Lincoln Electric SVM135-B User Manual

PPoowweerr WWaavvee 445555//PPoowweerr FFeeeedd 1100

SERVICE MANUAL

SVM135-B

July,2001

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.

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.

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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.

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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.

SAFETY

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.

WARNING

Mar ‘95

ELECTRIC AND MA GNETIC FIELDS may be dangerous

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

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

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

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

2.d.1.

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

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

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

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

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

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 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 Diesel Engines

The Above For Gasoline Engines

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SAFETY

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.

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.

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

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

5.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.

Mar ‘95

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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.

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.

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SAFETY

iii

Mar ‘95

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.

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

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

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

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even

though

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

Preparation

for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

6.f.

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

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

6.h. Also see item 1.c.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc tions 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.

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.

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.

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

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POWER WAVE 455/POWER FEED 10

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv

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

Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . . A-2

Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

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

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-61

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts

Parts List Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-291

Parts List Power Feed 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-306

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SECTION A-1

INSTALLATION

POWER WAVE 455/POWER FEED 10

SECTION A-1

TABLE OF CONTENTS

-INSTALLATION SECTION-

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

Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . . A-2

Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Feeder and Control Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Input Voltage Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Flexible Connection Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Electrode and Work Leads — Electrode Positive Applications . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Electrode and Work Leads — Electrode Negative Applications . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Voltage Sensing at the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Wire Drive Gear Ratio (High or Low Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

DIP Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

Standard Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

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A-2

POWER WAVE 455/POWER FEED 10

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND CONTROL BOX

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER

SPEC # TYPE LOW SPEED RATIO HIGH SPEED RATIO

* Included with K1538-1 Boom package and K1541-1 Bench Feeder. ∆ Dimensions do not include wire reel. # For Control Box and Wire Drive dimensions and weights, see individual component listings.

Wire Size Wire Size

Speed Solid Cored Speed Solid Cored

K1540-1

Power Feed 10

50-800 IPM .025 - 3/32 in. .035 - .125 in. 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in.

Wire Drive (1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm)

K1538-1

Power Feed 10

50-800 IPM .025 - 3/32 in. .035 - .125 in. 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in.

Boom Package#

(1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm)

K1541-1

Power Feed 10

50-800 IPM .025 - 3/32 in. .035 - .125 in. 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in. Bench Model (1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) Drive and Control Box

CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Dimensions

Height Width Depth Weight Operating Storage

K1539-1 Power 40 VDC 13.0 in. 8.50 in. 4.0 in. 8.5 lbs (Control Feed 10 (330 mm) ( 215 mm) (105 mm) (3.8 kg) Box Control Only)* Box

K1540-1 Power 40 VDC 7.6 in. 12.9 in. 13.7 in. 30 lbs +40˚C +40˚C (Wire Feed 10 (195 mm) (325 mm) (345 mm) (13.6 kg) to to Drive Wire -20˚C -40˚C Only)* Drive

K1541-1 Power 40 VDC 18.5 in. 13.5 in. 30.5 in. 62 lbs Bench Feed 10 ( 470 mm) (345 mm) (775 mm) (28.1 kg.) Model

Bench Model

Feeder∆ Drive and

Control Box

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A-3

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-3

RECOMMENDED INPUT WIRE AND FUSE SIZES

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

Input Volts

208V - 60Hz 230V - 60Hz 400V - 60Hz 460V - 60Hz 200V - 50Hz 220V - 50Hz 400V - 50Hz 440V - 50Hz

Open

Circuit

Voltage

75 VDC

Input

Voltage /

Frequency

208/60/50 230/60/50 400/60/50 460/60/50 208/60/50 230/60/50 400/60/50 460/60/50

Height

26.10 in. 663 mm

Width

19.86 in. 505 mm

Depth

32.88 in. 835 mm

Weight

250 lbs

114 kg

Type 75°C

(Super Lag)

or Breaker

Size (AMPS)

80 70 50 40 90 90 60 50

Type 75°C

Ground Wire in

Conduit AWG[IEC]

Sizes (mm2)

8 (10)

8 (10) 10 (6) 10 (6)

8 (10)

8 (6)

Type 75°C

Copper Wire in

Conduit AWG[IEC]

Sizes (mm2)

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

Input Ampere Rating

on Nameplate (AMPS)

70/72 65/67 39/40 35/36 87/79 82/74 50/45 48/41

Duty

Cycle

100% 100% 100% 100%

60%* 60%* 60%* 60%*

Process Current Ranges (DC)

MIG/MAG

FCAW SMAW

Pulse

Current

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

5-750 Amps

Pulse

Voltage

Range

5 - 55 VDC

Auxiliary

Power

40 VDC AT

10 AMPS

115 VAC AT

10 AMPS

Pulse and Background Time Range

100 MICRO SEC. -

3.3 SEC.

Current Range

5 - 570

Pulse

Frequency

0.15 - 1000 Hz

Input

Current

70 65 39 35 72 67 40 36

Input

Current

87 82 50 48 79 74 45 41

Rated Output @

100% Duty Cycle

450A@38V 100% 450A@38V 100% 450A@38V 100% 450A@38V 100% 450A@38V 100% 450A@38V 100% 450A@38V 100% 450A@38V 100%

Rated Output @ 60% Duty Cycle

570A@43V 60% 570A@43V 60% 570A@43V 60% 570A@43V 60% 500A@40V 60% 500A@40V 60% 500A@40V 60% 500A@40V 60%

Operating Temperature Range

0°C to 40°C

Storage Temperature Range

-50°C to 85°C

TECHNICAL SPECIFICATIONS – POWER WAVE 455

OUTPUT

*At 60% duty cycle with 50Hz input power, the machine is de-rated to 500 Amps at 40V.

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A-4

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-4

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn off the input power to the power source 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 this 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.

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

LOCATION AND MOUNTING

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. Using filters on the air intake to prevent dirt from building up restricts air flow. Do not use such filters. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

STACKING

Power Wave machines can be stacked to a maximum of three high. The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines toppling over if this precaution is not taken.

ENVIRONMENT

The Power Wave power source carries an IP21 environmental rating. If subjected to occasional falling water, such as rain, the machine should be sheltered.

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.

FEEDER AND CONTROL BOX MOUNTING

SEPARATION FROM BENCH MODEL

The Control Box can be removed from the bench model feeder and mounted in a different location. See Figure A-1.

FIGURE A.1 — SEPARATING CONTROL BOX

AND FEEDER.

Complete the following steps to remove the Control Box:

1. Remove the bottom and center option panels from the front of the Control Box.

2. Disconnect the connector between the Control Box and the wire drive located in the middle of the Control Box back near the bottom of the Control Box.

WIRE

DRIVE

CENTER

PANEL

CONTROL

BOX

BOTTOM

PANEL

CONNECTOR

MOUNTING

SCREW

WARNING

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A-5

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-5

3. Loosen the four screws inside the Control Box located along the sides of the back of the Control Box, two near the bottom and two near the middle.

4. Push the Control Box upwards and then pull the Control Box away from the wire drive.

5. Remove plug button taped to inside of Control Box and insert it into hole on front panel of wire drive.

BOOM MOUNTING

If you wish to convert to a boom mount, the following components are required to complete the conversion process:

Item 1 K1549-1 Receptacle Item 2 K1550-1 Receptacle

Assemble the components above as follows:

1. Remove plug button and mount item 1 to the left hole in the bottom of the Control Box.

2. Remove and save plug button and mount item 2 to the right hole in the bottom of the Control Box.

3. Insert connector from item 1 into either 4-pin connector on Control Box motherboard.

4. Insert 6-pin connector that went to wire drive unit into item 2.

5. Connect sense lead from item 1 to sense lead from 6-pin connector that went to wire drive unit.

6. Replace all option panels removed from front of Control Box.

7. Place plug button saved in step 2 into hole in back panel of Control Box.

CONTROL BOX POWER SOURCE MOUNTING

The Power Feed Control Box can be directly mounted on the front of the power source. If this control location is preferred, complete the following steps to mount Control Box on the power source:

1. Remove the bottom and center option panels from the front of the Control Box.

2. Mount Control Box to the power source, following the instructions supplied with that specific power source.

3. If the Control Box has an input Amphenol connector mounted on right side of bottom, then disconnect it’s 6-pin electrical connector from the input connector inside the Control Box.

NOTE: This input connector no longer functions.

4. Connect 6-pin connector that comes out of the back of the Control Box to the 6 pin connector. (See specific power source instructions.)

5. 67 sense lead from left bottom connector (if present) should be connected to 67 sense lead connection from 6-pin connector from motherboard.

6. Replace all option panels removed from front of Control Box.

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A-6

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-6

ELECTRICAL CONNECTIONS

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. An 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.2.

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. Refer to the

Technical Specifications

at the beginning of this

chapter for proper cable sizes.

HIGH FREQUENCY INTERFERENCE PROTECTION

If possible, locate the Power Wave away from radio controlled machinery. The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to the

Technical Specifications

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

INPUT VOLTAGE RECONNECT PROCEDURE

Turn main input power to the machine OFF before performing reconnect procedure. Failure to do so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON.

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

Welders are shipped connected for the highest input voltage listed on the rating plate. To connect to a different input voltage, refer to reconnect instructions located on the inside of the input access door or in Figure A.2. If the main reconnect switch is placed in the wrong position, the welder will not produce output power. 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.

WARNING

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A-7

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-7

CABLE CONNECTIONS

CONTROL CABLE CONNECTIONS

• All system control cables are the same but can vary in length.

• All control cables can be connected end to end to extend their length.

• All system equipment must be connected to a control cable.

Welding systems using the Power Feed 10 offer previously unprecedented flexibility in the connection of system components. This system uses the same type of control cable between each of the system components. Connections can be “daisy chained” from one system component to another. Since communication over the control cables is done by a robust communications network, the order of connection of the components makes no difference. The cables can be connected anywhere that there is a mating connector. See the flexible connections part of this section for more details.

NOTE: Maximum cable length between any two nodes is 250 feet.

TYPICAL BENCH FEEDER CONNECTION

Control cable is connected from Power Source (PS) to Feed Head (FH). If the Control Box is separated from the FH, a control cable will connect from the PS to the control box, which will have two control cable connectors. This could be the control box or the FH control box depending on how the units were separated. A second control cable would be connected from the second connector on the control box to the other FH control box.

TYPICAL BOOM FEEDER CONNECTION

Control cable is connected from PS to the control box. A second control cable would be connected from the second connector on the control box to the FH control box.

FLEXIBLE CONNECTION POSSIBILITIES

By using connector kits, a second connector can be added to the Control box or the FH. This allows the user to connect equipment types together in any order.

FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR.

200-208V

220-230V

380-415V

440-460V

200-208V

220-230V

VOLTAGE=220-230V

220-230V

200-208V

220-230V

380-415V

440-460V

200-208V

U / L1

440-460V

380-415V

inspecting or servicing machine. Do not operate with covers

removed. Do not touch electrically live parts.

Only qualified persons should install,

use or service this equipment.

'A'

VOLTAGE=380-415V

'A'

S23847

VOLTAGE=200-208V

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

'A'

VOLTAGE=440-460V

CR1

W / L3

V / L2

380-415V

440-460V

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

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A-8

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-8

CONTROL CABLE SPECIFICATIONS

The cable is a five copper conductor cable in a SOtype rubber jacket. There is one 20 gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propagation delay per foot of < 2.1 ns. There are two 12 gauge conductors that are used to supply the 40 VDC to the network. The fifth wire is 18 gauge and is used as an electrode sense lead. It is typically connected to the feed plate on the feed head when that feed head is active.

AVAILABLE CABLE ASSEMBLIES

K1543 Control cable only. Available in lengths of

8, 16, 25, 50 and 100 feet.

K1544 Control cable and a 3/0 (85 mm2 ) electrode

cable with stud terminal. It is rated at 600 amps, 60% duty cycle and is available in lengths of 8, 16, 25, and 50 feet.

K1545 Control cable and a 3/0 (85 mm2) electrode

cable with Twist-Mate™ connector on one end and a stud terminal on the other. It is rated at 500 amps, 60% duty cycle and is available in lengths of 8, 16, 25, and 50 feet.

CABLE CONNECTIONS

To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. Avoid excessive lengths, bundle the electrode and ground cables together where practical, and do not coil excess cable. Be sure the connection to the work makes tight metal-to-metal electrical contact.

Minimum work and electrode cables sizes are as follows:

When using an inverter type power source, 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.

ELECTRODE AND WORK LEADS — ELECTRODE POSITIVE APPLICATIONS

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). See Figure A.3.

FIGURE A.3 — ELECTRODE POSITIVE

APPLICATION.

A work lead must be run 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. Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding performance.

Minimum Copper Work Cable Size, AWG

Up to 100 ft Length (30m)

Current

60% Duty

Cycle

400 Amps 500 Amps 600 Amps

2/0 (67 mm2) 3/0 (85 mm2) 3/0 (85 mm2)

POWER WAVE

WIRE

FEEDER

WORK

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A-9

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-9

ELECTRODE AND WORK LEADS — ELECTRODE NEGATIVE APPLICATIONS

When negative electrode polarity is required, such as in some Innershield™ applications, install as above, except reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud). See Figure A.4.

VOLTAGE SENSING AT THE WORKPIECE

A four-pin voltage sense lead connector is located beneath the output stud cover. In certain installations, where the work connection is poor, arc performance may be improved by the use of an external voltage sensing lead. Contact the factory for information on connecting and using this feature.

FIGURE A.4 — ELECTRODE NEGATIVE

APPLICATION.

WIRE FEEDER SETUP

WIRE DRIVE GEAR RATIO (HIGH OR LOW SPEED)

The speed range capability and drive torque of the Power Feed 10 wire drive can be easily and quickly changed by changing the external drive gear. The Power Feed 10 is shipped with both a high speed and a low speed gear. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. If this is the desired gear ratio, no changes need to be made.

SELECTING THE PROPER GEAR RATIO

See the Technical Specifications at the front of this section for feed speed and wire size capabilities with high and low speed gear ratios. To determine whether you should be using the high or low speed ratio, use the following guidelines:

- If you need to operate at wire feed speeds greater than 800 IPM (20 m/m), you will need to install the high speed gear (large, 30 tooth, 1.6 inch diameter gear).

- If you need to operate at wire feed speeds less than 800 IPM (20 m/m), you should use the low speed gear (small, 20 tooth, 1.1 inch diameter gear). Using the low speed ratio will provide the maximum available wire driving force. Note: If you are feeding only small diameter wires you may, at your option, install the high speed ratio.

CHANGING THE WIRE DRIVE RATIO

Changing the ratio requires a gear change and a switch position change located on the feed head PC Board. The Power Feed 10 is shipped with both a high speed and a low speed gear. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. For identification purposes, the low speed (high torque) gear has 20 teeth and is

1.1 inches in diameter. The high speed gear has 30

teeth and is 1.6 inches in diameter. See Figure A.5.

FIGURE A.5 — CHANGING WIRE DRIVE RATIO.

TO WORK

WIRE

FEEDER

POWER WAVE

DRIVE

GEAR

PHILLIPS

HEAD SCREW

WIRE

FEEDER

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A-10

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-10

RATIO CHANGE PROCEDURE

1. Pull open the pressure door.

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

To remove feed plate: a. Loosen the clamping collar screw using a

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

b. Loosen the retaining screw, which is also

accessed from bottom of feeder, using a 3/16 in. Allen wrench. Continue to loosen the screw until the feed plate can be easily pulled off of the wire feeder.

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

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

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

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

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

8. Feed plate will be rotated out-of-position due to the gear change. Adjust the angle of the feed plate by loosening the clamping collar screw (Step 2a) and pivoting feed head.

9. Set the High/Low switch code on Feed Head PC board as follows:

a. Power down the Power Feed by turning off its

campanion Power Wave power source. For maximum safety, disconnect the control cable from the Power Feed.

b. Remove the cover from the back of the feed

head (2 screws).

c. Locate the 8-position DIP switch near the top

edge of the PC board, centered left to right. The setting will be made on the right most switch, S8.

d. Using a pencil or other small object, slide the

switch down, to the “0” position, when the low speed gear is installed. Conversely, slide the switch up, to the “1” position, when the high speed gear is installed. Refer to Figure A.6.

e. Replace the cover and screws. The PC board

will “read” the switch at power up, automatically adjusting all control parameters for the speed range selected.

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A-11

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-11 DIP SWITCH SETUP

SETTING DIP SWITCHES IN THE CONTROL BOX

There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and are located and oriented as shown in Figure A.3.

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FIGURE A.3

1 2 3 4 5 6 7 8

S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)

Switch Off On

1 US 4-Step Trigger Logic Euro 4-Step Trigger Logic 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing

Left Display is actual weld current when weld current is flowing

CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing

4 Run-in = Minimum Speed Available Run-in = weld WFS

If any option containing a Run-in setting is connected to the motherboard, it automatically overrides this switch regardless of position.

5 Spare 6 Acceleration, MSB (Sets acceleration rate for wire drive) see below 7 Acceleration (Sets acceleration rate for wire drive) see below 8 Acceleration, LSB (Sets acceleration rate for wire drive) see below

S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)

Switch Off On

Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.

A-12

INSTALLATION

A-12

POWER WAVE 455/POWER FEED 10

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S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)

Switch Off On

Standard speed gearbox limits adjustable

High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing

Left Display is actual weld current when weld current is flowing

CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing

4 Run-in = Minimum Speed Available Run-in = weld WFS

If any option containing a Run-in setting is connected to the motherboard, it automatically overrides this switch regardless of position.

