Linc-Net compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF-10, PF-10X2, PF-11).

C-1

POWER WAVE 455

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

PERIODIC MAINTENANCE

Calibration of the Power Wave 455 is critical to its
operation. Generally speaking the calibration will not
need adjustment. However, neglected or improperly
calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali­bration of output Voltage and Current should be

checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the facto­ry. Generally speaking the machine calibration will not
need adjustment. However, if the weld performance
changes, or the yearly calibration check reveals a
problem, contact the Lincoln Electric Company for the
calibration software utility.

The calibration procedure itself requires the use of a
grid, and certified actual meters for voltage and cur­rent. The accuracy of the calibration will be directly
affected by the accuracy of the measuring equipment
you use. Detailed instructions are available with the
utility.

POWER WAVE 455

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

E-2

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user inter­face, and feed head) has a status light, and when a
problem occurs it is important to note the condition of
each. In addition, errors displayed on the user inter­face in most cases indicate only that a problem exists
in the power source, not what the problem may be.

Therefore, prior to cycling power to the system,
check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays "Err 006"
or "Err 100" .

Included in this section is information about the power
source Status LED, and some basic troubleshooting

E-2

charts for both machine and weld performance.
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.

NOTE: The Power Wave 455 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.

LIGHT CONDITION

Status LED is solid green (no blinking).

Status LED is blinking green.

Status LED is blinking red and green.

Status LED is solid red (no blinking).

MEANING

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

2. Occurs during a reset, and indicates the Power
Wave 455 is mapping (identifying) each component
in the system. Normal for first 1-10 seconds after
power is turned on, or if the system configuration is
changed during operation.

3. Non-recoverable system fault. If the PS Status light
is flashing any combination of red and green, errors
are present in the Power Wave 455. Read the error

code before the machine is turned off.

Error Code interpretation through the Status light is
detailed in the Service Manual. Individual code digits
are flashed in red with a long pause between digits. If
more than one code is present, the codes will be
separated by a green light.

To clear the error, turn power source off, and back
on to reset.

Non recoverable hardware fault. Generally indicates
nothing is connected to the Power Wave 455 wire
feeder receptacle. See Trouble Shooting Section.

Status LED is blinking red.

Not applicable.

POWER WAVE 455

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWERWAVE

The following is a list of possible error codes that the Power Wave 455 can output via the status light (see
"Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11
these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.

Error Code #

11 CAN communication bus off.
1

2 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.
32 Capacitor "A" under voltage

33 Capacitor "B" under voltage

34 Capacitor "A" over voltage

35 Capacitor "B" over voltage

(Left side facing machine)
(Right side facing machine)

(Left side facing machine)

(Right side facing machine)

Indication

Probably due to excessive number of communication errors.
UI is no longer responding to the Power Source. The most likely
cause is a fault/bad connection in the communication leads or con­trol cable.

Contact the Service Department for instructions on reloading the
Welding Software.

Contact the Service Department for instructions on reloading the
Welding Software.
Contact the Service Department for instructions on reloading the
Welding Software.
Excessive Primary current present. May be related to a short in the
main transformer or output rectifier.

Low voltage on the main capacitors. May be caused by improper
input configuration, or an open/short circuit in the primary side of
the machine.

Excess voltage on the main capacitors. May be caused by improp­er input configuration, excessive line voltage, or improper capacitor
balance (see Error 43)

36 Thermal error

37 Soft start error
41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.

Capacitor precharge failed. May be accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this

occurs the machine output will phase back to 100 amps, typically
resulting in a condition refered to as "noodle welding"
NOTE: The maximum secondary limit is 570 amps for the standard
stud (500 amps for CE models), and 325 amps for the STT stud
and all single phase operation.
The maximum voltage difference between the main capacitors has
been exceeded. May be caused by an open or short in the primary
or secondary circuit(s).
Indicates machine is running on single phase input power. Usually
caused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the Power
Source Control Board. If cycling the input power on the machine
does not clear the error, try reloading the operating system. If this
fails, replace the control board.

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

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)

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

CAUSE

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

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)

Thermal LED is lit.

