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: [phone] FAX: [phone] 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.

____________________________________________________

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

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers

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

____________________________________________________

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

___________________________________________________

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

___________________________________________________

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

i

SAFETY

i

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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ii

SAFETY

ii

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.

iii

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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iv

SAFETY

iv

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

v

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

v

RETURN TO MAIN INDEX

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 (10)

8 (6)

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

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'

'A'

VOLTAGE=380-415V

'A'

S23847

VOLTAGE=200-208V

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

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

TO

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

S1

ON

1 2 3 4 5 6 7 8

S2

ON

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

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 Spare
7 Spare
8 Reserved

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

1

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

1

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 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”.

S1

ON

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

in

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

m

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.

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

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

PIN

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.

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

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