IM807-A

POWER WAVE 455 M

June, 2004
™
For use with machines having Code Numbers: 11007, 11203

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 thought-
ful 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.

IEC 60974-1

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• 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: [Link]
Downloaded from [Link] manuals search engine
 i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good [Link] hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95

Downloaded from [Link] manuals search engine

 ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and [Link] welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.g. Never dip the electrode in water for cooling. ucts.

3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

Downloaded from [Link] manuals search engine

 iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.

6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.

6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

Downloaded from [Link] manuals search engine

 iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
[Link] jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93

Downloaded from [Link] manuals search engine

 v SAFETY v

Downloaded from [Link] manuals search engine

 vi SAFETY vi

Downloaded from [Link] manuals search engine

 vii vii

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

Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

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

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

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

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

• For On-Line Registration: Go to our WEB SITE at [Link]. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

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

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

Downloaded from [Link] manuals search engine

 ix TABLE OF CONTENTS ix
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 455M .................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Lifting...............................................................................................................A-2
Stacking ..........................................................................................................A-2
Machine Grounding ...............................................................................................A-2
High Frequency Protection ....................................................................................A-2
Input Connection....................................................................................................A-2
Input Fuse and Supply Wire Considerations .........................................................A-3
Electrode and Work Cable Connections................................................................A-3
Cable Inductance, and its Effects on Pulse Welding ............................................A-4
Negative Electrode Polarity ...................................................................................A-4
Voltage Sensing ................................................................................................... A-4
Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-5
System Description................................................................................................A-5
Configuring the System .........................................................................................A-6
Alternate Hard Automatic Application ....................................................................A-7
Combinaation Hard Automtion Application ............................................................A-7
Dual Head Boom Feeder .......................................................................................A-7
Welding with Multiple Power Waves......................................................................A-8
Control Cable Specifications..................................................................................A-8
Multiple Arc Unsynchronized .................................................................................A-9
I / O Receptacle Specifications............................................................................A-10
Dip Switch Settings and Locations...............................................................A-10
Control Board Dip Switch ..............................................................................A-10
Water Flow Sensor........................................................................................A-10
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Graphic Symbols that appear on this machine or in this manual...........................B-2
Definition of Welding Terms...................................................................................B-3
General Description ...............................................................................................B-4
Recommended Processes and Equipment ...........................................................B-4
Required Equipment ..............................................................................................B-4
Limitations..............................................................................................................B-4
Duty Cycle and Time Period ..................................................................................B-4
Case Front Controls...............................................................................................B-5
Nominal Procedures ..............................................................................................B-6
Fringe Procedures...........................................................................................B-6
Making a Weld ................................................................................................B-6
Welding Adjustment ........................................................................................B-6
Constant Voltage Welding .....................................................................................B-7
Pulse Welding........................................................................................................B-8
________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Equipment ...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Compatible Lincoln Equipment .......................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance ............................................................................................D-1
Calibration Specification ........................................................................................D-1
________________________________________________________________________

Downloaded from [Link] manuals search engine

 x TABLE OF CONTENTS x
Page
Troubleshooting ..............................................................................................Section E
How to use Troubleshooting Guide .......................................................................E-1
Using the Status LED to Troubleshoot System Problems .....................................E-2
Error Codes For Power Waves..............................................................................E-3
Troubleshooting Guide.............................................................................E-4 thru E-6
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagrams ..................................................................................Section F-2
Dimension Print............................................................................................Section F-3
________________________________________________________________________
Parts Lists ....................................................................................................P438 Series
________________________________________________________________________

Downloaded from [Link] manuals search engine

 A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT OUTPUT CONDITIONS INPUT CURRENT OUTPUT CONDITIONS INPUT CURRENT
VOLTS AMPS / VOLTS / DUTY CYCLE AMPS AMPS / VOLTS / DUTY CYCLE AMPS

380V - 60HZ. 400A@36V. 100% 36A 500A@40V. 60% 48A

380V - 50HZ. 400A@36V. 100% 36A 500A@40V. 60% 48A
415V - 60HZ. 400A@36V. 100% 33A 500A@40V. 60% 44A
415V - 50HZ. 400A@36V. 100% 33A 500A@40V. 60% 44A