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

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Fan thermostat has opened.

Check for proper fan operation.
(Fan should run whenever out­put power is on.) Check for
material blocking intake or
exhaust louvers, or for excessive
dirt clogging cooling channels in
machine.

2. Secondary rectifier or Choke

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

3. DC Bus PC board thermostat

has opened check for excessive
load on 40VDC supply.

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.

3. Primary current limit has been

exceeded. Possible short in out­put circuit. Turn machine off.
Remove all loads from the out­put of the machine. Turn back
on. If condition persists, turn
power off, and contact an autho­rized Lincoln Electric Field
Service facility.

. This problem will normally be

4

accompanied by an error code.
Error codes are displayed as a
series of red and green flashes by
the status light. See
"Troubleshooting the Power Wave
/ Power Feed System Using the
Status LED" section of this text.

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

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-6

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, especially a procedure
with high WFS.

Machine won’t produce full output.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1.Secondary current limit has been

exceeded, and the machine has
phased back to protect itself.

2. Adjust procedure or reduce load

to lower current draw from the
machine.

3. 2. A single phase input (loss of

L2) or applications running from
the STT Stud will reduce the
secondary current limit to a max­imum of 325 Amps.

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.

3. Secondary current or voltage not

be properly calibrated. Check
values displayed on the Power
Feed 10/11 verses readings on
an external meter.

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 recon-

nect 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

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-7

RECOMMENDED

COURSE OF ACTION

General degradation of the weld per­formance

Excessively long and erratic arc.

1.Check for feeding problems, bad
connections, excessive loops in
cabling, etc.

2. Verify weld mode is correct for

processes.

3. The power source may require

calibration.

4. Check the actual current dis-

played on the Power Feed 10 vs.
actual current measured via exter­nal meter.

5. Check the actual voltage dis-

played on the Power Feed 10 vs.
actual voltage measured via exter­nal meter.

6. Check the actual WFS displayed

on the Power Feed 10 vs. actual
WFS measured via external
meter.

1. Check for proper configuration

and implementation of voltage
sensing circuits.

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

F-1

ENHANCED DIAGRAM

"H1A TO AUX #2"

CONNECTED HERE

ON EARLIER MACHINES

LEFT SIDE OF MACHINE

TO3WJ7

3R

DIGITAL POWER

CB3

612B

TO SW1

4-

3

+

SUPPLY BOARD

10A

TO CB4

H6

W

AUXILIARY TRANSFORMER #1

X1

SOLID

TO

J4

223

225

1

CIRCUIT

BREAKER

612A

H5A

H6A

H5

H6

H4

H5

(440-460)

(550-575)

U

(51V)

X2

1

2

STATE

RELAY

221

222

227

65432

J42

CB4

TO J61

TOX3AUX #2X5RECONNECT PANEL

H4A

(380-415)

TO POWER BD.

475

1

6A

CB3

612A

CB4

H4

X3

RECTIFIER

X3A

TP4

444

TO

J47

477

2

J41

CIRCUIT

BREAKER

JUMPER (H1A)

612

H1A

TO AUX #2

H1

H3A

H2A

H2

H3

H3

(200-208)H2(220-230)

N

W

(24V)

(115V)

X4

CHOKE

224A

TO AUX#1

TO FAN

476

478

1

2

3

4

DIAGRAMS

8

AUXILIARY TRANSFORMER #2

CB2

J10

J1,J6,J7

J43

J4,J13,

J8,

J47,J60 J3,J61

J50

J14,J40J42,

J1VS,J9,J10CH,

J41,J4

J2,J5,J11,

J10,J2VS

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537

RIGHT SIDE OF MACHINE

1

2

1

COMPONENT VALUES:

B=BLACK

16

9

1

7

14

8

1

6

12

7

11

5

10

6

4

8

11

5

3

6

4

4

3

2

RESISTORS=OHMS/WATTS

CAPACITORS=MFD/VOLTS

U=BLUE

R=RED

N=BROWN

G=GREEN

WATER

2

352

TO

12

11

LEFT)