5 Memory change with trigger disabled Memory change with trigger enabled 6 Acceleration, MSB (Sets acceleration rate for wire drive) see below 7 Acceleration (Sets acceleration rate for wire drive) see below 8 Acceleration, LSB (Sets acceleration rate for wire drive) see below

MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left. LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right.

S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)

Switch Off On

1 Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting) 2 Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting) 3 Spare 4 Spare 5 Spare 6 Must be off for normal operation Adjust lower limits 7 Must be off for normal operation Adjust upper limits 8 Must be on for European units only

Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.

A-13

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-13

S1 DIP Switch Bank on Control Box Motherboard (For software version S24456)

Switch Off On

Standard speed gearbox limits adjustable

High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing

Left Display is actual weld current when weld current is flowing

CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing

4 Run-in = Minimum Speed Available Run-in = weld WFS

If any option containing a Run-in setting is connected to the motherboard, it automatically overrides this switch regardless of position.

S2 DIP Switch Bank on Control Box Motherboard (For software version S24456)

Switch Off On

1 Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting) 2 Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting) 3 4-Step Domestic Configuration 4-Step European Configuration 4 Power Feed 10 / Dual Power Feed 11 5 Procedure Change with Trigger “OFF” Procedure Change with Trigger “ON” 6 Set lower limits 7 Set upper limits 8 Must be on for all units (Permits selection of extended modes)

Note: the factory shipped settings for the S2 switches are as follows: PF-10 (and Dual) Domestic - switches 1-7 “OFF”, 8 “ON” PF-10 (and Dual) European - switches 1,2,4-7 “OFF”, 3,8 “ON” PF-11 Domestic - switches 1-3,5-7 “OFF”, 4,8 “ON” PF-11 European - switches 1,2,5-7 “OFF”, 3,4,8 “ON”

Note: the factory shipped settings for the S1 switches are as follows: PF-10 (and Dual) Domestic - All switches “OFF” PF-10 (and Dual) European - switches 1 & 3-8 “OFF”, 2 “ON” PF-11 Domestic - switches 2-8 “OFF”, 1 “ON” PF-11 European - switches 3-8 “OFF”, 1,2 “ON”

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A-14

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-14

SETTING DIP SWITCHES IN THE WIRE DRIVE

There is one DIP switch bank on the control board of the wire drive. It’s labeled S1 and is located and oriented as shown in Figure A.4.

FIGURE A.4

S1 DIP Switch on Wire Drive Control Board (For software version S24029-All & S24467)

Switch Off On

1 Network Group ID, MSB (Assigns Wire Drive to a specific group) 2 Network Group ID, LSB (Assigns Wire Drive to a specific group ) 3 Network Feed Head ID, MSB (Assigns feed head number to wire drive) 4 Network Feed Head ID (Assigns feed head number to wire drive) 5 Network Feed Head ID, LSB (Assigns feed head number to wire drive) 6 Spare 7 Electrode Sense Polarity = Positive Electrode Sense Polarity = Negative

Switch position must match polarity of weld cable attached to feed plate.

8 Gear Box Ratio = Low Gear Box Ratio = High

Switch position must match actual gear box ratio of wire drive.

Note: the factory shipped settings for all of the S1 switches is “OFF”.

1 2 3 4 5 6 7 8

DIP SWITCH 6 DIP SWITCH 7 DIP SWITCH 8 Acceleration 1 (slow) Off Off On Acceleration 2 Off On Off Acceleration 3 Off On On Acceleration 4 On Off Off Acceleration 5 (fast ) (factory setting) Off Off Off

Setting Wire Drive Acceleration Rate Using (All software versions) DIP Switch S1 on the Control Box Motherboard

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A-15

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-15 GUN AND CABLE ASSEMBLIES

GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION

The Power Feed 10 wire feeder is equipped with a factory installed K1500-2 gun connection kit. This kit is for guns having a Tweco™ #2-#4 connector. The Power Feed 10 has been designed to make connecting a variety of guns easily and inexpensively with the K1500 series of gun connection kits. Gun trigger and dual procedure lead connections connect to the single five pin receptacle on the front of the feed head box. See

Gun Adapters

Accessories

section.

GENERAL GUN CONNECTION GUIDELINES

The instructions supplied with the gun and K1500 series gun adapter should be followed when installing and configuring a gun. What follows are some general guidelines that are not intended to cover all guns.

a. Check that the drive rolls and guide tubes

are proper for the electrode size and type being used. If not, change them per drive roll installation instructions in the

Operation

section.

b. Lay the cable out straight. Insert the connec-

tor on the welding conductor cable into the brass conductor block on the front of the wire drive head. Make sure it is all the way in and tighten the hand clamp. Keep this connection clean and bright. Connect the trigger control cable polarized plug into the mating five cavity receptacle on the front of the wire drive unit.

NOTE: For Fast-Mate and European connector style guns, connect gun to gun connector making sure all pins and gas tube line up with appropriate holes in connector. Tighten gun by turning large nut on gun clockwise.

c. For GMA gun cables with separate gas fit-

tings, connect the 3/16 in. I.D. gas hose from the wire drive unit to the gun cable barbed fitting.

d. For water cooled guns, refer to the instruc-

tions supplied with the kit.

GMAW SHIELDING GAS

CYLINDER may explode if damaged.

• Keep cylinder upright and chained to support.

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits.

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not in use.

SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING SOCIETY.

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

Customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow valve to the gas inlet fitting of the wire drive unit.

Connect a supply hose from the gas cylinder flow valve outlet to the 5/8-18 female inert gas fitting on the back panel of the wire drive or, if used, on the inlet of the Gas Guard Regulator. See

Accessories

section.

WARNING

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A-16

INSTALLATION

POWER WAVE 455/POWER FEED 10

A-16

CV/GOUGE PANEL NOTE: Installation Instructions for the standard

equipment panels will be required only if you have removed a standard panel and wish to reinstall it.

The CV/Gouge Panel fits into the lower position of the Control Box.

Installation is as follows:

1. Turn off power.

2. Remove the two screws from the front of the Control Box panel. Save the screws, discard the old panel or save for future use.

3. Tilt the new option panel away from the front opening of the Control Box cabinet. Plug the electrical connector into the proper connector on the right side of the main printed circuit board (12 pin). Make sure the connector latches in place.

4. Position the panel to the opening, taking care not to damage the switch connections on the back.

5. Align the screw holes, replace the two screws and tighten.

OPTIONAL PANELS FOR CONTROL BOX

All optional panels for the control box are described in the

Accessories

section of this manual.

STANDARD PANEL INSTALLATION

CONTROL/DISPLAY PANEL NOTE: Installation Instructions for the standard

equipment panels will be required only if you have removed a standard panel and wish to reinstall it.

The Control/Display Panel fits into the upper or middle slots of the Control Box, and is used to adjust WFS, Amps, Voltage, and Trim. It is also the location of the Status indicator, a diagnostic tool provided for system troubleshooting.

Installation is as follows:

1. Turn off power.

2. Remove the two screws from the front of the blank option panel at the location you choose to install your new panel, (top or middle), of the Control Box cabinet. Discard the blank panel or save for future use and save the screws.

3. Tilt the new panel away from the front opening of the Control Box cabinet. Plug the electrical connector into the proper connector on the right side of the main printed circuit board (14 pin). Make sure the connector latches in place.

4. Position the new panel, taking care not to damage the printed circuit boards on the back and align the screw holes.

5. Replace the two screws and tighten.

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OPERATION

POWER WAVE 455/POWER FEED 10

TABLE OF CONTENTS

-OPERATION SECTION-

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

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Duty Cycle and Welding Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

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

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Power Wave Controls and Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Power Feed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Display Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Board Level Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Constant Voltage (CV/MIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

To Mount a 30 lb (14 kg) Readi-Reel Package

(Using the Molded Plastic K363-P Readi-Reel Adapter) (Figure B.4): . . . . . . . . . . . . . . . . . B-7

To Mount 10 to 44 lb (4.5 to 20 kg) Spools [12 in. (300 mm) Diameter]

or 14 lb (6 kg) Innershield Coils (Figure B.4): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil (Using K1504-1 Coil Reel) (Figure B.5): . . . . . . . B-8

Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

SECTION B-1SECTION B-1

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B-2

OPERATION

B-2

OPERATING INSTRUCTIONS

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

SAFETY INSTRUCTIONS

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

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 Safety Guidelines detailed in the beginning of this manual.

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

SYSTEM DESCRIPTION

The Power Wave 455 is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. The Power Feed 10 is a high performance, digitally controlled, modular wire feeder. Properly equipped, they can support the GMAW, GMAW-P, and FCAW processes.

Operating as a system, each component in the system has special circuitry to “talk with” the other system components, so each component (power source, wire feeder, electrical accessories) knows what the other is doing at all times. This shared information lays the groundwork for a system with superior welding performance.

The Power Feed 10 is a four driven roll feeder that operates on 40 VDC input power, and is available configured in both boom and bench models. In addition, the Control Box and wire feed unit can also be purchased separately. The bench model is designed so that it can easily be converted to a boom feeder.

RECOMMENDED EQUIPMENT

The Power Feed 10 must be used with the Power Wave 455.

POWER WAVE 455/POWER FEED 10

WARNING

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B-3

OPERATION

B-3 DUTY CYCLE AND WELDING

CAPABILITIES

The Power Feed 10 wire feeder is capable of welding at a 100% duty cycle (continuous welding). The power source will be the limiting factor in determining system duty cycle capability.

The Power Wave 455 is rated 450 amps at 38 volts, 100% duty cycle, and 570 amps at 43 volts, 60% duty cycle. On 50 Hz, the 60% rating is 500 amps at 40 volts, 60% duty cycle. The duty cycle is based upon a ten minute period. A 60% duty cycle represents six minutes of welding and four minutes of idling in a ten minute period.

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

LIMITATIONS

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

• The Power Wave can only be used with Power Feed wire feeders. Other models of Lincoln feeders, or any models of non-Lincoln wire feeders, cannot be used.

CONTROLS AND SETTINGS

POWER WAVE CONTROLS AND STATUS LIGHTS

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

FIGURE B.1 — POWER WAVE CONTROLS

AND STATUS LIGHTS.

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 as follows:

NOTE: The Power Wave 455 status light will flash green, and sometimes red and green, for up to one minute when the Power Wave 455 is first turned on. This is a normal situation as the machine goes through a self test at power up.

POWER WAVE 455/POWER FEED 10

HIGH

TEMPERATURE

LIGHT

STATUS

LIGHT

ON/OFF

SWITCH

POSITIVE

TERMINAL

CIRCUIT

BREAKERS

CONTROL

CABLE

CONNECTOR

NEGATIVE TERMINAL

SPRING LOADED

OUTPUT COVER

(CUTAWAY)

115 VAC

AUXILIARY

RECEPTACLE

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

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

5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER: Protects 115 volt AC receptacle.

POWER FEED CONTROLS

1. 2-STEP/4-STEP SWITCH OPERATION

The Power Feed head unit has a 2-Step/4-Step switch shown in Figure B.2. This switch has no effect in CC modes of operation such as stick welding. When in the 2-step position, the gun trigger functions as follows:

2-Step Operation:

1. Closing the gun trigger initiates gas preflow time followed by run in speed and strike voltage until welding current is established.

2. Opening the gun trigger during a weld stops wire feed and initiates burnback time, followed by gas postflow time.

Meaning

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

Nothing connected to Wire Feeder Receptacle.

Recoverable system fault. See Troubleshooting Section.

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

See Troubleshooting Section.

B-4

OPERATION

B-4

FIGURE B.2 — WIRE FEEDER CONTROLS.

When the switch is in the 4-step position, the gun trigger functions as follows:

4-Step Operation (Current interlock):

1. Closing trigger initiates gas preflow time followed by run in speed and strike voltage until welding current is established.

2. Once current is established, the trigger may be released and welding will continue.

3. When the trigger is closed again, welding will continue but the current interlock function will be disabled.

4. Releasing the trigger stops the wire feed and initiates burnback followed by gas postflow.

2. COLD FEED/GAS PURGE SWITCH

The Power Feed head unit has a Cold Feed/Gas Purge switch. When left untouched, this switch returns to a center position where no action results.

POWER WAVE 455/POWER FEED 10

Light

Condition

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

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CONTROL BOX

(SHOWN ATTACHED

TO WIRE FEEDER)

2. COLD FEED/ GAS PURGE

SWITCH

COLDFEED

STATUS

4-STEP

2-STEP

3. STATUS LIGHT

1. 2-STEP/ 4-STEP

SWITCH

B-5

OPERATION

B-5

Cold feed function:

When this switch is held in the up position, the unit automatically feeds wire, but does not activate output to the power source or gas solenoid. The speed of this cold feed is factory preset to 200 IPM. It can be adjusted while the switch is held up, by rotating the WFS encoder knob on the Control Box. Note that this cold feed speed is independent of WFS or run in speeds. When the cold feed switch is released, the cold feed value is memorized for the next time cold feed is activated.

Gas purge function:

When this switch is held in the down position only the gas solenoid valve is energized.

3. STATUS LIGHT

A two color light that indicates system errors. Normal operation is a steady green light.

DISPLAY CONTROL PANEL

The Display Control panel is the main input to the system. From it, the operator can control WFS, amps, voltage, and trim depending on the active weld mode. It is also the location of the Status indicator, a multicolored diagnostic LED (see

Troubleshooting

section). Refer to Figure B.3.

FIGURE B.3 — CONTROL BOX.

1. Indicator Lights:

Indicates either WFS or AMPS for the left display, and VOLTS or TRIM for the right display.

2. Displays:

Two extra bright, 3 1/2 digit, red LED displays. The values of the active parameters are displayed, as defined by their associated indicators. The left display is for WFS or Amps, while the right display is for voltage or trim.

3. Left Encoder-Wire Feed Speed or Output Amps:

The left encoder is used to adjust the parameters for either wire feed speed or output amps, dependent upon the process and weld mode being used. Rotating the encoder knob CCW decreases the number value, while rotating the knob CW increases the number value. The ranges and limits are as follows:

WFS - Low Range: 50 to 800 IPM (1.25 to 19.99 MPM)

High Range: 75 to 1200 IPM (2.0 to 30.5 MPM)

AMPS - Limited by the power source based on mode

and process.

4. Right Encoder - Trim or Output Volts:

The right encoder operates in the same manner as the left except that either output Volts or Trim is adjusted. The ranges and limits are as follows:

VOLTS - 00.0 to 99.9 volts, limited by power source

based on mode and process.

TRIM - 0.50 to 1.50, nominal value is 1.00 When not welding (no output current flow) the displays

reflect the preset values. During welding (output current flowing) the displays depict actual values. These actual values are held for a period of five seconds after welding (output current) ceases. This hold feature is canceled if a trigger pull or encoder adjustment occurs during the hold time. The actual value displayed is dependent upon the weld mode and process being used.

5. Status light:

A two color light that indicates system errors. Normal operation is a steady green light.

POWER WAVE 455/POWER FEED 10

GOUGE

STATUS

WFS AMPS VOLTS

TRIM

A V T

CV/MIG

WELD MODE

1. INDICATOR LIGHTS

2. DISPLAYS

1. INDICATOR LIGHTS

3. WFS/ AMPS

ENCODER

5. STATUS LIGHT

6. CV/GOUGE PANEL

BLANK PANEL

DISPLAY

CONTROL

PANEL

4. VOLTS/ TRIM

ENCODER

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B-6

OPERATION

B-6

6. CV/GOUGE PANEL

The CV/Gouge Panel provides a fixed toggle switch selection of two power source modes. The upper position selects the generic CV/MIG mode from the power source while the lower position selects the GOUGE mode.

OPTIONAL PANELS

A number of Optional Features are available for use with the Power Feed 10. Some Installation information is provided in the

ACCESSORIES

section, REFER TO THE INSTRUCTIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLATION.

BOARD LEVEL ADJUSTMENTS

The control box motherboard provides the capability to adjust some basic parameters as follows.

BURNBACK

The BURNBACK trimmer (R5) is provided as a basic adjustment for burnback time. The range is 0.0 to

0.25 seconds, CCW limit is minimum, CW limit is maximum. This value is overridden by any option with the ability to independently adjust burnback.

ACCELERATION

See

DIP Switch setup

in the

Installation

section.

RUN IN

See

DIP Switch setup

in the

Installation

section.

WELD MODE DESCRIPTIONS

CONSTANT VOLTAGE (CV/MIG)

For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special softwares at the factory. This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed. If the wire feed speed is changed on the wire feeder, the voltage automatically changes with it.

In some cases, the operator may want to change the

preprogrammed voltages; for example, to compensate for cable and fixture voltage drops. The preset voltages can be adjusted on the wire feeder’s voltage display. When a change is made to the voltage at one wire feed speed, this change is applied to all other wire feed speed settings. For example, if the operator turns up the voltage by 10 percent, the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent. The preset voltage, programmed at the factory, may be changed with the wire feeder VOLTS adjustment.

ARC GOUGING

Arc gouging can be performed by choosing the arc gouging weld mode. Doing so automatically energizes the output terminals on the Power Wave, making the power source immediately ready to gouge. The output current is set by the AMPS control on the Power Weld wire feeder. The VOLTS/TRIM adjustment has no effect in this mode.

The ARC CONTROL adjusts the arc force. Increasing the ARC CONTROL setting increases the arc force, making the arc more harsh but less likely to stick. Decreasing the ARC CONTROL setting decreases the arc force, making the arc softer and smoother.