OUTPUT
OPEN CURRENT PULSE PULSE PULSE AND AUXILIARY
CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND POWER
VOLTAGE AMPS RANGE TIME RANGE

75 VDC 5 - 570A 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. - 40 VDC AT

3.3 SEC. 10 AMPS

220 VAC AT
5 AMPS
PROCESS CURRENT RANGE (DC) CURRENT
MIG/MAG 50-570 Amps
FCAW 40-570 Amps
SMAW 30-570 Amps
GTAW 15-500 Amps
Pulse 5-750 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT DUTY INPUT AMPERE TYPE 75°C TYPE 75°C TYPE 75°C
VOLTAGE / CYCLE RATING ON COPPER WIRE GROUND WIRE (SUPER LAG)
FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)
(mm2) (mm2)

380V HZ. 100% 36A 8 (10) 10 (6) 40A

415V HZ. 100% 33A 8 (10) 10 (6) 40A

PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
663 mm 505 mm 835 mm 114 kg.
(26.10 in) (19.86 in) (32.88 in) (250 lbs.)

TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
-20°C to 40°C -40°C to 40°C

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-2 INSTALLATION A-2
SAFETY PRECAUTIONS Read this LIFTING
entire installation section before you start installa-
Lift the machine by the lift bail only. The lift bail is
tion. designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.
WARNING
STACKING
ELECTRIC SHOCK can kill.
Power Wave machines can be stacked to a maximum
• Only qualified personnel should of 3 high.
perform this installation.
• Turn the input power OFF at the WARNING
disconnect switch or fuse box
before working on this equipment. Turn off the
• Lift only with equipment of
input power to any other equipment connected to
adequate lifting capacity.
the welding system at the disconnect switch or
fuse box before working on the equipment. • Be sure machine is stable
when lifting.
• Do not touch electrically hot parts. • Do not lift this machine using
lift bail if it is equipped with a
• Always connect the Power Wave 455M (CE) heavy accessory such as trail-
grounding lug (located inside the reconnect input er or gas cylinder.
access door) to a proper safety (Earth) ground.
FALLING • Do not lift machine if lift bail is
---------------------------------------------------------- EQUIPMENT can damaged.
SELECT SUITABLE LOCATION cause injury. • Do not operate machine while
Do not use Power Wave 455M (CE) in outdoor envi- suspended from lift bail.
ronments. The Power Wave 455M (CE) power source Do not stack the Power Wave 455M (CE) on top of
should not be subjected to falling water, nor should any other machine.
any parts of it be submerged in water. Doing so may ------------------------------------------------------------------------
cause improper operation as well as pose a safety
hazard. The best practice is to keep the machine in a The bottom machine must always be placed on a
dry, sheltered area. firm, secure, level surface. There is a danger of
machines toppling over if this precaution is not
Do not mount the Power Wave 455M (CE) over com- taken.
bustible surfaces. Where there is a combustible sur- -------------------------------------------------------------
face directly under stationary or fixed electrical equip-
ment, that surface shall be covered with a steel plate
MACHINE GROUNDING
at least .060" (1.6mm) thick, which shall extend not The frame of the welder must be grounded. A ground
less than 5.90" (150mm) beyond the equipment on all terminal marked with the symbol is located inside
sides. the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
Place the welder where clean cooling air can freely cir- grounding methods.
culate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign mater-
ial that can be drawn into the welder should be kept at HIGH FREQUENCY PROTECTION
a minimum. Do not use air filters on the air intake Locate the Power Wave away from radio controlled
because the air flow will be restricted. Failure to machinery.
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns. CAUTION
Machines are equipped with F.A.N. (fan as needed)
circuitry. The fan runs whenever the output is enabled, The normal operation of the Power Wave may
whether under loaded or open circuit conditions. The adversely affect the operation of RF controlled
fan also runs for a period of time (approximately 5 min- equipment, which may result in bodily injury or
utes) after the output is disabled, to ensure all compo- damage to the equipment.
nents are properly cooled.
If desired, the F.A.N. feature can be disabled (causing the
fan to run whenever the power source is on). To disable
F.A.N., connect leads 444 and X3A together at the output
of the solid state fan control relay, located on the back of
the Control PC board enclosure. (See Wiring Diagram)
POWER WAVE 455M (CE)
Downloaded from [Link] manuals search engine
 A-3 INSTALLATION A-3
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

INPUT SUPPLY CONNECTION DIAGRAM

. Disconnect input power before

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.