COOLER

TO

AUX #2

MAIN TRANSFORMER

19C

20C

D3

RECEPTACLE

3

4

33A

TO

TO RECONNECT SWITCH

12

11

16

15

14

F3

F3

REAR OF MACHINE

POS

SWITCH

RECONNECT

HARMONIC

9
1

20

FILTER

NEG

D
9
1

20C

TO J6, J10B

17

15

TO

SWITCH

BD #2

PRI

RIGHT)

(BOTTOM

SEC

RIGHT)

(BOTTOM

.022

800V

F2

D2

2.7 10W

TOJ4J43

262

TO

268

268A

POS

R5

POWER BD

RECTIFIER

TO

IFACE

ROBOT

C3

X2

AC

F2

AC

INPUT BOARD

AUX. #1

D6TOJ11

J47

AC

1

POS

POS

AC

2

INPUT

AC

3

NEG

RECTIFIER

NEG

TO J61

TO

TO

CR1

J6

AUX #1

238

X3

232

601

604

1

5

6

4

2

3

J60

18

17

506

6

5

505

4

504

3

503

2

5

1

8

1

5

4

1

CR1

T1T2612

231

1

8

7

5

2

3

4

J61

+

J50

#2

SWITCH BOARD

11

13

BD #1

TO

SWITCH

PRI

(TOP

RIGHT)

SEC

(TOP

2.7 10W

TP7

X1

NEG

S1

TO

RIGHT)

NEG

J73

RIGHT SIDE

F1

F1

.022

800V

D1

TO J46

POS

POS

POS

POWER BD RECT

NEG

NEG

C3

+

oF

100V

2400

L1

T1

T2

T3

CR1

601

TO J60

SW1

CB4

T3

H1D

6

7

8

9

10

oF

500V

3500

19D

C5

20D

16
15

U

G

L1A

TO SW1

L2

V

TO SUPPLY LINES

L3

W

TO A SYSTEM GROUND PER

L3A

TO SW1

X4

TO AUX #1

H6A

H6A

5

P50 JUMPER

(MAY NOT BE PRESENT

ON EARLIER MACHINES)

H6

(550-575)

TO

SWITCH

RECONNECT

TO

MAIN

TRANSFORMER

NOTES:

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

ALIGNS WITH BLACK LEAD OF LED SOCKET.

NATIONAL ELECTRICAL CODE.

H4A

H2A

H5A

H3A

H1A

1

3

4

625

H1A

1

2

3

4

6

H2

H1

H4

H5

H3

(220-230)

(200-208)

(440-460)

(380-415)

R

W

(115V)

(230V)

1

4

P52

2

352

350

33A

4

1

2

33

32

S4

TO

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT

OPERATION.

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

OPERATION.

VOLTAGE. CONNECTION SHOWN IS FOR 440-575V

S8

200-208V

220-230V

440-460V

FAN

X5

444

TO AUX#1

TO SOLID STATE RELAY

J60

CR1

4

P91

216

TO J8

R5

266

765

8

J43

REAR OF MACHINE

THIS AREA VIEWED FROM

X3A

TO SOLID STATE RELAY

MAIN

CURRENT

TRANSDUCER

++

3

1

2

211

213

212

TO J5

224

2733228

267

262

9

12

10

11

DC BUS

N.B.

RECONNECT SWITC H

TO J6,J10B

LEFT SIDE

TRANSFORMER

OUTPUT

220A

220

224A

TO C3

BOARD

TO

RECT

POS

POS

1

2

J46

TO AUX #1

H1

TO FAN

H1

R

TO

THERMTO RECT

291

THERM

L1

MAIN CHOKE

TOJ4J11

274

226

268A

4

550-575V

TO SW1

’A

N.C.