ELECTRODE ROUTING

The electrode supply may be either from reels, Readi-Reels, spools, or bulk packaged drums or reels. Observe the following precautions:

a. The electrode must be routed to the wire

drive unit so that the bends in the wire are at a minimum, and also that the force required to pull the wire from the reel into the wire drive unit is kept at a minimum.

b. The electrode is “hot” when the gun trigger is

pressed and must be insulated from the boom and structure.

c. If more than one wire feed unit shares the

same boom and are not sharing the some power source output stud, their wire and reels must be insulated from each other as well as insulated from their mounting structure.

POWER WAVE 455/POWER FEED 10

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B-7

OPERATION

B-7

WIRE SPINDLE PLACEMENT

The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommodate various reel sizes. Each mounting location consists of a tube in the center of the reel stand, and a locating pin on the right side (viewed from the front) of the reel stand. The bolt, used with a plain washer and lock washer, slides through the tube from the left side of the reel stand. The large plain washer is placed between the wire spindle hub and the reel stand. The bolt should be threaded into the wire spindle such that the locating pin aligns with the largest of the three holes (the hole that is not recessed) in the back side of the wire spindle base.

The upper location must be used for 50 to 60 lb Readi-Reels, spools and coils.

For smaller coils (44 lb, 30 lb, 10 lb, etc.), the spindle can be placed in either the upper or lower location. The goal is to make the wire path from the coil to the incoming wire guide as straight as possible. This will optimize wire feeding performance.

WIRE REEL LOADING READI-REELS, SPOOLS OR COILS

TO MOUNT A 30 LB (14 KG) READIREEL PACKAGE (USING THE MOLDED PLASTIC K363-P READI-REEL ADAPTER) (FIGURE B.4):

The spindle should be located in the LOWER mounting hole.

1. Depress the release bar on the retaining collar

and remove it from the spindle.

2. Place the adapter on the spindle.

3. Re-install the retaining collar. Make sure that the

release bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

4. Rotate the spindle and adapter so the retaining

spring is at the 12 o'clock position.

5. Position the Readi-Reel so that it will rotate in a

direction when feeding so as to be de-reeled from the bottom of the coil.

FIGURE B.4 — READI-REEL MOUNTING.

6. Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

7. Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

8. Slide cage all the way onto the adapter until the retaining spring “pops up” fully.

Check to be sure the retaining spring has fully returned to the locking position and has SECURELY locked the Readi-Reel cage in place. Retaining spring must rest on the cage, not the welding electrode.

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9. To remove Readi-Reel from adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

POWER WAVE 455/POWER FEED 10

CAUTION

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2 IN. O.D. SPINDLE

BRAKE

HOLDING

ADAPTER

GROOVES

READI-REEL

RETAINING

SPRING

INSIDE

CAGE

WIRES

RETAINING

COLLAR

RELEASE

BAR

B-8

OPERATION

B-8 TO MOUNT 10 TO 44 LB (4.5 TO 20

KG) SPOOLS [12 IN. (300 MM) DIAMETER] OR 14 LB (6 KG) INNERSHIELD COILS (FIGURE B.4):

The spindle should be located in the LOWER mounting hole.

(For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.)

(For 13 to 14 lb (6 kg) Innershield coils, a K435 coil adapter must be used).

1. Depress the release bar on the retaining collar and remove it from the spindle.

2. Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool. Be certain the wire comes off the reel in a direction so as to de-reel from the bottom of the coil.

3. Re-install the retaining collar. Make sure that the release bar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

TO MOUNT A 50 TO 60 LB (22.7 TO

27.2 KG) COIL (USING K1504-1 COIL

REEL) (FIGURE B.5):

NOTE: (For 50 to 60 lb Readi-Reels a K438

Readi-Reel adapter must be used). The spindle must be located in the UPPER mounting

hole.

1. With the K1504-1 coil reel mounted on to the 2 in. (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner nut and remove the reel cover. See Figure B.5.

2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as the reel rotates. The slots in the cardboard liner should align over the spring loaded arms.

3. Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage. DO NOT hammer on the spinner nut arms.

4. Cut and remove only the tie wire holding the free end of the coil. Hook the free end around the rim of the reel cover and secure it by wrapping it around. Cut and remove the remaining tie wires.

FIGURE B.5 — K1504-1 COIL REEL.

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in “backlashing” of the coil, which may tangle the wire. A tangled coil will not feed so it must either be untangled or discarded.

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5. Be sure the coil reel is engaged with the spindle brake pin and the release bar on the retaining collar “pops up” and that the collar retainers fully engage the retaining groove on the spindle.

POWER WAVE 455/POWER FEED 10

CAUTION

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SPINNER NUT

COVER PLATE

SLOTS

CARDBOARD COIL LINER

COIL

TIE WIRE

SPRING LOADED ARM

REEL

B-9

OPERATION

B-9

FEEDING ELECTRODE AND BRAKE ADJUSTMENT

1. Turn the reel or spool until the free end of the electrode is accessible.

2. While tightly holding the electrode, cut off the bent end and straighten the first 6 in. (150 mm). Cut off the first 1 in. (25 mm). (If the electrode is not properly straightened, it may not feed or may jam causing a “birdnest”.)

3. Insert the free end through the incoming guide.

4. Press the Cold Feed Switch while pushing the electrode into the incoming wire guide.

If feeding with the Gun Trigger, the electrode and wire drive may be electrically “HOT”.

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5. Feed the electrode through the gun.

6. Adjust the brake tension with the thumbscrew on the spindle hub, until the reel turns freely but with little or no overrun when wire feeding is stopped. Do not overtighten.

DRIVE ROLL KIT INSTALLATION (KP1505-[])

1. Turn off welding power source.

2. Pull open pressure door to expose rolls and wire guides.

3. Remove outer wire guide by turning knurled thumb screws counterclockwise to unscrew them from Feedplate.

4. Remove the drive rolls, if any are installed, by pulling straight off the shaft. Remove the inner guide.

5. Insert the inner wire guide, groove side out, over the two locating pins in the feedplate.

6. Install each drive roll by pushing over the shaft until it butts up against the locating shoulder on the drive roll shaft. (Do not exceed maximum wire size rating of the wire drive).

7. Install the outer wire guide by sliding over the locating pins and tightening in place.

8. Engage the upper drive rolls if they are in the “open” position and close pressure door.

To set drive roll pressure, see

Drive Roll Pressure

Setting.

DRIVE ROLL PRESSURE SETTING

The Power Feed 10 pressure is factory pre-set to about position “2” as shown on the pressure indicator on the front of the feedplate door. This is an approximate setting.

The optimum drive roll pressure varies with type of wire, surface condition, lubrication, and hardness. Too much pressure could cause “birdnesting”, but too little pressure could cause wire feed slippage with load and/or acceleration. The optimum drive roll setting can be determined as follows:

1. Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds.

2. If the wire “birdnests”, jams, or breaks at the drive roll, the drive roll pressure is too great. Back the pressure setting out one turn, run new wire through the gun, and repeat above steps.

3. If the only result is drive roll slippage, disengage the gun, pull the gun cable forward about 6 in. (150 mm). There should be a slight waviness in the exposed wire. If there is no waviness, the pressure is too low. Increase the pressure setting one turn, reconnect the gun, tighten locking clamp and repeat the above steps.

PROCEDURE FOR SETTING ANGLE OF FEEDPLATE

1. Loosen the clamping collar screw using a 3/16 in. Allen wrench. The clamping collar screw is accessed from the bottom of the feedplate. It is the screw which is perpendicular to the feeding direction.

2. Rotate feedplate to the desired angle and tighten clamping collar screw.

POWER WAVE 455/POWER FEED 10

WARNING

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B-10

OPERATION

B-10

WIRE FEED OVERLOAD PROTECTION

The wire drive has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time the wire drive will issue a shutdown command to the Control Box and force its STATUS light to blink between green and red. The Control Box turns off the power source, wire feed and gas solenoid. The status light on the wire drive will continue to blink between green

and red for about 30 seconds before the wire drive will automatically reset. At that time, the wire drive will issue a shutdown over command to the Control Box that will return the system to normal operation. The wire drive will force its STATUS light to solid green.

Overloads can result from improper tip size, liner, drive rolls, or guide tubes, obstructions or bends in the gun cable, feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding.

POWER WAVE 455/POWER FEED 10

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ACCESSORIES

POWER WAVE 455/POWER FEED 10

SECTION C-1SECTION C-1

TABLE OF CONTENTS

-ACCESSORIES SECTION-

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Input Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Cable Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Reel Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Guns and Gun Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Conduit Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Dual Procedure Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Gas and Water Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Chassis Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Description and Installation of Optional Control Box Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

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C-2

ACCESSORIES

C-2

GENERAL

The following is a list of the accessories that can be used with the Power Feed 10 wire feeder and the Power Wave 455. A description of each item is given later in the section.

POWER WAVE 455/POWER FEED 10

K1570-1 DUAL CYLINDER UNDERCARRIAGE KP1505 Series DRIVE ROLL AND GUIDE TUBE KITS K1543 INPUT CABLE ASSEMBLY (CONTROL CABLE ONLY) K1544 INPUT CABLE ASSEMBLY K1548-1 RECEPTACLE KIT (INPUT AND OUTPUT) K162h WIRE SPINDLE ADAPTER K1504-1 COIL ADAPTER K435 COIL ADAPTER K363P READI-REEL ADAPTER K438 READI-REAL ADAPTER K489-7 FAST-MATE™ GUN ADAPTERS K489-2 K466-10 CONNECTOR KIT K471-21,-22, -23 MAGNUM 400 WELDING GUNS K497-20, -21 MAGNUM 200 WELDING GUNS K613-7 MAGNUM 550 WELDING GUN CONNECTOR KIT K556 (250XA) LINCOLN FUME EXTRACTION GUNS K556 (400XA) K206 K289 K309 K489-2 FAST-MATE™ ADAPTER KIT K1500-1 LINCOLN INNERSHEILD GUN STANDARD CONNECTION K1500-2 TWECO™ #2-#4 CONNECTION K1500-3 TWECO™ #5 CONNECTION K1500-4 MILLER CONNECTION K1546-1 CONDUIT ADAPTER K1546-2 CONDUIT ADAPTER K683-1 DUAL PROCEDURE SWITCH K683-3 DUAL PROCEDURE SWITCH K590-5 WATER CONNECTION KIT (FOR DRIVE ONLY) K1536-1 WATER FLOW SENSOR KIT K659-1 GAS GUARD REGULATOR K1557-1 SWIVEL MOUNT K1556-1 LIGHT DUTY CASTER KIT K1574-1 SECURITY DOOR (LARGE) K1555-1 INSULATED LIFT HOOK K1542-5 DUAL PROCEDURE PANEL K1542-6 “M” PANEL K1546-7 MX PANEL (LARGE) K1542-8 MSP PANEL (LARGE) K1542-9 DUAL PROCEDURE / MEMORY PANEL (SMALL) K1542-11 MX2 PANEL (LARGE) K1542-12 MSP2 PANEL (LARGE)

TABLE C.1 — POWER FEED 10 AND POWER WAVE 455 ACCESSORIES.

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C-3

ACCESSORIES

C-3

POWER WAVE OPTIONS AND ACCESSORIES

The following is a list of available Power Wave options.

FACTORY INSTALLED

There are no factory installed options available for the Power Wave machines.

FIELD INSTALLED

The following options/accessories are available for your Power Wave from your local Lincoln Distributor.

K1570-1 DUAL CYLINDER UNDERCARRIAGE

This is a platform undercarriage for mounting up to two gas cylinders at the rear of the welder.

WIRE FEEDER OPTIONS AND ACCESSORIES

The following is a list of available Wire Feeder options.

DRIVE ROLL AND GUIDE TUBE KITS

POWER WAVE 455/POWER FEED 10

TABLE C.2 — DRIVE ROLL AND GUIDE TUBE KITS.

Wire Size 4-Roll

Drive

(4-Driven)

Solid Steel Electrode

in. mm

0.023 - 0.025 0.6 KP1505 - 030S

0.030 0.8 KP1505 - 030S

0.035 0.9 KP1505 - 035S

0.040 1.0 KP1505 - 045S

0.045 1.2 KP1505 - 045S

0.052 1.4 KP1505 - 052S 1/16 1.6 KP1505 - 1/16S 5/64 2.0 KP1505 - 5/64 3/32 2.4 KP1505 - 3/32

Cored Electrode

in. mm

0.030 0.8 KP1505 - 035C

0.035 0.9 KP1505 - 035C

0.040 1.0 KP1505 - 045C

0.045 1.2 KP1505 - 045C

0.052 1.4 KP1505 - 052C 1/16 1.6 KP1505 - 1/16C

0.068 1.7 KP1505 - 068 5/64 2.0 KP1505 - 5/64 3/32 2.4 KP1505 - 3/32 7/64 Hard Facing,smooth U groove 2.8 KP1505 - 7/64H 7/64 2.8 KP1505 - 7/64

0.120 3.0 KP1505 - 120

Aluminum Wire

.035" (0.9 mm) Aluminum KP1507-035A .040" (1.0 mm) Aluminum KP1507-040A 3/64" (1.2 mm) Aluminum KP1507-3/64A 1/16" (1.6 mm) Aluminum KP1507-1/16A 3/32” (2.2 mm) Aluminum KP1507-3/32A

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C-4

ACCESSORIES

C-4

POWER WAVE 455/POWER FEED 10

INPUT CABLE ASSEMBLIES

K1543 (Control Cable Only) - Consists of a 5-conductor control cable with a 5-pin control cable plug, without electrode cable, and is available in lengths of 10 ft, 15 ft, 20 ft, 50 ft, and 100 ft.

K1544 - Consists of a 5-conductor control cable with a 5-pin control cable plug and a 3/0 electrode cable. It is rated at 600 amps, 60% duty cycle and is available in lengths of 10 ft,15 ft, 20 ft, and 50 ft.

With input power disconnected from the power source, install the input cable by performing the following:

CABLE RECEPTACLES

K1548-1 RECEPTACLE KIT (INPUT AND OUTPUT)

This kit contains the contents of both the K1549-1 and K1550-1 kits. Refer to the instructions for each, below.

RECEPTACLE (OUTPUT)

Optional Output Connector installation into the Control Box cabinet and/or into the feed head enclosure.

Control Box Cabinet Procedure

1. Turn off power.

2. Remove the screws from the front of the lower and middle option panels of the Control Box.

3. Tilt the option panels away from the front opening of the Control Box cabinet. If the option panel has an electrical connector, disconnect it from the main printed circuit board (note connection point for re-connection later). Remove the option panel and set aside.

4. Remove the plastic plug (black) from the left hole

in the bottom of the Control Box cabinet and store it in the bottom of the Control Box cabinet for future use, should the Optional Output Connector be removed.

5. Place the Optional Output Connector (Amphenol) through the hole opened by the previous step (place from the inside, out). Rotate the Optional Output Connector so its aligning key is positioned to the front of the Control Box cabinet. Fasten the Optional Output Connector to the bottom wall of the Control Box cabinet with the four screws provided.

6. Secure the choke (large circular component of the Optional Output Connector) by inserting its leads into the white nylon clip located near the Optional Output Connector on the back wall of the Control Box cabinet. Insert the choke leads only.

7. The Optional Output Connector has two internal connectors, a four pin, and a single lead connector. Connect the four pin connector to the unused four pin connector on the main printed circuit board. Connect the single lead connector to a similar connector found on a lead nearby that branches out of the Control Box wiring harness.

8. Re-install the lower and middle option panels by reversing the removal process. While reinstalling the option panels, ensure clearance between Optional Output Connector components, Control Box wiring harness, and option panel harness (if any).

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C-5

ACCESSORIES

C-5

POWER WAVE 455/POWER FEED 10

Feed Head Enclosure Procedure

1. Turn power off.

2. Remove the Feed Head rear access door. The Feed Head cover can be removed to aid installation, but is not required.

3. Remove the plastic plug (black) from the hole at the right rear of the Feed Head and store it in the left side of the Feed Head rear compartment for future use, should the Optional Output Connector be removed.

4. Disconnect a printed circuit board connector, located at the bottom right corner of the printed circuit board, and position it to the left so as to provide clear access to the lower right corner of the Feed Head enclosure.

5. Place the Optional Output Connector (Amphenol) through the hole opened by the two previous steps (place from the inside, out). Rotate the Optional Output Connector so its aligning key is positioned to the top of the Feed Head enclosure. Fasten the Optional Output Connector to the back wall of the Control Box cabinet with the four screws provided.

6. Secure the choke (large circular component of the Optional Output Connector) by inserting its leads into the white nylon clip located near the Optional Output Connector on the floor of the Feed Head. Insert the long choke leads rather than the short leads that run between the choke and the Output Connector. Insert the choke leads only.

7. The Optional Output Connector has two internal connectors, a four pin, and a single lead connector. Connect the four pin connector to the unused four pin connector on the printed circuit board. Connect the single lead connector to a similar connector found on a lead nearby that branches out of the Feed Head wiring harness.

8. Reconnect the printed circuit board connector that was disconnected earlier.

9. Replace the rear access door and Feed Head cover if removed.

RECEPTACLE (INPUT)

Power Feed Wire Feeder Optional Input Connector Installation into the Control Box Cabinet and Conversion to Fixture Wire Feeder

1. Turn off power.

2. Remove the screws from the front of the lower and middle option panels of the Control Box cabinet.

4. Disconnect the connector located at the back wall of the Control Box cabinet.

5. Loosen (do not remove) the four screws located on the back wall of the Control Box cabinet.

6. Lift Control Box cabinet off of the four screws loosened above and set on a work surface. Retighten the four screws to secure for future use.

7. Remove the plastic plug (black) from the right hole in the bottom wall of the Control Box cabinet and insert it into the hole in the front of the Feed Head.

