Lincoln Electric IM808-A User Manual

IM808-A

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POWER WAVE 455M/STT

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.

™

11008, 11204

June, 2004

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

IEC 60974-1

NRTL/C

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

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

i

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.

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

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

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can kill.

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

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

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

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

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

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

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

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

FUMES AND GASES
can be dangerous.

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

fumes and gases away from the breathing zone. When

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

5.b.

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

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

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

vapors

to

5.e. Also see item 1.b.

Mar ‘95

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

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

v

SAFETY

v

vi

SAFETY

vi

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___________________________________________________________________________

viivii

Where Purchased_________________________________________________________________________

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.

viii

TABLE OF CONTENTS

Page

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

Technical Specifications - POWER WAVE 455M/STT .........................................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

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

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

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

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

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

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

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

Alternate Hard Automatic Application ....................................................................A-7

Combinaation Hard Automtion Application ............................................................A-7

Dual Head Boom Feeder.......................................................................................A-7

Welding with Multiple Power Waves......................................................................A-8

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

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

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

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

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

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

________________________________________________________________________

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

STT Welding ...................................................................................................B-9

________________________________________________________________________

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

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

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

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

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

________________________________________________________________________

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

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

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

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

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

________________________________________________________________________

viii

ix

TABLE OF CONTENTS

Page

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

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

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

Error Codes For Power Waves .............................................................................E-3

Troubleshooting Guide ............................................................................E-4 thru E-7

________________________________________________________________________

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

Connection Diagrams...........................................................................Section F-2, F-3

Dimension Print............................................................................................Section F-4

________________________________________________________________________

Parts Lists....................................................................................................P450 Series

________________________________________________________________________

ix

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT
VOLTS

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

EXCEPT STT PROCESS

INPUT

CURRENT

AMPS

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

EXCEPT STT PROCESS

INPUT

CURRENT

AMPS

A-1

380V - 60Hz.
380V - 50Hz.
415V - 60Hz.
415V - 50Hz.

OPEN

CIRCUIT

VOLTAGE

75 VDC

PROCESS CURRENT RANGE (DC) CURRENT AMPS

400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%

STT PROCESS ALL VOLTAGES

325A@33V. 100%

CURRENT

RANGE

AMPS

5 - 570 A

PULSE

FREQUENCY

0.15 - 1000 Hz

MIG/MAG

FCAW

SMAW

Pulse

STT

VOLTAGE

5 - 55 VDC

PULSE

RANGE

36 A
36 A
33 A
33 A

OUTPUT

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC.

3.3 SEC.

500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%

STT PROCESS ALL VOLTAGES

325A@33V. 100%

STT PARAMETERS

PEAK & BACK-

GROUND CURRENT

15-450 AMPS

-

50-500 A
40-500 A
30-500 A

5-750 A

40-325 A

48 A
48 A
44 A
44 A

AUXILIARY

POWER

40 VDC AT

10 AMPS

220 VAC AT

5 AMPS

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE /

FREQUENCY

380V Hz.
415V Hz.

HEIGHT

663 mm

(26.10 in)

OPERATING TEMPERATURE RANGE

DUTY

CYCLE

100%
100%

-20°C to 40°C

INPUT AMPERE

RATING ON

NAMEPLATE

36 A
33 A

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG[IEC] SIZES

(mm

8 (10)
8 (10)

PHYSICAL DIMENSIONS

WIDTH

505 mm

(19.86 in)

TEMPERATURE RANGES

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG[IEC] SIZES

2

)

DEPTH

835 mm

(32.88 in)

STORAGE TEMPERATURE RANGE

-40°C to 40°C

(mm

10 (6)
10 (6)

2

)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

WEIGHT

121 kg.

(267 lbs.)

40 A
40 A

POWER WAVE 455M/STT (CE)

A-2

INSTALLATION

SAFETY PRECAUTIONS Read this

entire installation section before you start installa­tion.

WARNING

ELECTRIC SHOCK can kill.

A-2

LIFTING

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

• 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 455M/STT (CE)

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

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

SELECT SUITABLE LOCATION

Do not use Power Wave 455M/STT (CE) in outdoor
environments. The Power Wave 455M/STT (CE) power
source should not be subjected to falling water, nor
should any parts of it be submerged in water. Doing so
may cause improper operation as well as pose a safe­ty hazard. The best practice is to keep the machine in
a dry, sheltered area.

Do not mount the Power Wave 455M/STT (CE) 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 1.6mm (.060") thick, which shall extend
not less than 150mm (5.90") beyond the equipment on
all sides.

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

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

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

POWER WAVE 455M/STT (CE)

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

WARNING

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail­er or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

Do not stack the Power Wave 455M/STT (CE) on
top of any other machine.

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

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.

A-3

W / L3

V / L2

U / L1

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

XA

S24190

use or service this equipment.

Do not touch electrically live parts.

removed.

Only qualified persons should install,

Do not operate with covers

inspecting or servicing machine.

Disconnect input power before

.

.

.

.

CR1

INPUT SUPPLY CONNECTION DIAGRAM

INSTALLATION

A-3

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

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 CONNECTION

WARNING

Only a qualified electrician should connect the
input leads to the Power Wave 455M/STT (CE).
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 45 mm (1.75 inch)
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.

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.

POWER WAVE 455M/STT (CE)

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) MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-30 m Length (100 Ft.)

400 Amps 67 mm

2

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

NOTE: K1796 coaxial welding cable is recommended to
reduce the cable inductance in long cable lengths. This is
especially important in Pulse and STT applications.

CAUTION

When using inverter type power sources like the
Power Waves, use the largest welding (electrode and

ground) cables that are practical. At least 67 mm
(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.

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

2

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
may be used without any effects on welding performance. For
the total welding loop length greater than
K1796 Coaxial Welding Cables are recommended. The weld­ing loop length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See Figure A.3).

POWER
WAVE

For long work piece lengths, a sliding work connection should
be considered to keep the total welding loop length less than
50 feet. (See Figure A.4.)

K1796 COAXIAL CABLE

Output connections on some Power Waves are made via 1/2­13 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 welding with the STT process, use the positive output
connection labeled “STT” for STT welding. (If desired ,other
welding modes can be used on this stud; however, the aver­age output current will be limited to 325 amps.) For non-STT
processes, use the positive output connection labeled “Power
Wave”, so that the full output range of the machine is avail­able.

15.24m (50 ft.), traditional welding cables

15.24m (50 ft.), the

FIGURE A.3

A

B

FIGURE A.4

POWER
WAVE

MEASURE FROM END
OF OUTER JACKET OF
CABLE

FIGURE A.4

A

WORK

C

B

SLIDING WORK CONNECTION

C

WORK

A

C

B

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).

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

VOLTAGE SENSING

The best arc performance occurs when the Power Waves
have accurate data about the arc conditions. Depending
upon the process, inductance within the electrode and
work lead cables can influence the 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 (K940-10, -25 or

-50) 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 semi-automatic
processes. The WORK sense lead (21) connects to the
Power Wave 455M/STT (CE) at the four pin connector locat­ed underneath the output stud cover. By default the WORK
voltage is monitored at the output stud in the Power Wave
455M/STT (CE). For more information on the WORK sense
lead (21), see "Work V oltage Sensing” in the following para­graph.

All constant current processes sense the voltage at the out­put studs of the POWER WAVE 455M/STT (CE) by default.

Do Not connect the STT and Power Wave stud together.
Paralleling the connection will bypass the STT circuitry and
severely deteriorate STT welding performance.

POWER WAVE 455M/STT (CE)