H2

H5

H3

TO AUX #1

PANEL

RECONNECT

19C

TO

SWITCH BD #1

TO

INPUT RECTIFIER

19

POS

INPUT RECTIFIER

TO HARMONIC

FILTER

14

13

6

0

4

6

0

4

5

5

0

4

4

4

0

3

4

3

2

1

4

8

4

1

4

1

1

’

350

H6

NEG

20

TO HARMONIC

FILTER

20D

TO

SWITCH BD #2

oF

500V

3500

+

C4

J40

#1

SWITCH BOARD

16

TO

PRI

SEC

291

292

THERM

RECT

TO

THERM

CHOKE

51

NEG

NEG

1503

2

3

4

12

18

BD #2

SWITCH

(TOP

LEFT)

(TOP

LEFT)

F4

D4

S1

J41

CB1

TO

4755

47664777478

4

J47

BD #1

TO

SWITCH

PRI

LEFT)

(BOTTOM

SEC

(BOTTOM

F4

.022

800V

2.7 10W

THERM

TO RECT

8

220A

292

THERM

DC BUS

F-1

C

G4005

(VIEWED FROM COMPONENT SIDE OF BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

W=WHITE

1

2

POWER WAVE™ 455 WIRING DIAGRAM

CONTROL BOARD

TO

CB1

J47

TO J9

TO TP3

202

TO

TO

J43

S1

TO

S3

TO

251

253

254

1

1

7148

5

4

6

3

J1

C1

202A

TO R1

-

WORK

2

5

9

10

L2

L5

.05/600V

3

13

16

15

12

11

J2

J9

TO

J11

J47

CB1

67B

54A

53A

67A

54E53

C

B

A

S1

WIRE

FEEDER

TP1

8

7

6

4

234

J3

S1

TO

52

52A

51A

51A

54A

53A

D

4

3

2

1

P16

USER

INTERFCE

RECEPTACLE

TO

J42

J43

R5

RECT

THERM

THERM

TO

225

223

222

228

226

224

221

267

266

268

227

1

9

3

4

2

10

J9

TO

L4

21A

67B

52A

1

2513

6

5

S2

SENSE

VOLTAGE

1

5

4

RECEPTACLE

2

8

7

6

9

10

12

11

J5

J4

J2

TO

251

254

253

1

2

7

5

3

4

6

20

S3

RS232

CONNECTOR

220

231

1

3

4

J40

TO

504

503

406

232

5

4

6

3

2

TO

L2

BUSS BD

50

52

CB1

BREAKER

10A CIRCUIT

7

J50

405

8

J6

TO

238

5054506

9

10

ELECTRODE

WORK

TP3

404

4032B604

1W

1B

1

4

3

2

15

1411121316

32

115V

RECEPTACLE

EARLIER MODEL

31

(NEUTRAL FLOATING)

34

S4

115V

RECEPTACLE

32

(NEUTRAL BONDED)

SSR

TO

P90

TO

SSR

J10CH

2W

7

8

5

9

6

10

J7

S4

AUX 2

TO

33

CB2

TO

CB2

AUX 2

P91

3R3R

3W

212

213

216

211

1

2

6

4

5

3

14

13

16

151112

J8

TO

ELECTRODE

WORK

206A

202A

R

1

50Y

CB2

WORK

ELECTRODE

S2

TO

202

206

67A

7

8

2

3

J9

S4

TO

AUX 2

33

34

BREAKER

10A CIRCUIT

J40,J50

418

5141273

274

5182414

54

21A

53

1

2

1

2

6

1

3

5

4

J11

J10A

J10B

L1A

L3A

TO CONTACTOR

TO CONTACTOR

(TOP)

LOAD LINE

TO TP3

C2

.05/600V

THERMAL LED (Y)

TO J7

N.A.

STATUS LED (R/G)

TO J7

N.A.

1B

2W

2B

1W

TP2

TO RECONNECT PANEL

206A

TO R1

206

TO J9

+

612B

H1D

TO J61

TO CB3

A

SW1

POWER

ELECTRODE

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

F-2

Connection Diagram Semi-automatic "Simple System"

(Electrode Positive, CV/Pulse Configuration shown)

CONNECTION DIAGRAM

POWER WAVE

F-2

TO

WORK

WIRE

FEEDER

CONTROL CABLE K1543

POWER WAVE 455

F-3

DIAGRAMS

32.88

11-14-97

M18241

F-3

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

NOTES

POWER WAVE 455

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