8. Place the Optional Input Connector (Amphenol) through the hole opened by the previous step (place from the inside, out). Rotate the Optional Input Connector so it’s aligning key is positioned to the front of the Control Box cabinet. Fasten the Optional Input Connector to the bottom wall of the Control Box cabinet with the four screws provided and connect the option’s opposite end to the connector previously disconnected in step 4.

9. Secure the choke (large circular component of the Optional Input Connector) by inserting it’s leads into the white nylon clip located near the Optional Input Connector on the back wall of the Control Box cabinet. Insert the choke leads only.

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C-6

ACCESSORIES

C-6

POWER WAVE 455/POWER FEED 10

10. Install an Optional Output Connector into the Control Box cabinet, if not already present.

11. Mount the Control Box cabinet to the work station fixture at this time, if desired. The four holes in the back wall of the Control Box cabinet can be used for this purpose.

12. Re-install the lower and middle option panels by reversing the removal process. While reinstalling the option panels, ensure clearance between Optional Input Connector components, Control Box wiring harness, and option panel wiring harness (if any).

REEL ADAPTERS

K162H - WIRE SPINDLE ADAPTER

Spindle for boom mounting Readi-Reels and 2 in. (51 mm) I.D. spools with up to 60 lb (27.2 kg) capacity. User mounted to appropriately prepared boom framework. Includes an easily adjustable friction brake for control of overrun (a 2 in. spindle is standard on Power Feed 10 bench model).

When a 2 in. (51 mm) spindle is used with ReadiReels, or coils not on 12 in. (305 mm) O.D. spools, an adapter is required:

K1504-1 - COIL ADAPTER

Permits 50 lb to 60 lb (22.7 to 27.2 kg) coils to be mounted on 2 in. (51 mm) O.D. spindles.

K435 - COIL ADAPTER

Permits 14 lb (6 kg) Innershield coils to be mounted on 2 in. (51 mm) O.D. spindles.

K363P - READI-REEL ADAPTER

Adapts Lincoln Readi-Reel coils of electrode 30 lb (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spindle. Durable molded plastic one piece construction. Designed for easy loading; adapter remains on spindle for quick changeover.

K438 - READI-REEL ADAPTER

Adapts Lincoln Readi-Reel coils of electrode 50 to 60 lb (22.7 to 27.2 kg) to a 2 in. (51 mm) spindle.

GUNS AND GUN ADAPTERS

The Power Feed 10 wire feeder is equipped with a factory installed K1500-2 gun connection kit. This kit is for guns having a Tweco™ #2-#4 connector. The Power Feed 10 has been designed to make connecting a variety of guns easy and inexpensive with the K1500 series of gun connection kits. Gun trigger and dual procedure lead connections connect to the single 5 pin receptacle on the front of the Feed Head box.

FAST-MATE™ GUNS (INCLUDING THE MAGNUM 450 WATER COOLED GUN)

A K489-7 adapter will install directly into the wire drive feedplate, to provide for use of guns with FastMate™ or European style gun connections. This K489-7 will handle both standard Fast-Mate™and Dual Schedule Fast-Mate™ guns.

Another way to connect a gun with a Fast-Mate™ or European style gun connector to the Power Feed 10, is to use the K489-2 Fast-Mate™ adapter kit. Installation of this adapter also requires a K1500-1 gun connector.

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C-7

ACCESSORIES

C-7

POWER WAVE 455/POWER FEED 10

MAGNUM 200/300/400 GUNS

The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 wire feeder is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun having the K466-10 connector (such as the K471-21, -22, and -23 dedicated Magnum 400 guns and the K49720 and -21 Magnum 200 guns).

MAGNUM 550 GUNS

The easiest and least expensive way to use the Magnum 550 guns with Power Feed 10 wire feeders is to order the gun with the K613-7 connector kit, and install a K1500-3 gun connection kit to the wire feeder.

LINCOLN INNERSHIELD AND SUB ARC GUNS

All of these guns can be connected to the Power Feed by using the K1500-1 Adapter Kit.

LINCOLN FUME EXTRACTION GUNS

The K556 (250XA) and K566 (400XA) guns require that a K489-2 Fast-Mate™ adapter kit be installed. Installation of this adapter also requires a K1500-1 gun connector kit.

The K206, K289, and K309 require only the installation of a K1500-1 connector in the Power Feed wire feeder.

NON-LINCOLN GUNS

Most competitive guns can be connected to the Power Feed by using one of the K1500 series adapter kits.

K1500-1 (LINCOLN INNERSHIELD GUN STANDARD CONNECTION)

Use this kit to connect the following guns: Guns having a Lincoln standard innershield gun connector, Fast-Mate™ guns with K489-2 Fast-Mate™ Adapter Kit, Magnum 200/300/400 with K466-1 connector kit, and Magnum 550 guns with the K613-1 gun connection kit.

K1500-2 (TWECO™ #2-#4 CONNECTION)

The K1500-2 gun adapter comes factory installed on the Power Feed 10 wire feeder. Use this adapter for guns that have a Tweco™ #2-#4 connector. Such guns include Magnum 200/300/400 guns with K46610 connector kit, and completely factory assembled Magnum guns that are factory equipped with the K466-10 connector (such as the K497-21 dedicated Magnum 400).

K1500-3 (TWECO™ #5 CONNECTION)

The K1500-3 gun adapter is for Magnum 550 guns with a K613-7 connection kit, and any other gun having a Tweco™ #5 connector.

K1500-4 (MILLER CONNECTION) for any gun having a Miller connector.

Install gun adapters per the instructions shipped with them.

CONDUIT ADAPTERS

K1546-1 ADAPTER

For use with Lincoln Magnum conduit (wire sizes

0.023 to 0.052) Install the K1546-1 gun adapter at the incoming end

of the feed plate, secure with the set screw located at the back of the feed plate. If a brass fitting is supplied with the conduit, remove it from the feeder end of the conduit by unscrewing it. Insert the conduit into the K1546-1, secure the conduit by fastening it to the adapter with the supplied knob screw.

K1546-2 ADAPTER

For use with Lincoln Magnum conduit (wire sizes 1/16 to 0.120)

Install the K1546-2 gun adapter at the incoming end of the feed plate; secure with the set screw located at the back of the feed plate. If a brass fitting is supplied with the conduit, remove it from the feeder end of the conduit by unscrewing it. Insert the conduit into the K1546-2, secure the conduit by fastening it to the adapter with the supplied knob screw.

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POWER WAVE 455/POWER FEED 10

DUAL PROCEDURE SWITCH OPTIONS

K683-3 DUAL PROCEDURE SWITCH

Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 5-pin plug with two leads to connect to gun trigger.

Connect the 5-pin plug of the K683-3 Dual Procedure Switch to the Power Feed 10 wire feeder trigger/dual procedure 5-socket receptacle.

The two lead plug cord extending out of the 5-pin plug of the Dual Procedure Switch is to be connected to the two trigger leads of the welding gun per instructions shipped with the kit.

K683-1 DUAL PROCEDURE SWITCH

The K683-3 Dual Procedure Switch is the recommended method of obtaining dual procedure; but if it is desired to use an existing K683-1 with the Power Feed 10, it can be done. A K683-1 Dual Procedure Switch can be used on the Power Feed 10 if a K6862 adapter is used. The K682-1 kit includes gun switch and mountings for Lincoln Innershield and Magnum guns, with 15 ft (4.5 m) control cable and 3pin plug. K686-2 adapter permits 3-pin plug and 5pin gun trigger plug to be connected to Power Feed 10 5-pin trigger/dual procedure receptacle.

GAS AND WATER KITS

K590-5 WATER CONNECTION KIT (FOR DRIVE ONLY)

Install per the instructions shipped with the kit.

K1536-1 WATER FLOW SENSOR KIT

Install per the instructions shipped with the kit.

K659-1 GAS GUARD REGULATOR

Adjustable flow regulator with removable adjuster key for CO2and Argon blend gases. Mounts onto feeder

inlet, and reduces gas waste and arc start “blow” by reducing surge caused by excess pressure in supply hose.

Install the 5/8-18 male outlet of the regulator to the 5/8-18 female gas inlet on the back panel of the wire drive. Secure fitting with flow adjuster key at top. Attach gas supply to 5/8-18 female inlet of regulator.

CHASSIS OPTIONS

K1557-1 SWIVEL PLATFORM

The K1557-1 Swivel platform attaches to the power source. This kit includes a feeder adapter plate that allows the feeder to rotate on top of the power source. The feeder can be easily separated from the swivel mount at any time. This option is compatible with the K1556-1 Light Duty Caster Kit.

K1556-1 LIGHT DUTY CASTER KIT

This option provides four casters and all required hardware to mount it to the Power Feed 10. This option is compatible with the K1557-1 Swivel Platform.

K1574-1 SECURITY DOOR (LARGE)

K1574-1 Security Door Installation into the Control Box cabinet.

1. Turn off power.

2. Unlatch and swing open the small door. Remove the two screws from the horizontal hinge rod. Save the screws.

3. While holding the door so it doesn’t fall, slide the rod out sideways releasing the door.

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POWER WAVE 455/POWER FEED 10

4. Position the new door between the panel holes and re-install the rod so the screw holes can be accessed.

5. Replace the two screws and tighten.

6. Swing the door into the up position. A lock may be installed through the side holes for security purposes.

K1555-1 INSULATED LIFT BAIL

For applications where an insulated lift bail is required. This kit provides an easily installed, heavy duty insulated lift eye that mounts to the wire reel stand mast. See the instructions provided with the kit for installation.

DESCRIPTION AND INSTALLATION OF OPTIONAL CONTROL BOX PANELS

K1542-5 DUAL PROCEDURE PANEL

The Dual Procedure Panel provides a fixed large toggle switch or the use of a gun switch for the selection of either of two procedures. The upper position of the switch selects PROCEDURE A, while the lower selects PROCEDURE B. The middle position selects the GUN switch, in which case the procedure is determined by the position of the switch located at the gun.

NOTE: Due to the nature of fixed position switches, this option does not allow the indication of a remotely selected procedure. When in the gun mode there is no provision to indicate, at the Control Box, which procedure has been remotely selected (at the gun).

Installation is as follows:

1. Turn off power.

2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option, (middle or top), of the Control Box cabinet. Save the screws, discard the old panel or save for future use.

4. Position the new panel, taking care not to damage the switch connections on the back.

5. Align the screw holes, replace the two screws and tighten.

K1542-6 M PANEL

The M Panel provides a large toggle switch selection of three power source modes. The upper position selects the generic CV/MIG mode from the power source, the middle position selects the CV/FLUX CORED mode, and the lower position selects the CC/STICK/GOUGE mode. Arc control is accomplished through the use of the ARC CONTROL potentiometer. The arc control value is actually a trim with zero being the nominal and the scale ranging from (-10) to (+10). Preflow, postflow, and spot time default to zero or off. Run in defaults to the minimum value, or weld speed depending on the position of its associated DIP switch. See

Installation

section for DIP switch settings. Burnback defaults to the on board trimmer adjustment.

NOTE: Due to the nature of fixed position switches, potentiometers, and default values, this option does not allow the mode, arc control, timers, or burnback values to be included in dual procedure or memory information. They are overridden by the fixed values.

CC/STICK/GOUGE Mode

Selecting the CC/STICK/GOUGE mode on this panel automatically energizes the output terminals on the power source, making the power source immediately ready to weld. In the CC modes, the output current is set by the AMPS control, and the VOLTS/TRIM adjustment has no effect in this mode. In this mode, the ARC CONTROL adjusts the arc force. Increasing the ARC CONTROL setting increases the arc force, making the arc more harsh but less likely to stick. Decreasing the ARC CONTROL setting decreases the arc force, making the arc softer and smoother.

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Constant Voltage (CV/MIG and CV/Flux Cored) Procedures

When in this mode, the ARC CONTROL adjusts the inductance. (This adjustment is often referred to as “pinch”. Inductance is inversely proportional to pinch.) Increasing the ARC CONTROL setting decreases the inductance, which results in the arc getting colder and pinched tighter. Decreasing the ARC CONTROL setting increases the inductance, which results in the arc getting wider (reduced pinch).

Installation is as follows:

1. Turn off power.

2. Remove the two screws from the front of the blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use.

4. Position the new panel, taking care not to damage the connections on the back.

5. Align the screw holes, replace the two screws and tighten.

K1542-7 MX PANEL (LARGE PANEL)

The MX Panel provides a selection of four power source modes. In addition, it provides for the adjustment of the following parameters: PREFLOW, RUN IN, ARC CONTROL, BURNBACK, POSTFLOW, and SPOT time.

Descriptions

Indicator Lights - Extra bright red LED’s indicate the mode and active parameter being displayed.

Display - Displays the value or status of the active parameter.

Available Modes - CV/MIG

CV/ FLUX CORED CC/STICK CRISP CC/STICK SOFT

Due to the nature of the system, the following feature is required for safety reasons. Upon entering any constant current (CC) mode, the right encoder, labeled VOLTS, TRIM, on the Display/Control Panel acts as a “soft” contactor switch. The encoder knob must be turned CW at least 45° to activate the output (turning CCW 45° deactivates the output). This prevents the output from inadvertently becoming “hot” when scrolling through the weld modes. The exception to this rule is when the weld mode is entered by a change in procedure (using a memory panel such as the K1542-9 Memory/Dual Procedure panel). In this case, the state of the contactor is recalled as it was left when the procedure was exited.

In the CC modes, the output current is set by the AMPS control, and the VOLTS/TRIM adjustment has no effect in this mode. In this mode, the ARC CONTROL adjusts the arc force. Increasing the ARC CONTROL setting increases the arc force, making the arc more harsh but less likely to stick. Decreasing the ARC CONTROL setting decreases the arc force, making the arc softer and smoother.

Parameter Ranges

PREFLOW -

0.0 to 2.5 seconds (0.1 sec. increments).

RUN IN -

Low Range: 50 to 150 IPM (1.25 to 3.80 MPM). High Range: 75 to 150 IPM (2.00 to 3.80 MPM).

ARC CONTROL -

Trim (-10.0) to (+10.0) , (0) is nominal.

BURNBACK -

0.0 to 0.25 sec. (0.01 sec. increments).

POSTFLOW -

0.0 to 2.5 sec. (0.1 sec. increments).

SPOT -

0 to 25 sec. (0.1 sec. increments).

POWER WAVE 455/POWER FEED 10

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Mode Selection

The MODE SELECT switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch up advances the mode indicator in the upward direction, down advances it in the downward direction. Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction, until the switch is released. When the indicator reaches its upper or lower limit, advancing ceases until the direction of the switch is changed.

Parameter Selection

The PARAMETER SELECT switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch up advances the parameter indicator in the upward direction, down advances it in the downward direction. Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction, until the switch is released. When the indicator reaches its upper or lower limit, advancing ceases until the direction of the switch is changed.

Parameter Adjustment

The value of the active parameter, as defined by the parameter indicator, is displayed on the parameter display. The PARAMETER SET switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch bat up advances the displayed value in the positive direction, down advances it in the negative direction. Holding the switch in either direction will result in the displayed value advancing at a high rate of speed in that direction, until the switch is released. When the indicator reaches its upper or lower limit, advancing ceases until the direction of the switch is changed.

Installation is as follows:

1. Turn off power.

2. Remove the two screws from the front of the

blank option panel at the location you choose to install your new option (bottom) of the Control Box cabinet. Save the screws, discard the old panel or save for future use.

4. Position the new panel, taking care not to damage the connections on the back.

5. Align the screw holes, replace the two screws and tighten.

K1542-8 MSP PANEL (LARGE PANEL)

The MSP Panel provides a selection of numerous process specific and generic power source modes. In addition, it provides for the adjustment of the following parameters: PREFLOW, RUN IN, ARC CONTROL, BURNBACK, POSTFLOW, and SPOT time. Only one parameter, as defined by the parameter indicator, may be displayed and adjusted at a time.

Description

Indicator Lights - Red LED’s indicate the active parameter being displayed.

Display - 3 1/2 digit, red LED display. Displays the value or status of the active parameter.

Parameter Ranges

WELD MODE -

Adjustable per mode schedule.

PREFLOW -

0.0 to 2.5 seconds (0.1 sec. increments).

RUN IN -

Low Range: 50 to 150 IPM (1.25 to 3.80 MPM). High Range: 75 to 150 IPM (2.00 to 3.80 MPM).

ARC CONTROL -

Trim (-10.0) to (+10.0) , (0) is nominal.

BURNBACK -

0.0 to 0.25 sec. (0.01 sec. increments).

POSTFLOW -

0.0 to 2.5 sec. (0.1 sec. increments).

SPOT -

0 to 25 sec. (0.1 sec. increments).

POWER WAVE 455/POWER FEED 10

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Mode Schedule - Table on the front of the option used by the operator to correlate the displayed mode number to an actual power source mode.

Parameter Selection

Parameter Adjustment

The value of the active parameter, as defined by the parameter indicator, is displayed on the parameter display. The PARAMETER SET switch is a momentary large three position toggle switch that defaults to the center (off) position. Moving the switch up advances the displayed value in the positive direction, down advances it in the negative direction. Holding the switch in either direction will result in the displayed value advancing at a high rate of speed in

that direction, until the switch is released. When the indicator reaches its upper or lower limit, advancing ceases until the direction of the switch is changed.

GMAW Pulse Procedures

In these procedures, the actual voltage greatly depends on the waveform used. The peak currents, background currents, rise times, fall times, and pulse times all affect the actual voltage. The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known. In this case, it is not practical to preset an actual voltage for the procedure. Instead, an arc length adjustment is provided. The machine “knows” what the best arc length is at the given wire feed speed but allows the operator to change it.

The arc length trim (usually referred to simply as “trim”) can be adjusted between 0.500 and 1.500 on the Control Box’s VOLTS/TRIM display. A trim of

1.000 means that no adjustments will be made to the preset arc lengths. A trim setting less than 1.000 decreases the preset arc lengths. The arc length trim adjustment is factored in at all wire feed speed settings. Increasing the trim by 10 percent at a given wire feed speed also increases all the other arc length trim settings of the procedure by 10 percent.

Lincoln Power Wave power sources utilizes a control scheme known as adaptive control in all pulse modes. Because the Power Wave utilizes adaptive control, it can adjust the pulsing parameters based on changes in the arc due to changes in the electrical sitckout of the electrode. (Electrical stickout is the distance from the contact to the workpiece.) The Power Wave is optimized for use with a 0.75 in. stickout. The adaptive behavior is programmed to support a stickout range from 0.5 in. to 1.25 in. In the low and high end of the wire feed speed ranges of most processes, the adaptive behavior may be restricted. This is a physical restriction due to reaching the edge of the operating range for the process.

The ARC CONTROL adjustment allows the pulse frequency to be varied. Increasing the ARC CONTROL causes the frequency setting to increase, while decreasing the ARC CONTROL causes the frequency to decrease. Varying the ARC CONTROL, and hence, the pulse frequency, affects the droplet transfer and allows fine-tuning for different welding positions.

POWER WAVE 455/POWER FEED 10

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Installation is as follows:

1. Turn off power.

4. Position the new panel, taking care not to damage the connections and the printed circuit board on the back.

5. Align the screw holes, replace the two screws and tighten.

K1542-9 DUAL PROCEDURE/MEMORY PANEL (SMALL PANEL)

The Dual Procedure/Memory panel provides for the selection of either of two procedures, or a gun switch for remote selection of the procedure. In addition, there are six permanent memory storage locations for saving commonly used procedures. Procedures A and B are “soft” type memories that record any changes made to them. The six memory locations are “hard” or more permanent type memories. Any changes made must be consciously saved back to them. Furthermore, each memory contains only one procedure, therefore any combination of memories may be recalled to procedure A and B.

Descriptions

Indicator Lights - Red LED’s indicate the procedure and active memory and save mode if applicable.

Dual Procedure Selection

The procedure switch is used to scroll the indicator to select PROCEDURE A, PROCEDURE B, or the GUN switch. When the GUN switch is selected, the procedure is determined by the position of the switch located at the gun. Under this condition, indicators will show that the gun switch has been selected and also which procedure the gun switch is requesting.

Memory Selection

RECALL - When a memory key is depressed, its indicator comes on and its contents are copied to the active procedure. As long as no changes are made to the contents of that procedure, the memory indicator will be on any time that procedure is active. This indicates that their contents are the same. Any change to that procedure will cause the memory indicator to go off, indicating that they are no longer equal.

SAVE - The save mode allows “hard” memories to be changed. Pressing the SAVE key will light the save indicator, and enter the save mode. In the save mode, the indicator for the memory that was the source of the active procedure’s contents will blink, whether their contents are still equal or not. This feature allows the user to choose to save an active procedure back to its source, or some other location.

To complete the save transaction requires the selection of one of the memory keys. When the memory key is pressed in the save mode, it’s contents are overwritten with the contents of the active procedure. This means that the contents of the memory location and the active procedure are now equal, and thereore, by definition, each of their indicators will be lit, and the save mode will be exited. To exit the save mode without saving, depress the save key a second time. This feature allows the operator to determine the source of the active procedure’s contents without actually overwriting it.

POWER WAVE 455/POWER FEED 10

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Installation is as follows:

1. Turn off power.

4. Position the new panel, taking care not to damage the connections and the printed circuit board on the back.

5. Align the screw holes, replace the two screws and tighten.

K1542-11 MX2 Panel:

This panel provides a selection of four weld modes: CV/MIG, CV/Flux Cored, CC/Stick/soft and CC/Stick/Crisp through a toggle switch and indicator lights (LEDs). It allows for adjustment of all set up parameters, Preflow, Run In, Arc Control, Burnback, Postflow, and Crater, through an up/down toggle switch, indicator lights and a 3 digit display.

Weld modes are selected with the Mode Select switch, an up/down center-off momentary toggle switch. Moving the switch bat up or down moves the Weld Mode LED in the corresponding direction. Holding the switch in either direction will cause the indicator to move quickly in the corresponding direction until the switch is released, or the upper or lower limit is reached.

To adjust Set Up parameters, first select the Set Up parameter for adjustment, and then adjust the displayed value up or down.

Set Up parameters are selected with the Select switch, an up/down center-off momentary toggle switch. Moving the switch bat up or down moves the Weld Mode LED in the corresponding direction. Holding the switch in either direction will cause the indicator to move quickly in the corresponding direction until the switch is released, or the upper or lower limit is reached.

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The value of the active Set Up parameter, as defined by the Set Up LED, is displayed on the MX2 panel Set Up display. The value can be modified with the Set switch. The Set switch is an up/down center-off momentary toggle switch. Moving the switch bat up or down adjusts the displayed value in the corresponding direction. Holding the switch in either direction will cause the display to move quickly in the corresponding direction until the switch is released, or the upper or lower parameter limit is reached.

To energize the output studs in either CC/Stick mode, the right Control/Display panel knob, labeled Volts/Trim, must be used. The Volts/Trim knob must be turned clockwise roughly a quarter revolution to energize the output studs. (The Volts/trim display will indicate ‘On’ when the studs are energized.) Similarly, turning the knob a quarter turn counterclockwise de-energizes the output studs. If a CC/Stick weld mode is entered through use of the Dual Procedure, the studs will be in the same state as when they were last used. If a CC/Stick weld mode is entered through a Memory recall, the studs will be de-energized.

K1542-12 MSP2 Panel:

This panel provides a selection of over 25 weld modes, including CV, pulse, FCAW and CC, through a toggle switch and indicator lights (LEDs). It allows for adjustment of all set up parameters, Preflow, Run In, Arc Control, Burnback, Postflow, and Crater, through an up/down toggle switch, indicator lights and a 3 digit display.

To adjust a set up parameter (Weld Mode being one of those parameters), first select one of the set up parameters for adjustment, and then adjust the displayed value up or down.

Set up parameters are selected with the Select switch, an up/down center-off momentary toggle switch. Moving the switch bat up or down moves an LED in the corresponding direction. Holding the switch in either direction will cause the indicator to move quickly in the corresponding direction until the switch is released, or the upper or lower limit is reached.

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The value of the active set up parameter is shown on the MSP2 panel digital display. The value can be modified with the Set switch. The Set switch is an up/down center-off momentary toggle switch. Moving the switch bat up or down adjusts the displayed value in the corresponding direction. Holding the switch in either direction will cause the display to move quickly in the corresponding direction until the switch is released, or the upper or lower parameter limit is reached.

CONTROL BOX PANELS -- SET UP CONTROLS DESCRIPTION

Certain large option panels can modify the set up parameters Preflow, Run In, Arc Control, Burnback, Postflow, and Crater. The meaning of those parameters, and their maximum and minimum values, follows.

Preflow - Time delay after the trigger is pulled, but before weld starts, during which shielding gas flows. Weld start is defined as the time when both the power source is energized and the Wire Drive begins feeding wire. Adjustable from 0.0 (Off) to 2.5 seconds in 0.1s increments.

Run In - Wire feed speed during arc starting. Wire Drive will feed wire at the Run In speed for one second, or until weld current flows. Low speed gear range: Off (Run In speed equals weld wire feed speed) or adjustable from 50 to 150 IPM (1.25 to 3.80 MPM). High speed gear range: Off (Run In speed equals weld wire feed speed) or adjustable from 75 to 150 IPM (2.00 to 3.80 MPM). NOTE: Run In settings over 150 IPM produce strange display values used for troubleshooting and service. If encountered, reset Run In to 150 IPM or less.

Arc Control - Unitless characteristic, also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from “soft” to “harsh” in all weld modes. Adjustable from -10.0 to 10.0 in increments of

0.1. Off (0.0) is nominal. Burnback - Time delay after the trigger is released-

during which the power source remains energized but the Wire Drive stops feeding wire. Adjustable from

0.00 (Off) to 0.25 seconds in 0.01 second increments. Postflow - Time delay after burnback is complete,

during which shielding gas flows. Adjustable from 0.0 (Off) to 10.0 seconds in 0.1 second increments.

Crater - Used only when welding with the 4-Step trigger mode. Can be set to Off or On. When On, Adjustments can be made to WFS and Volts/Trim on the Control/Display panel. These settings are then used for ‘cratering’ when in the 4-Step trigger mode (see explanation of 2 Step and 4 Step operation below). When Off, ‘cratering’ is not possible.

CONTROL BOX -- PC BOARD ADJUSTMENTS

The Control Box Mother board provides the capability to adjust some wire feeding parameters as follows:

Acceleration: The motor acceleration can be varied in five steps, from slow to fast. See “Setting DIP Switches in the Control Box” section.

Burnback: For the options which cannot adjust the Burnback set up parameter (CV/G and M panels) a PC board adjustment (trimmer R5) is provided. The range is 0.0 to 0.25 seconds, increasing in the clockwise direction. This is ignored by options which have the ability to adjust Burnback (MX2 and MSP2 panels).

Run In: For the options which cannot adjust the Run In set up parameter (CV/G and M panels) a PC board DIP switch setting is provided. In one position, the run in speed will be the minimum Wire Drive WFS. At the other setting, run in will occur at the same speed as set on the WFS knob. This DIP switch setting is ignored by options which have the ability to adjust Run In (MX2 and MSP2 panels). See “Setting DIP Switches in the Control Box” section.

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ACCESSORIES

C-16 CONTROL BOX -- SETTING OPERATING LIMITS

Upper and lower operating limits can be set for the WFS/Amps setting and the Volts/Trim setting. Doing so requires knowledge of how to set the limits, and access to the PC board in the Control Box.

There are two independent sets of limits, Procedure A limits and Procedure B limits. If a DP/M door option is installed, the A and B limits must be set independently. If there is no DP/M door option, the Control Box defaults to Procedure A, and only Procedure A limits can be set.

With system power on, select the weld mode for which you want to set limits. If a Dual Procedure option is installed, select the procedure A. Turn the system power off. Remove the two screws holding the Control/Display panel to the Control Box, but do not unplug it. Tilt the panel down to allow access to DIP switches S1-1, S2-6 and S2-7. (See “Setting DIP Switches in the Control Box” section.) Do not allow the panel to hang by the wiring harness.

Determine if the Wire Drive is set up for low or high speed. If low speed, S1-1 should be off. If high speed, set S1-1 to on.

To adjust the lower limit, set S2-6 to on. Turn the power on and adjust the WFS/Amps and Volts/Trim knobs to the desired lower limits. Note: You will not be able to adjust the lower limit outside of the minimum and maximum wire feed speed of the Wire Drive, nor above the upper limit. Turn the system power off. Return S2-6 to off.

To adjust the upper limit, set S2-7 to on. Turn the power on and adjust the WFS/Amps and Volts/Trim knobs to the desired upper limits. Note: You will not be able to adjust the upper limit outside of the minimum and maximum wire feed speed of the Wire Drive, nor below the lower limit. Turn the system power off. Return S2-7 to off.

If a Dual Procedure panel is installed, repeat the above procedure with the Procedure B selected. When done, attach the Control/Display panel to the Control Box. The machine is now ready for normal operation with the new limits.

CONTROL BOX -- USING OPERATING LIMITS

Once set, limits apply to all weld modes. Limiting Procedure A to 200 to 300 inches per minute, for example, limits the ability of the operator to adjust his WFS in pulse, CV and FCAW weld modes. Limiting the Volts to 23.0 to 24.5 would limit the ability of the

operator to adjust his Volts in synergic and non-synergic CV modes. Procedure B could be set up with different limits. Limits are absolute -- they will override values stored in the memories. Note that limits do not apply to set up parameters, such a Preflow and Arc Control.

OPERATION WITH PREVIOUS SOFTWARE VERSION

The operation of the previous Control Box software version (S24004-2) is different than described earlier in this section. The differences are as follows:

• The Memory/Dual Procedure panel is not a valid option.

• The MX (K1542-1) and MSP (K1542-8) are are used in place of the MX2 and MSP2 options.

• Limits cannot be set.

The key difference in the MX/MSP panels, compared to the MX2/MSP2 panels, is the Spot function. In the old software, a 0.1 to 2.5 second Spot function was available on these two panels. No Crater function was available (Crater replaced Spot in the graphics on these two panels).

An upgrade kit is available to change the software from S24004-2 to the latest version of Control Box software. Once the upgrade is done, the Dual Procedure/ Memory panel becomes a valid option, limits can be set, and Spot is replaced by Crater.

POWER WAVE 455/POWER FEED 10

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SECTION D-1

MAINTENANCE

SECTION D-1

POWER WAVE 455/POWER FEED 10

TABLE OF CONTENTS

-MAINTENANCE SECTION-

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

Safety Precautions............................................................................................................................. D-2

Routine Maintenance......................................................................................................................... D-2

Power Wave................................................................................................................................ D-2

Wire Feeder................................................................................................................................. D-2

Periodic Maintenance ........................................................................................................................ D-2

Wire Drive Motor and Gearbox.................................................................................................... D-2

Gun and Cable Maintenance....................................................................................................... D-2

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D-2

MAINTENANCE

D-2

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Only qualified personnel should perform maintenance work.

Observe all additional Safety Guidelines detailed throughout this manual.

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

ROUTINE MAINTENANCE

POWER WAVE

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.

WIRE FEEDER

DRIVE ROLLS AND GUIDE TUBES

After feeding every coil of wire, inspect the drive roll section. Clean as necessary. Do not use a solvent for cleaning the drive rolls because it may wash the lubricant out of the bearing. The drive rolls and Inner Wire Guides are stamped with the wire sizes they will feed. If a wire size other than that stamped on the roll(s) is to be used, the roll(s) and Inner Wire Guides must be changed.

All drive rolls have two identical grooves. The rolls may be flipped over to use the other groove.

See

Procedure to Install Drive Rolls and Wire

Guides

in the

Operation

section for roll changing

instructions.

WIRE REEL MOUNTING - READI-REELS AND 10 THROUGH 30 LB (4.5-14 KG) SPOOLS

No routine maintenance required. Do not lubricate 2 in. (51 mm) spindle.

AVOIDING WIRE FEEDING PROBLEMS

Wire feeding problems can be avoided by observing the following gun handling and feeder set up procedures:

a. Do not kink or pull cable around sharp cor -

ners.

b. Keep the electrode cable as straight as pos-

sible when welding or loading electrode through cable.

c. Do not allow dolly wheels or trucks to run

over cables.

d. Keep cable clean by following maintenance

instructions.

e. Use only clean, rust-free electrode. The

Lincoln electrodes have proper surface lubrication.

f. Replace contact tip when the arc starts to

become unstable or the contact tip end is fused or deformed.

g. Do not use excessive wire spindle brake set-

tings.

h. Use proper drive rolls, wire guides and drive

roll pressure settings.

PERIODIC MAINTENANCE

WIRE DRIVE MOTOR AND GEARBOX

Every year inspect the gearbox and coat the gear teeth with grease. Do not use graphite grease. Refer to the

Troubleshooting

section for disassem-

bly of Drive Motor and Wire Feed Assembly.

GUN AND CABLE MAINTENANCE

See appropriate

Operator’s Manual.

POWER WAVE 455/POWER FEED 10

WARNING

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SECTION E-1

THEORY OF OPERATION

SECTION E-1

POWER WAVE 455/POWER FEED 10

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation ................................................................................................................................. Section E

Modular Inverter Based Welding System........................................................................................... E-2

System Diagram A............................................................................................................................. E-2

System Diagram B............................................................................................................................. E-3

System Diagram C............................................................................................................................. E-4

Power Source General Description.................................................................................................... E-5

Input Voltage and Precharge............................................................................................................. E-5

Switch Boards and Main Transformer................................................................................................ E-6

Control Board..................................................................................................................................... E-7

Output Rectifier and Choke................................................................................................................ E-8

Thermal Protection............................................................................................................................. E-9

Protective Circuits.............................................................................................................................. E-9

Over Current Protection..................................................................................................................... E-9

Under/Over Voltage Protection.......................................................................................................... E-9

Insulated Gate Bipolar Transistor (IGBT) Operation.......................................................................... E-10

Pulse Width Modulation..................................................................................................................... E-11

Minimum Output.......................................................................................................................... E-11

Maximum Output......................................................................................................................... E-11

Control Box (User Interface).............................................................................................................. E-12

Power Feed 10 Feed Head................................................................................................................ E-13

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E-2

THEORY OF OPERATION

E-2

POWER WAVE 455/POWER FEED 10

specific requirements and also locate and identify each piece of equipment for maximum efficiency and ease of operation.

SYSTEM DIAGRAM A

This basic system utilizes two physical pieces of equipment. Refer to Figure E.1. The power source (Power Wave 455) and the combination Control Box and wire drive (Power Feed 10) are the two circuit elements. Note the Control Box (user interface) is attached to, and internally connected to, the wire drive unit.

The communication cable is depicted by the heavy black connector line. PC board power, communications and intelligence between the power source and the combination wire drive/control box unit are conveyed through this cable.

MODULAR INVERTER BASED WELDING SYSTEM

The Welding Network is an assembly of welding equipment joined together by a common network communication cable. These individual welding components consist of a power source (Power Wave 455), a user interface (Power Feed 10 Control Box) and a modular wire drive (Power Feed 10 Wire Drive). Each discrete element in the system is designed to “talk” with the other system components so that all information is shared and the entire system is in sync. This communication and shared information network lays the groundwork for a system with superior welding performance and capabilities.

The equipment can be connected together in a daisy-chain fashion. Lincoln customers can configure a system to meet their

FIGURE E.1 — SYSTEM DIAGRAM A.

POWER

SOURCE

CONTROL BOX

(USER INTERFACE)

WIRE DRIVE

INTERNAL

CONNECTION

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E-3

THEORY OF OPERATION

E-3

POWER WAVE 455/POWER FEED 10

The communication cable is depicted by the heavy black connector line. PC board power, communications and intelligence between the wire drive and combination power source/Control Box unit are conveyed through this cable.

SYSTEM DIAGRAM B

This system utilizes two physical pieces of equipment. Refer to Figure E.2. The combination Control Box (user interface) and power source (Power Wave 455) make up one of the circuit elements. This combination unit is coupled to the wire drive module (Power Feed 10). Note the Control Box is attached to and internally connected to the power source.

FIGURE E.2 — SYSTEM DIAGRAM B.

CONTROL

BOX

(USER

INTERFACE)

POWER

SOURCE

INTERNAL

CONNECTION

WIRE DRIVE

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E-4

THEORY OF OPERATION

E-4

POWER WAVE 455/POWER FEED 10

cables. All PC board power, communications and intelligence are transmitted via the two cables.

This component configuration might be used if the wire drive unit was mounted on a boom and the Control Box located remotely from the power source.

SYSTEM DIAGRAM C

The power source (Power Wave 455), the Control Box (user interface) and the wire drive (Power Feed 10) are the three discrete and physically separate circuit components employed in this configuration. Refer to Figure E.3. The three elements are daisychained together via the communication

FIGURE E.3 — SYSTEM DIAGRAM C.

POWER

SOURCE

CONTROL BOX

(USER

INTERFACE)

WIRE DRIVE

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E-5

THEORY OF OPERATION

E-5

POWER WAVE 455/POWER FEED 10

voltage developed by the No. 2 auxiliary transformer is applied to the 115 VAC receptacle.

The 65 VDC produced from the power board rectifier is utilized by the power board to provide various DC voltages for the control board and wire feeder.

The two phases which are connected to the input board, through the power switch, are connected to the input rectifier. During precharge or “soft start” these two phases are current limited by the input board. This AC input voltage is rectified, and the resultant DC voltage is applied through the reconnect switches to the input capacitors located on the switch boards. The control board monitors the voltage across the capacitors. When the capacitors have charged to an acceptable level, the control board signals the input board to energize the main input contactor making all three phases of input power, without current limiting, available to the input capacitors. At this point, the Power Wave 455 is in the “Run Mode” of operation. If the capacitors become under or overvoltage, the control board will signal the input board to deenergize the main input contactor, and the Power Wave 455 will be disabled.

POWER SOURCE GENERAL DESCRIPTION

The Power Wave 455 is an inverter based welding power source that is designed to be part of a modular, multi-process welding system. It is a high performance, digitally controlled inverter capable of complex, high-speed waveform control. With the appropriate modular components it can support constant current, constant voltage and pulse welding processes. The output rating is 450 amps at 38 volts with a 100% duty cycle.

INPUT VOLTAGE AND PRECHARGE

The Power Wave 455 can be connected for a variety of three phase voltages. Refer to Figure E.4. The initial input power is applied to the Power Wave 455 through a line switch located on the front of the machine. Two phases of the three-phase input power is applied to the input board and both auxiliary transformers. The various secondary voltages developed by the #1 auxiliary transformer are applied to the input board, the power board rectifier and the fan motor. The 115 VAC secondary

FIGURE E.4 — INPUT VOLTAGE AND RECHARGE.

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER RECEPTACLE

RS232

CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

CAPACITOR VOLTAGE FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

S W I T C H

DRIVE

FEEDBACK

VOLTAGE

CAPACITOR

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E-6

THEORY OF OPERATION

E-6

POWER WAVE 455/POWER FEED 10

Each switch board feeds current to a separate, oppositely wound primary winding of the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondary of the main transformer. These primary currents are monitored by the current transformer (CT). If the primary currents become abnormally high, the control board will shut off the IGBTs, thus disabling machine output. The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer primary winding. The firing of the two switch boards occurs during halves of a 50 microsecond interval, creating a constant 20 kHz output.

SWITCH BOARDS AND MAIN TRANSFORMER

There are two switch boards in the Power Wave 455, each containing an input capacitor and insulated gate bipolar transistor (IGBT) switching circuitry. Refer to Figure E.5. When the machine reconnect switches are configured for a lower input voltage (below 300 VAC) the input capacitors are connected in parallel. When the machine is configured for higher input voltages (300 VAC and above) the input capacitors are connected in series.

When the input capacitors are fully charged they act as power supplies for the IGBT switching circuit. The Insulated Gate Bipolar Transistors switch the DC power, from the input capacitors, “on and off” thus supplying pulsed DC current to the main transformer primary windings. See

IGBT

Operation Discussion and Diagrams

this section.

FIGURE E.5 — SWITCH BOARDS AND MAIN TRANSFORMER.

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER RECEPTACLE

RS232 CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

DRIVE

CAPACITOR VOLTAGE FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

S W I T C H

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E-7

THEORY OF OPERATION

E-7

POWER WAVE 455/POWER FEED 10

pulse width modulation (PWM) signal (See

Pulse Width Modulation

in this section) is sent to the switch board IGBTs. In this manner, the digitally controlled high-speed welding waveform is created.

The control board also monitors the thermostats, main transformer primary current, and capacitor voltage, and activates either the thermal light and/or the status light. Dependent upon the fault situation, the control board will either disable or reduce machine output, or de-energize the main input contactor.

CONTROL BOARD

The control board performs the primary interfacing functions to establish and maintain output control of the Power Wave 455. Refer to Figure E.6. The control board sends and receives digital command information through the wire feeder receptacle and or the RS232 connector. The software that is contained within the control board processes and compares these commands with the voltage and current feedback information it receives from the current sensor and voltage sensing leads. The appropriate

FIGURE E.6 — CONTROL BOARD.

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE

RS232 CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

DRIVE

CAPACITOR VOLTAGE FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

S W I T C H

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E-8

THEORY OF OPERATION

E-8

POWER WAVE 455/POWER FEED 10

rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. Refer to Figure E.7.

OUTPUT RECTIFIER AND CHOKE

The output rectifier receives the AC output from the main transformer secondary and

FIGURE E.7 — OUTPUT RECTIFIER AND CHOKE.

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE

RS232 CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

DRIVE

CAPACITOR VOLTAGE FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

S W I T C H

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E-9

THEORY OF OPERATION

E-9

POWER WAVE 455/POWER FEED 10

OVER CURRENT PROTECTION

If the average current exceeds 590 amps, then the peak current will be limited to 100 amps until the average current decreases to under 50 amps.

UNDER/OVER VOLTAGE PROTECTION

A protective circuit is included on the control board to monitor the voltage across the input capacitors. In the event that a capacitor voltage is too high, or too low, the protection circuit will de-energize the input contactor. Machine output will be disabled and the “soft start” mode will be repeated. The protection circuit will prevent output if any of the following circumstances occur.

1. Capacitor conditioning is required. (May be required if machine has been off for a long period of time and is connected for high input voltage operation.)

2. Voltage across a capacitor exceeds 390 volts. (High line surges or improper input voltage connections.)

3. Voltage across a capacitor is under 70 volts. (Due to improper input voltage connections.)

4. Internal component damage.

THERMAL PROTECTION

Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board. One of the thermostats is located on the heat sink of the output rectifier and the other is located near the fan. (On later production machines this thermostat is located on the output choke) Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15minute period. If the fan is not turning or the air intake louvers are obstructed, then the power must be removed from the machine, and the fan problem or air obstruction corrected. On later production machines (above code 10500) the cooling fan runs only when necessary. The F.A.N. (fan as needed) system is controlled by the control board via a solid state relay.

PROTECTIVE CIRCUITS

Protective circuits are designed into the Power Wave 455 to sense trouble and shut down the machine before damage occurs to the machine's internal components.

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E-10

THEORY OF OPERATION

E-10

POWER WAVE 455/POWER FEED 10

connected to the source. The circuit is turned OFF like a light switch.

Example B shows the IGBT in an active mode. When the gate signal , a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to the circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high current applications.

Example A in Figure E.8 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components

FIGURE E.8 — IGBT OPERATION.

DRAIN

SOURCE

GATE

A. PASSIVE

B. ACTIVE

BODY REGION DRAIN DRIFT REGION

BUFFER LAYER INJECTING LAYER

DRAIN

SOURCE

GATE

BODY REGION DRAIN DRIFT REGION

BUFFER LAYER INJECTING LAYER

n+ n+

n+ P+

n+ n+

P n-

P+

POSITIVE VOLTAGE APPLIED

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E-11

THEORY OF OPERATION

E-11

POWER WAVE 455/POWER FEED 10

microsecond. The negative portion is the other IGBT group1. The dwell time (off time)

is 48 microseconds (both IGBT groups off). Since only two microseconds of the 50microsecond time period is devoted to conducting, the output power is minimized.

MAXIMUM OUTPUT

By holding the gate signal on for 24 microseconds each, and allowing only two microseconds of dwell time (off time) during the 50-microsecond cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more dark area that is under the curve indicates that more power is present.

An IGBT group consists of two IGBT modules feeding one transformer primary winding.

PULSE WIDTH MODULATION

The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as modulation. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.

MINIMUM OUTPUT

By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the cycle. The top drawing in Figure E.9 shows the minimum output signal possible over a 50-microsecond time period.

The positive portion of the signal represents one IGBT group1conducting for one

FIGURE E.9 — TYPICAL IGBT OUTPUTS.

(+)

1 µsec

48 µsec 50 µsec

1 µsec

(-)

(+)

(-)

2 µsec

24 µsec

50 µsec

24 µsec

MINIMUM OUTPUT

MAXIMUM OUTPUT

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E-12

THEORY OF OPERATION

E-12

POWER WAVE 455/POWER FEED 10

In addition to the large and smaller size options, there is a Display Panel which is standard on the Control Box unit. The Display Panel, typically installed in the upper position of the Control Box assembly, houses the encoder controls and the STATUS LED. The controls are used to adjust the wire feed speed, current, voltage and trim parameters. The STATUS LED is designed to blink a red and green code if a fault should occur.

The internal Network Connector is used when the Control Box is mounted on either the power source or the wire drive units. See

System Diagram A

and

System

Diagram B

in this section.

The optional Network Input and Output receptacles are utilized when the Control Box assembly is mounted independently from both the wire drive and power source. See

System Diagram C

in this section.

There are two DIP switch banks located on the motherboard. They are labeled S1 and S2 and are used to set display, trigger, acceleration and run in functions.

CONTROL BOX (USER INTERFACE)

The system Control Box is the main entry point for all system parameters, and from it the user can control both power source and wire feeder functions. Refer to Figure E.10. The user interface motherboard is the heart of the Control Box. Dependent upon the option panels and the information received through the network cable, it directs the entire system as to the options, wire feed speed, and weld cycle requirements and parameters.

The options are divided into two physical size categories. The smaller option, typically installed in the middle section of the control box, is dedicated to dual procedure, head selection, and memory related functions. The larger, or bottom section, is reserved for control of the setup functions for the power source (Power Wave 455) and wire drive (Power Feeder 10) such as mode, arc control, run in and timer set up.

FIGURE E.10 — CONTROL BOX (USER INTERFACE).

SMALL PANEL

OPTIONS

LARGE

PANEL

OPTIONS

AMPHENOL-OUTPUT

NETWORK RECEPTACLE

(OPTIONAL)

AMPHENOL-INPUT

NETWORK RECEPTACLE

(OPTIONAL)

NETWORK

CONNECTOR

(INTERNAL)

DIP

SWITCHES

STATUS

LED

DISPLAY AND

ENCODER PANEL

(STANDARD)

USER

INTERFACE

MOTHER-

BOARD

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E-13

THEORY OF OPERATION

E-13

POWER WAVE 455/POWER FEED 10

the correct commands are transmitted to the feed drive. The feed drive control board then sends the signals to energize the active components such as the solenoid and wire drive motor. The tach feedback signal is processed on the control board which regulates the motor armature voltage so as to maintain the required wire feed speed.

When the gun trigger is pulled, the voltage sense board relays the electrode sense signal to the input network receptacle for processing by the Control Box.

The optional shutdown feature can be implemented as a means of stopping the wire feeding in the event that the water cooler (if used) is not turned on.

The STATUS LED is designed to blink a red and green code if a fault should occur.

There is one DIP switch bank located on the wire drive control board. It is labeled S1 and is used to set gear ratios, arc polarity, and for network identification purposes.

POWER FEED 10 FEED HEAD

The Power Feed 10 is a four roll, high performance, digitally controlled, modular wire feeder that operates on 40 VDC input power. It is designed to be part of a modular, multi-process welding system. Refer to Figure E.11.

Network communications, intelligence, PC board input power, and arc voltage feedback is received and transmitted through the input network receptacle. The internal network connector plug is utilized when the Control Box is mounted directly to the wire drive unit. See

System Diagram A

in this section. The optional network output receptacle is used when the system components are connected in a daisy-chain fashion.

The feed drive control board processes the information it receives from the various user operated switches such as the gun trigger, 2-step/4-step, and cold inch switches and sends this information to other system components. This information is evaluated and

FIGURE E.11 — POWER FEED 10 FEED HEAD.

CONTROL BOARD

LEAD #67A

VOLTAGE

SENSE

LEAD #67

DRIVE

MOTOR

GEAR BOX

AND

CONDUCTOR

BLOCK

TACH

FEEDBACK

STATUS LED

2-STEP/

4-STEP

GUN TRIGGER AND DUAL PROCEDURE

RECEPTACLE

TO POWER

SOURCE OR

CONTROL

BOX

DIP SWITCH

INPUT

NETWORK

RECEPTACLE

NETWORK

CONNECTOR

(INTERNAL)

COLD

INCH/

GAS

PURGE

GAS

SOLENOID

NETWORK

OUTPUT

RECEPTACLE

(OPTIONAL)

SHUTDOWN

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E-14

NOTES

POWER WAVE 455/POWER FEED 10

E-14

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TROUBLESHOOTING AND REPAIR

POWER WAVE 455/POWER FEED 10

SECTION F-1SECTION F-1

TABLE OF CONTENTS

-TROUBLESHOOTING AND REPAIR SECTION-

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Power Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Power Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Power Wave 455 Control Board LED Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-22

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-25

Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-29

Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-31

Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-35

Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-37

Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-39

Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-43

Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-47

Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-51

Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-53

Voltage Sense PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-55

Dual Encoder PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-57

Control Cable Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-59

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-61

Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-61

Wire Feeder Control Board Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-63

Tach (Hall Effect) Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-65

Gear Box and Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-67

Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . F-71

Meter Accuracy Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-74

Control or Power Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-75

Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . F-79

Main Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-83

Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-87

Output Rectifier and Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-89

Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-93

Power Source Error Interpretation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-93

Performance Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-94

Functional Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-95

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POWER WAVE 455/POWER FEED 10

F-2

TROUBLESHOOTING AND REPAIR

F-2

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. Symptoms are grouped into the following categories: function problems, feeding problems, and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF ACTION.

The last column labeled “RECOMMENDED COURSE OF ACTION” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

HOW TO USE TROUBLESHOOTING GUIDE

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.

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

WARNING

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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

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F-3

TROUBLESHOOTING AND REPAIR

F-3

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

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

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

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

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

- Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

- If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

- Remove the PC board from the staticshielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board cannot be installed immediately, put it back in the static-shielding bag.

- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

- If you return a PC board to the Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

POWER WAVE 455/POWER FEED 10

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

CAUTION

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Reusable Container Do Not Destroy

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F-4

TROUBLESHOOTING AND REPAIR

F-4

4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

NOTE: Do not substitute boards that show physical damage.

a. If the original problem does not reap-

pear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring

harness, junction blocks, and terminal strips.

b. If the original problem is recreated

by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

POWER WAVE 455/POWER FEED 10

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F-5

TROUBLESHOOTING AND REPAIR

F-5

POWER WAVE 455/POWER FEED 10

TROUBLESHOOTING GUIDE

POWER WAVE

Observe all Safety Guidelines detailed throughout this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

The machine is dead -- no output -no fan -- no LEDs.

The main input fuses (or breaker) repeatedly fail.

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

1. Make certain the input power switch SW1 is in the ON position.

2. Check the main input fuses. If open, replace.

3. Check the 6 amp circuit breaker (CB4). Reset if tripped.

4. Make certain the reconnect panel is configured correctly for the applied input voltage.

1. Make certain the fuses or breakers are properly sized.

2. Make certain the reconnect panel is configured properly for the applied input voltage.

3. The welding procedure may be drawing too much input current or the duty cycle may be too high. Reduce the welding current and/or reduce the duty cycle.

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

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353 (WELD).

1. Check the input power switch (SW1) for proper operation. Also check the associated leads for loose or faulty connections. See wiring diagram.

2. Check CB4 for proper operation.

3. Perform the

T1 Auxiliary

Transformer Test.

4. Perform the

Power Board Test.

1. Check the reconnect switches and associated wiring. See wiring diagram.

2. Perform the

Input Rectifier

Test.

3. Perform the

Switch Board

Test.

OUTPUT PROBLEMS

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F-6

TROUBLESHOOTING AND REPAIR

F-6

POWER WAVE 455/POWER FEED 10

POWER WAVE

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The Power Wave has no output -the fan is running -- a “clicking” sound may be heard coming from the machine. The main contactor CR1 is not “pulling in”. If the STATUS LED is not steady green, see

LED Code Table.

The fan runs slow or intermittently

-- low or no weld output.

1. Turn the input power OFF immediately.

2. Make certain the reconnect panel is configured correctly for the applied input voltage.

3. If the machine is connected for 380 VAC or higher and has not been used for a long period of time, the capacitors may require “conditioning”. Let the Power Wave 455 run at an idle state for 30 minutes.

1. Make certain the reconnect panel is configured correctly.

1. Perform the

T1 Auxiliary

Transformer Test.

2. Perform the

Main Contactor

Test.

3. Perform the

Input Rectifier

Test.

4. Perform the

Switch Board

Test.

5. The power board rectifier may be faulty. Check or replace. Also check associated wiring. See wiring diagram.

6. Perform the

Power Board Test.

7. The input voltage board may be faulty.

8. The control board may be faulty.

1. Perform the

T1 Auxiliary

Transformer Test.

2. The power board rectifier may be faulty. Check or replace.

OUTPUT PROBLEMS (Continued)

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F-7

TROUBLESHOOTING AND REPAIR

F-7

POWER WAVE 455/POWER FEED 10

POWER WAVE

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The thermal LED is lit. The machine regularly overheats.

The Auxiliary Receptacle is “dead”. The 115 VAC is missing.

The Power Wave 455 won’t produce full output.

1. Welding application may exceed recommended duty cycle.

2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the

Mainte-

nance Section

of this manual.

3. Air intake and exhaust louvers may be blocked due to inadequate clearance around machine.

4. Make sure the fan is functioning correctly.

1. Check the 10 amp circuit breaker (CB2) located on the case front. Reset if necessary.

2. Check the 10 amp circuit breaker (CB3) located in the reconnect area. Reset if necessary.

1. The input voltage may be too low, limiting the output capability of the Power Wave 455. Make certain the input voltage is proper for the machine and reconnect panel configuration.

2. Make sure all three phases of input power are being applied to the machine.

1. One of the thermostats may be faulty. Check or replace. See wiring diagram.

1. Check the receptacle and asso-

ciated wiring for loose or faulty connections. See wiring diagram. (Plugs P80 and P81)

2. Perform the

Auxiliary Transfor-

mer T2 Test.

1. Perform the

Output Rectifier

Test.

2. Perform the

Power Board Test.

3. Compare the display voltage

reading with an actual voltage reading at the output terminals. If the discrepancy is greater than two volts the control board may be faulty.

4. Perform the

Current Trans-

ducer Test.

OUTPUT PROBLEMS (Continued)

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F-8

TROUBLESHOOTING AND REPAIR

F-8

POWER WAVE 455/POWER FEED 10

POWER WAVE

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

For no apparent reason, the welding characteristics have changed.

The machine often “noodle welds” with a particular procedure.

The arc burns back to the tip.

1. Check for proper wire feed speed setting. In the MIG/MAG and FCAW modes, check for proper voltage settings. In the MIG/MAG pulse modes, check the arc length trim setting. These controls are on the Control Box (user interface).

2. Check for proper shielding gas and gas flow.

3. Check for loose or faulty welding cables and connections.

1. The machine may be trying to deliver too much power. When the average output current exceeds a maximum limit, the machine will “phase back” to protect itself. Adjust the procedure or reduce the load to lower the current draw from the Power Wave 455 machine.

Power Wave 455 - When the average output current exceeds 570 amps, the output current is phased back to 100 amps.

1. The voltage settings may be too high for the procedure.

2. The voltage sensing lead or connection may be faulty. See the Power Feed 10 Wiring Diagram

1. If zero arc voltage is displayed on the Control Box while welding, the voltage sense leads may be broken. Check lead #67 at the wire drive. See wiring diagram. Also check leads #202 (Neg. output terminal) and #206 (Pos. output terminal). See Power Wave 455 wiring diagram. If external voltage sensing is utilized, check the #21 lead between the 4-pin receptacle on the Power Wave 455 and the workpeice.

2. Perform the

Output Rectifier

Test.

3. The control board may be faulty.

4. Perform the

Current Trans-

ducer Test.

1. Perform the

Current Trans-

ducer Test.

2. The control board may be faulty.

1. Perform the

Voltage Sense PC

Board Test.

WELDING PROBLEMS

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F-9

TROUBLESHOOTING AND REPAIR

F-9

POWER WAVE 455/POWER FEED 10

POWER WAVE

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The wire feeder won’t work. No lights. Apparently the wire feeder is not being powered-up.

1. Make certain the Power Wave 455 is turned on.

2. Check circuit breaker CB1 located on the case front of the Power Wave 455. Reset if necessary.

3. Check the 6 amp circuit breaker (CB4) located on the reconnect panel. Reset if necessary.

4. Check the control cable between the power source and the wire feeder.

Check for loose or broken connections. Check continuity on all five leads from one end to the other.

1. Check for 40 VDC on pin “D” (+) and pin “E” (-) at the Power Wave 455 wire feeder receptacle. See wiring diagram.

If 40 volts DC is not present at the Power Wave wire feeder receptacle, perform the

Power

Board Test.

2. Check the power board rectifier. See wiring diagram.

3. Perform the

T1 Auxiliary

Transformer Test.

4. If the 40 volts DC is present at the Power Wave wire feeder receptacle, the problem is in the control cable or the wire drive/control box. See

Wire Drive/Control Box Troubleshooting.

FUNCTION PROBLEMS

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F-10

TROUBLESHOOTING AND REPAIR

F-10

POWER WAVE 455/POWER FEED 10

POWER WAVE 455 STATUS LED CHART

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

CAUTION

STATUS LED CONDITION

LED is solid green (not blinking) LED is solid red

LED is solid red (not blinking)

LED is blinking red and green

POSSIBLE FAULT(S)

System operating normally.

-- Indicates that nothing is connected to the wire feeder receptacle. Connect a control cable to the Power Wave 455 wire feeder receptacle. The other end of the control cable must be connected to either a Control Box or wire drive unit.

-- The control cable may be faulty. Check continuity on all five leads from end to end in the control cable.

-- The wire drive and/or Control Box may not be properly configured or connected together. See

Installation

section of

Power Feed 10

Instruction Manual.

-- If the wire drive unit and Control Box are properly configured, consult the

Status LED Error Code Table.

-- The Power Wave 455 cannot communicate with the wire drive unit and/or the Control Box due to a problem within the Power Wave 455. Consult the three column

Troubleshooting Guide.

-- The welding software may be corrupt. Contact the Lincoln Electric Service Department.

-- If the Thermal LED is also lit, consult the Power Wave three column

Troubleshooting Guide

“Thermal LED is lit”.

-- The input voltage is too high or too low. Make certain the input voltage is proper according to the rating plate located on the rear of the Power Wave 455.

-- The Power Wave 455 is having trouble communicating with the wire drive or control box. Turn the Power Wave 455 off. Disconnect the control cable from the wire feeder receptacle on the power source. Turn the Power Wave 455 on. If the status LED then blinks green, the problem is external to the power source. If the LED is still blinking red and green, consult

Status LED Error Code Table.

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F-11

TROUBLESHOOTING AND REPAIR

F-11

POWER WAVE 455/POWER FEED 10

STATUS LED ERROR CODE TABLE

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CAUTION

DIGITAL COMMUNICATION ERRORS

#11 CAN bus off (Excessive number of communication errors).

#12 Ul time out (Loss of communication to control box).

WELDING FILE ERRORS

#21 Unprogrammed mode

#22 Empty weld table

#23 Weld table check sum (table is corrupt)

ERROR CODE LED SEQUENCE

[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

ERROR CODE LED SEQUENCE

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

NOTE: The error code signal sequence is always preceeded by a 2 second green light. If more than one error code is present, a 4 second off signal will separate the individual error code signals. Note that the [2 sec.green] is only displayed at the beginning of the entire code sequence, not between codes if more than one error code is present.

Example: (Code. #11 “one long red” followed by “one short red”) followed by (Code. #21 “two long reds”

followed by “one short red”). [2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [4.0 sec.off] [1.2 sec.red] [0.4 sec.off]

[1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

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F-12

TROUBLESHOOTING AND REPAIR

F-12

POWER WAVE 455/POWER FEED 10

STATUS LED ERROR CODE TABLE (Continued)

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

CAUTION

POWER SOURCE ERRORS

#31 Primary over current

#32 Capacitor “A” under voltage

#33 Capacitor “B” under voltage

#34 Capacitor “A” over voltage

#35 Capacitor “B” over voltage

#36 Thermal overload

#37 Machine failed soft start

ERROR CODE LED SEQUENCE

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

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F-13

TROUBLESHOOTING AND REPAIR

F-13

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

No wire feed, solenoid or arc voltage. The STATUS LEDs are steady green.

No control of wire feed speed. All STATUS LEDs are steady green. The preset wire feed speed is adjustable on the Control Box.

No welding arc voltage when the gun trigger is activated. The wire feeds normally and the gas solenoid functions properly. The STATUS LEDs are steady green on the wire drive unit and the Contol Box.

The wire feed speed does not change when welding current is established. The WFS stays at the run-in speed. The STATUS LEDs are steady green.

1. Contact your local authorized

Lincoln Electric Field Service Facility for technical assistance.

1. The gun trigger may be faulty.

Check or replace.

2. Make certain the Control Box is

configured for a wire feeding mode.

3. Check option panel connec-

tions and switch(s) for proper operation.

1. Check for a mechanical restric-

tion in the wire feed path.

1. The power source may unable

to produce welding output due to a thermal fault or other malfunction. Check STATUS LED on Power Wave 455 machine. See

Power Wave 455

Troubleshooting.

1. The run in and weld wire feed

speeds may be set to the same value. Set run in speed to a value that gives best starting results.

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353 (WELD).

1. Check the continuity of leads #556 and #557 from the gun trigger receptacle to plug J5 pins #11 and #12. See wire drive wiring diagram.

2. The wire drive control board may be faulty.

3. The Control Box control board may be faulty.

1. Perform the

Tach Feedback

Test.

2. The wire drive control board may be faulty.

1. Make certain the Power Wave

455 power source is functioning correctly.

2. The wire drive control board may be faulty.

3. The Control Box control board may be faulty.

1. Perform the

Current Trans-

ducer Test.

2. If the run in wire feed speed cannot be adjusted, perform the

Tach Feedback Test

and also

the

Drive Motor Test.

3. The wire drive control board may be faulty.

FUNCTION PROBLEMS

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

F-14

TROUBLESHOOTING AND REPAIR

F-14

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The purge switch on the wire drive unit does not activate the gas solenoid, but gun trigger closure in the MIG or Pulse modes does acitvate the solenoid. The LEDs are steady green on the power source, Control Box and wire drive unit.

The COLD INCH/GAS PURGE switch does not turn on the wire drive motor but gun trigger closure in the MIG or Pulse modes does activate the wire drive motor. The LEDs are steady green on the power source, Control Box and wire drive unit.

The voltmeter on the Control Box does not function properly even though the STATUS LEDS are steady green.

1. Make certain the COLD INCH/GAS PURGE switch is operating properly.

2. Check for loose or faulty leads between COLD INCH/GAS PURGE switch and the wire drive control board. See wiring diagram.

1. Make certain the COLD INCH/GAS PURGE switch is operating properly.

2. Check for loose or faulty leads between the COLD INCH/GAS PURGE switch and the wire drive control board. See wiring diagram.

1. Make sure the DIP switches are configured correctly for the welding polarity being used. See

Setting DIP Switches in the Wire Drive

in the

Installation

section of this manual.

2. Check the #67 lead on the wire drive unit. Make sure it is connected to the motor gear box and also the voltage sense PC board.

3. Check the work sensing leads on the Power Wave 455 power source. Check leads #202 (Neg. output terminal) and #206 (Pos. output terminal). See Power Wave 455 wiring diagram. If external voltage sensing is utilized, check the #21 lead between the 4-pin receptacle on the front of the Power Wave 455 and the workpiece.

1. If the COLD INCH/GAS PURGE switch is operating correctly and the associated leads are OK, the wire drive control board may be faulty.

1. Check leads #512B and #511 from plug J4 on the wire drive control board to the voltage sense PC board.

2. Perform the

Voltage Sense

Board Test.

3. The display board may be faulty.

4. The wire drive control board may be faulty.

5. The Control Box control board may be faulty.

FUNCTION PROBLEMS (Continued)

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F-15

TROUBLESHOOTING AND REPAIR

F-15

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The ammeter on the Control Box does not function properly even though the STATUS LEDs are steady green.

The display and/or indicator LEDs do not change when their corresponding switches and or knobs are activated or turned.

The mode and/or settings change while welding under normal conditions.

The feeder resets when the gun trigger is activated. The LEDs blink and the displays are intermittent.

1. Make sure the DIP switches are configured correctly for the welding process and polarity being used. See

Setting DIP

Switches in the Wire Drive

the

Installation

section of this

manual.

2. Check the following connections on the Power Wave 455 machine. Check for loose or faulty connections between plug J90 at the current transducer and plug J21 on the Power Wave 455 control board.

1. Check for loose or faulty connections between the encoder panel and the Control Box control board.

2. Check for loose or faulty connections between the appropriate switches and the Control Box control board.

1. Contact the Lincoln Electric service dept. for possible software updates 1-800-833-9353. (Please ref. your current software number.)

1. The auxiliary reconnect (Lead “A”) may not be configured correctly.

See Figure A.2.

in the Installation Section of this manual.

1. Perform the

Current Trans-

ducer Test.

2. The display board, located in the control box, may be faulty.

3. The control board, located in the power source, may be faulty.

1. Check suspected potentiometer and/or switches for correct resistances and operation.

2. Perform the

Encoder PC Board

Test.

3. The Control Box control board may be faulty.

1. Perform the

Power Board Test

2. Perform the

Auxiliary

Transformer Test #1.

FUNCTION PROBLEMS (Continued)

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F-16

TROUBLESHOOTING AND REPAIR

F-16

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The displays are blank (not lit). The wire feeds when the gun trigger is activated.

The dual procedure is not functional when using the remote Dual Prodedure switch. The STATUS LEDs are steady green on the power source, Control Box and wire drive units.

1. Check for loose or faulty connections at plug J1 on the display board, to plug J4 on the Control Box control board.

1. Make certain the the bat switch on the Dual Procedure Panel is in the middle position. This enables the gun remote dual procedure switch.

1. Check for 12 VDC at plug J1 pin 7 (lead #512+) to plug J1 pin 8 (lead #500-) on the display board. If the 12 VDC is present, then the display board may be faulty.

2. If the 12 VDC is low or not present, check for loose or faulty connections on leads #512 and #500.

3. The Control Box control board may be faulty.

1. The remote Dual Procedure switch may be faulty. Check switch and associated leads.

2. The local dual procedure switch may be faulty.

Remove power to the machine. Disconnect plug J5 from the Control Box control board. Check for continuity (less than one ohm) between pins 1 and 7 when the Dual Procedure switch is in position “A”. Next check for continuity (less than one ohm) between pins 1 and 8 when the Dual Procedure switch is in the “B” position. If either of these continuity tests fail, replace the switch. When the switch is in the center postion there should not be any continuity between pins.

3. The Control Box control board may be faulty.

FUNCTION PROBLEMS (Continued)

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F-17

TROUBLESHOOTING AND REPAIR

F-17

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The Dual Procedure is not functioning when using the local Dual Procedure switch on the Control Box. The STATUS LEDs are steady green on the power source, Control Box and wire drive units.

The wire feed speed is consistent and adjustable, but runs at the wrong speed.

The unit shuts off while welding or attempting to weld. The STATUS LED is alternating between red and green every second. The unit tries to recover after 30 seconds and may repeat sequence.

1. Check the leads and plug J5 between the switch and the Control Box control board for loose or faulty connections. See wiring diagram.

1. The DIP switch on the wire drive unit may not be set for the correct gear ratio. See the

Instal-

lation

section of this manual.

1. The shut down circuit in the wire drive unit may be electrically “open”. Make sure leads #570 and #571 are connected together.

2. The drive motor may be over loaded due to a mechanial restriction in the wire feeding path. See

Operation

section of

this manual.

1. The local dual procedure switch may be faulty.

Remove power to the machine. Disconnect plug J5 from the Control Box control board. Check for continuity (less than one ohm) between pins 1 and 7 when the Dual Procedure switch is in position “A”. Next check for continuity (less than one ohm) between pins 1 and 8 when the Dual Procedure switch is in the “B” position. If either of these continuity tests fail, replace the switch. When the switch is in the center position, there should not be any continuity between pins.

2. The Control Box control board may be faulty.

1. The wire drive control board may be faulty.

1. Disconnect any shutdown device from leads #570 and #571 (0.25 in. insulated tab terminals). Connect leads #570 and #571 together. If the feeder STATUS LED is now steady green, the problem is in the external shutdown circuit.

2. If there are no restrictions in the wire feeding path, the drive motor or gear box may be faulty.

3. The wire drive control board may be faulty.

FUNCTION PROBLEMS (Continued)

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F-18

TROUBLESHOOTING AND REPAIR

F-18

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

When the gun trigger is activated, the drive rolls do not turn. The arc voltage is present and the solenoid is energized. The STATUS LEDs are steady green.

The wire is feeding rough or not feeding, but the drive rolls are turning.

When in CC modes with the optional “MX” or “MSP” panels, the output does not energize.

1. Check plug J3 on the wire drive control board, and leads #550 and #551 for loose or faulty connections. See wiring diagram.

1. The drive roll pressure may be incorrect. Set drive roll pressure. See

Operation

section in

this manual.

2. Check for dirty or rusty electrode wire.

3. Make sure the drive rolls and wire guides are positioned and installed correctly. See

Opera-

tion

section of this manual.

4. Check for mechanical restrictions in the wire feeding path.

1. Rotate Volts/Trim encoder knob at least 45° clockwise. This is normal. See

Accessories

sec-

tion for detailed operation.

1. Perform the

Drive Motor Test

2. The wire drive control board may be faulty.

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353

(WELD).

1. Check option panel installation for loose or faulty connections.

FUNCTION PROBLEMS (Continued)

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F-19

TROUBLESHOOTING AND REPAIR

F-19

POWER WAVE 455/POWER FEED 10

POWER FEED

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

The gun tip seizes in diffuser.

Poor arc striking with sticking or “blast-offs”. The weld bead may be narrow and ropy with weld porosity.

The arc is variable and/or hunting. The power source, Control Box and drive units seem to be operating properly.

1. The tip may be overheating due to prolonged or excessive high current and /or duty cycle. Do not exceed the current and duty cycle rating of the gun.

2. A light application of high temperature antiseize lubricant (such as Graphite Grease) may be applied to tip threads.

1. Make sure the weld procedures are correct for the process being used. Check gas, wire feed, speed and arc voltage.

2. Remove the gun liner and check the rubber seal for any sign of deterioration or damage. Be sure the set screw in the connector block is in place and tightened against the liner bushing.

3. Check the welding cables for loose or faulty connections.

1. Check the contact tip. It may be worn or the wrong size for the electrode wire being used.

2. Check for loose or faulty welding cables and connections.

3. Make sure the weld procedures are correct for the process being used. Check gas, wire feed speed and arc voltage.

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353

(WELD).

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353

(WELD).

1. Contact the Lincoln Electric Service Department, 216-3832531 or 1-800-833-9353

(WELD).

WELDING PROBLEMS

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F-20

TROUBLESHOOTING AND REPAIR

F-20

POWER WAVE 455/POWER FEED 10

POWER FEED ERROR CODE CHART

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

CAUTION

DISPLAYED CODE

POSSIBLE CAUSE (FAULT)

RECOMMENDED COURSE OF ACTION

Err 011

Err 003

Err 004

Err 005

Err 006

Err 020

More than one control box has the same group number.

There are too many objects in the group.

More than one object of the same equipment type with the same group number and feed head number.

A wire drive unit has its DIP switches set to zero. It is in a group that has more than one object.

The unit did not receive a recognition command from the power source.

An attempt was made to reprogram the Control Box or the wire drive unit, but the program did not verify.

Make sure the group DIP switch setting is unique for each Control Box. See

Installation

section of

this manual. A given group can support a max-

imun of seven objects. Remove any objects over seven either by changing the group DIP switch settings or physically disconnecting the “extra” objects. See

Instal-

lation

section of this manual.

Adjust the DIP switch setting to make either the group number or the feed head number unique for all objects of the same equipment type. See

Installation

section of

this manual. The appropriate wire drive numbers

are 1 through 7. Check the DIP switch setting chart in the

Instal-

lation

section of this manual.

Check to see if the STATUS LED on the Power Wave 455 is not steady green. If it is not steady green, refer to the

Power Wave 455 Status

LED Chart and Code Table

. Check the control cables for loose or faulty connections. Also check the continuity of all five leads from one end to the other. The control board in the PW 455 may be faulty.

Check for potential electrical high frequency noise in the surrounding area. Remove any potential HF noise and program the unit again. If the Err 020 still occurs, either replace the EEPROM chip(s) in the board being programmed or replace the entire PC board being programmed.

CONTROL BOX/WIRE DRIVE ERROR CODE CHART

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F-21

TROUBLESHOOTING AND REPAIR

F-21

POWER WAVE 455/POWER FEED 10

POWER FEED ERROR CODE CHART

Observe all Safety Guidelines detailed throughout this manual.

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

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

Err 100

Err 200

Err 201

Err 210

Err 211

- - - (three dashes)

For some reason the Power Wave 455 issued a shutdown command.

No response from the Power Wave

455. No response from either the

Control Box or wire feed unit.

EEPROM error

A microprocessor RAM error occurred in the Control Box.

Appears on the control box display.

See

Err 006

in this chart.

See

Err 006

in this chart.

If this condition occurs while welding, the status LED should be flashing red on the problem unit. Otherwise, check for any units that are flashing green. This indicates that the particular unit has not been recognized and there is a power source problem. See

Power Wave

455 Troubleshooting

. If the STATUS LED is either flashing red or steady red, there may be a fault in the control cable(s).

The parameter(s) recalled at power up was out of range. Rotate Encoder Knob to reset. Check all settings before proceeding to weld. If this condition persists, replace the Control Box control board.

Remove the input power. Wait five seconds. Turn power on. If Err 211 is displayed again, the Control Box control board may be faulty.

This is an indication that constant current such as STICK or GOUGE mode has been selected. Turning the right encoder clockwise when in this state will activate output from the Power Wave 455. Turning the right encoder counterclockwise will deactivate output.

CONTROL BOX/WIRE DRIVE ERROR CODE CHART (Continued)

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F-22

NOTES

POWER WAVE 455/POWER FEED 10

F-22

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PW 455 CONTROL BOARD LED DEFINITIONS

LED COLOR AND NUMBER CIRCUIT INDICATORS

Green LED 1 -15 VDC Supply Green LED 3 +15 VDC Supply Green LED 4 +5 VDC Supply

Red LED 5 On when jumper removed from J26

Green 6 LED +5 VDC Communication Supply

Red LED 7 Fault Error Indicator

Green LED 8 +5 VDC RS232 Supply

NOTE: The only LED that changes state when the machine is running is LED 7 (Fault Indicator). The rest are either on or off depending upon the power supply or jumper status.

F-23

TROUBLESHOOTING AND REPAIR

F-23

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

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 or 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.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353(WELD).

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

TEST DESCRIPTION

This “safety” procedure should be performed before any internal maintenance or repair procedures are attempted on the Power Wave 455. Capacitance normally discharges within 2 minutes of removing input power. This procedure is used to check that the capacitors have properly discharged.

This procedure takes approximately 9 minutes to perform.

MATERIALS NEEDED

3/8 in. nutdriver Volt-Ohmmeter 25-1000 ohms @ 25 watts (minimum) resistor Electrically insulated gloves and pliers

POWER WAVE 455/POWER FEED 10

WARNING

TEST PROCEDURES

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F-24

TROUBLESHOOTING AND REPAIR

F-24

POWER WAVE 455/POWER FEED 10

6. Using the high wattage resistor (251000 ohms @ 25 watts (minimum), electrically insulated gloves and pliers, connect the resistor across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS.

NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.

7. Repeat procedure for the other capacitor.

8. Recheck the voltage across the capacitor terminals. The voltage should be zero. If any voltage remains, repeat the discharge procedure.

NOTE: Voltage present after the discharge has been performed is an abnormal condition and may indicate a switch board problem.

TEST PROCEDURE

1. Remove input power to the Power Wave 455.

2. Using the 3/8 in. nutdriver, remove the left and right case sides.

3. Be careful not to make contact with the capacitor terminals that are located in the bottom center of the left and right side switch boards. See Figure F.1.

4. Carefully check for a DC voltage at the capacitor terminals on both boards. Note the polarity is marked on the PC board and also lead #19 is positive.

5. If any voltage is present, proceed to Step #6. If no voltage is present, the capacitors are discharged.

FIGURE F.1 — CAPACITOR DISCHARGE PROCEDURE.

CAPACITOR TERMINALS

SWITCH

BOARD

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

(continued)

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F-25

TROUBLESHOOTING AND REPAIR

F-25

SWITCH BOARD TEST

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

TEST DESCRIPTION

This test will help determine if the “power section” of the switch boards are functioning correctly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because these boards can be damaged easily. In addition, it is dangerous to work on these boards with the machine energized.

This procedure takes approximately 20 minutes to perform.

MATERIALS NEEDED

3/8 in. nutdriver 3/8 in. wrench Analog Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

WARNING

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F-26

TROUBLESHOOTING AND REPAIR

F-26

POWER WAVE 455/POWER FEED 10

4. Locate label and remove leads 19C and 19D from the reconnect switches with the 3/8 in. wrench. Note lead placement for reassembly. Clear leads. Refer to Figure F.2.

5. Using the Analog ohmmeter, perform the resistance tests detailed in Table F.1. Refer to Figure F.3 for the test points.

TEST PROCEDURE

1. Remove input power to the Power Wave 455.

2. Using the 3/8 in. nutdriver, remove the case top and sides.

3. Perform the

Capacitor Discharge

Procedure.

FIGURE F.2 — RECONNECT SWITCHES.

19C

19D

RECONNECT

SWITCHES

SWITCH BOARD TEST

(continued)

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F-27

TROUBLESHOOTING AND REPAIR

F-27

POWER WAVE 455/POWER FEED 10

8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are installed in the same location they were removed from.

9. Install the right and left case sides using the 3/8 in. nutdriver.

6. If any test fails replace both switch boards. See

Switch Board Removal

and Replacement.

7. If the switch board resistance tests are OK, check the molex pin connections and associated wiring from the switch boards to the control board. See wiring diagram.

FIGURE F.3 — SWITCH BOARD TEST POINTS.

SWITCH

BOARD

-20+19

11/12

15/16

13/14

17/18

SWITCH BOARD TEST

(continued)

APPLY POSITIVE TEST APPLY NEGATIVE TEST NORMAL

PROBE TO TERMINAL PROBE TO TERMINAL RESISTANCE READING

+19 11/12 OR 15/16 Greater than 1000 ohms

+19 13/14 OR 17/18 Greater than 1000 ohms 11/12 OR 15/16 - 20 Greater than 1000 ohms 13/14 OR 17/18 - 20 Greater than 1000 ohms

- 20 11/12 OR 15/16 Less than 100 ohms

- 20 13/14 OR 17/18 Less than 100 ohms 11/12 OR 15/16 +19 Less than 100 ohms 13/14 OR 17/18 +19 Less than 100 ohms

TABLE F.1 — SWITCH BOARD RESISTANCE TEST.

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F-28

NOTES

POWER WAVE 455/POWER FEED 10

F-28

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F-29

TROUBLESHOOTING AND REPAIR

F-29

OUTPUT RECTIFIER TEST

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

TEST DESCRIPTION

The test will help determine if any of the output rectifiers are shorted.

This procedure takes approximately 10 minutes to perform.

MATERIALS NEEDED

Analog Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

WARNING

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F-30

TROUBLESHOOTING AND REPAIR

F-30

POWER WAVE 455/POWER FEED 10

3. With the analog ohmmeter, measure the resistance between the positive and negative output terminals. Refer to Figure F.4. IMPORTANT: The positive (+) meter probe must be attached to the positive (+) output terminal and the negative (-) meter probe must be attached to the negative (-) output terminal.

4. If the reading is more than 200 ohms, the output rectifier modules are not shorted. If the reading is less than 200 ohms, one or more of the rectifier modules are shorted. Refer to the

Output Rectifier Module Replacement Procedure.

TEST PROCEDURE

1. Remove main input supply power to the Power Wave 455.

NOTE: Later code machines have a 50 ohm resistor across the welding output terminals. It will be necessary to remove the case sides and

Perform the Input Filter

Capacitor Discharge Procedure.

Remove and insulate one of the resistor leads (# 202A or #206A) from the appropriate welding output terminal. See the wiring diagram.

2. Remove any output load that may be connected to the Power Wave 455.

FIGURE F.4 — OUTPUT RECTIFIER TEST.

NEGATIVE (-)

OUTPUT

TERMINAL

POSITIVE (+)

OUTPUT

TERMINAL

OUTPUT RECTIFIER TEST

(continued)

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F-31

TROUBLESHOOTING AND REPAIR

F-31

INPUT RECTIFIER TEST

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

TEST DESCRIPTION

This test will help determine if the input rectifier has “shorted” or “open” diodes.

This procedure takes approximately 15 minutes to perform.

MATERIALS NEEDED

Analog Volt-Ohmmeter Phillips head screwdriver Wiring diagram 3/8 in. nutdriver

POWER WAVE 455/POWER FEED 10

WARNING

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F-32

NEG (-)

POS (+)

INPUT

RECTIFIER

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER TEST (continued)

FIGURE F.5 — INPUT RECTIFIER TEST.

F-32

TEST PROCEDURE

1. Remov e i nput pow er to t he Power Wave 455.

2. Using the 3/8 in. nutdriver, remove the case top.

3. Perfo rm the C apaci tor Di sch arge

Procedure.

4. Locate the Input Re ct if ie r and lead locations. Refer to Figure F.5.

NOTE: Some RTV sealant may have to be removed from the input rectifier terminals. The RTV should be replaced when test is complete.

5. With the P hilli ps he ad sc rewdr iver

6. Use the analog ohmmeter to perform

remove the positive and negative leads from the rectifier.

the tests detailed in Table F.2.

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POWER WAVE 455/POWER FEED 10

F-33

TROUBLESHOOTING AND REPAIR

F-33

POWER WAVE 455/POWER FEED 10

9. If the input rectifier is good, be sure to reconnect the positive and negative leads to the correct terminals and torque to 31 in/lbs. See wiring diagram.

10. Replace any RTV sealant previously removed.

11. Install the case top.

7. If the input rectifier does not meet the acceptable readings outlined in the table, the component may be faulty. Replace.

NOTE: Before replacing the input rectifier, perform the

Switch Board Test

and the

Input Contactor Test.

8. When installing a new input rectifier, see

Input Rectifier Removal and

Replacement

procedure.

TABLE F.2 — INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS.

INPUT RECTIFIER TEST

(continued)

TEST POINT TERMINALS ANALOG METER X10 RANGE

+ Probe - Probe Acceptable Meter Readings

A NEG Greater than 1000 ohms B NEG Greater than 1000 ohms C NEG Greater than 1000 ohms

A POS Less than 100 ohms B POS Less than 100 ohms C POS Less than 100 ohms

NEG A Less than 100 ohms NEG B Less than 100 ohms NEG C Less than 100 ohms

POS A Greater than 1000 ohms POS B Greater than 1000 ohms POS C Greater than 1000 ohms

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F-34

NOTES

POWER WAVE 455/POWER FEED 10

F-34

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F-35

TROUBLESHOOTING AND REPAIR

F-35

INPUT CONTACTOR TEST

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

TEST DESCRIPTION

This test will help determine if the input contactor is functional and if the contacts are functioning correctly.

This procedure takes approximately 17 minutes to perform.

MATERIALS NEEDED

3/8 in. nutdriver Volt-Ohmmeter External 24 VAC supply

POWER WAVE 455/POWER FEED 10

WARNING

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F-36

TROUBLESHOOTING AND REPAIR

F-36

POWER WAVE 455/POWER FEED 10

FIGURE F.7 — INPUT CONTACTOR

TEST POINTS.

6. When the contactor is NOT activated, the resistance should be infinite or very high across the contacts. If the resistance is low, the input contactor is faulty.

7. Reconnect the four leads (601, 601A, X4, and X4A) to the input contactor coil.

8. Install the input access door and case top using the 3/8 in. nutdriver.

TEST PROCEDURE

1. Remove input power to the Power Wave 455.

2. Using the 3/8 in. nutdriver, remove the input access panel and case top.

3. Locate, mark, and remove the four leads (601, 601A, X4 and X4A) that are connected to the input contactor coil. Refer to Figure F.6.

4. Using the external 24 VAC supply, apply 24 VAC to the terminals of the input contactor coil. If the contactor does NOT activate, the input contactor is faulty. Replace.

5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is normal). Refer to Figure F.7. If the resistance is high, the input contactor is faulty. Replace the input contactor.

FIGURE F.6 — INPUT CONTACTOR COIL.

INPUT

CONTACTOR

X4/X4A

601/601A

INPUT CONTACTOR TEST

(continued)

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Lincoln Electric SVM135-B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

The main input fuses (or breaker) repeatedly fail.

The thermal LED is lit. The machine regularly overheats.

The Auxiliary Receptacle is “dead”. The 115 VAC is missing.

The machine often “noodle welds” with a particular procedure.

The arc burns back to the tip.

The wire feeder won’t work. No lights. Apparently the wire feeder is not being powered-up.

LED is solid red (not blinking)

LED is blinking red and green

#11 CAN bus off (Excessive number of communication errors).

#21 Unprogrammed mode

#22 Empty weld table

#23 Weld table check sum (table is corrupt)

#31 Primary over current

#32 Capacitor “A” under voltage

#33 Capacitor “B” under voltage

#34 Capacitor “A” over voltage

#35 Capacitor “B” over voltage

#36 Thermal overload

#37 Machine failed soft start

No control of wire feed speed. All STATUS LEDs are steady green. The preset wire feed speed is adjustable on the Control Box.

The voltmeter on the Control Box does not function properly even though the STATUS LEDS are steady green.

The ammeter on the Control Box does not function properly even though the STATUS LEDs are steady green.

The feeder resets when the gun trigger is activated. The LEDs blink and the displays are intermittent.

The displays are blank (not lit). The wire feeds when the gun trigger is activated.

The wire feed speed is consistent and adjustable, but runs at the wrong speed.

The wire is feeding rough or not feeding, but the drive rolls are turning.

When in CC modes with the optional “MX” or “MSP” panels, the output does not energize.

The gun tip seizes in diffuser.

Poor arc striking with sticking or “blast-offs”. The weld bead may be narrow and ropy with weld porosity.

Err 011

Err 003

Err 004

Err 005

Err 006

Err 020

Err 100

Err 200

Err 201

Err 210

Err 211

- - - (three dashes)