W / L3

V / L2 CR1

U / L1

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

XA S24190

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to
do so will result in damage to the machine.
ELECTRODE AND WORK CABLE
INPUT CONNECTION CONNECTIONS
WARNING Connect a work lead of sufficient size and length (Per
Table 1) between the proper output terminal on the
Only a qualified electrician should power source and the work. Be sure the connection to
connect the input leads to the the work makes tight metal-to-metal electrical contact. To
Power Wave 455M (CE). avoid interference problems with other equipment and to
Connections should be made in achieve the best possible operation, route all cables
accordance with all local and directly to the work and wire feeder. Avoid excessive
national electrical codes and the connection dia- lengths and do not coil excess cable.
gram located on the inside of the reconnect/input Minimum work and electrode cable sizes are as follows:
access door of the machine. Failure to do so may TABLE A.1
result in bodily injury or death. Current (60% Duty Cycle) MINIMUM COPPER
------------------------------------------------------------- WORK CABLE SIZE AWG
Use a three-phase supply line. A 45 mm (1.75 inch) Up To-30 m (100 Ft.
diameter access hole for the input supply is located on Length) 400 Amps 67 mm2 (2/0)
the upper left case back next to the input access door. 500 Amps 85 mm2 (3/0)
Connect L1, L2, L3 and ground according to the Input 600 Amps 85 mm2 (3/0)
Supply Connection Diagram decal located on the
NOTE: K1796 coaxial welding cable is recommended to
inside of the input access door or refer to Figure A.1. reduce the cable inductance in long cable lengths. This
is especially important when Pulse welding up to 350
INPUT FUSE AND SUPPLY WIRE amps.
CONSIDERATIONS
CAUTION
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and When using inverter type power sources like the
wire sizes. Fuse the input circuit with the recommend- Power Waves, use the largest welding (electrode and
ed super lag fuse or delay type breakers (also called work) cables that are practical. At least 67 mm2 2/0
“inverse time” or “thermal/magnetic” circuit breakers). copper wire - even if the average output current
Choose an input and grounding wire size according to would not normally require it. When pulsing, the
local or national electrical codes. Using fuses or circuit pulse current can reach very high levels. Voltage
breakers smaller than recommended may result in drops can become excessive, leading to poor weld-
“nuisance” shut-offs from welder inrush currents, even ing characteristics, if undersized welding cables are
if the machine is not being used at high currents. used.
POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-4 INSTALLATION A-4
CABLE INDUCTANCE, AND ITS AFFECT For additional Safety information regarding the elec-
ON PULSE WELDING trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
For Pulse Welding processes, cable inductance will
Instruction Manuals.
cause the welding performance to degrade. For the
total welding loop length less than 15.24m (50 ft.), tra-
ditional welding cables may be used without any CAUTION
effects on welding performance. For the total welding
Excessive voltage drops caused by poor work
loop length greater than 15.24m (50 ft.), the K1796
piece connections often result in unsatisfactory
Coaxial Welding Cables are recommended. The weld-
welding performance.
ing loop length is defined as the total of electrode
------------------------------------------------------------------------
cable length (A) + work cable length (B) + work length
(C) (See Figure A.3). NEGATIVE ELECTRODE POLARITY
FIGURE A.3 When negative electrode polarity is required, such as
in some Innershield applications, switch the output
POWER
WAVE
connections at the power source (electrode cable to
A the negative (-) stud, and work cable to the positive (+)
stud).
C

WORK When operating with electrode polarity negative the

B "Electrode Sense Polarity" DIP switch must be set to
For long work piece lengths, a sliding ground should the "Negative" position on the Wire Drive Feed Head
be considered to keep the total welding loop length PC Board. The default setting of the switch is positive
less than 15.24m (50 ft.). (See Figure A.4.) electrode polarity. Consult the Power Feed instruction
manual for further details.
FIGURE A.4
FIGURE A.4
POWER
WAVE
A A VOLTAGE SENSING
The best arc performance occurs when the Power
C WORK C
Waves have accurate data about the arc conditions.
B B Depending upon the process, inductance within the
SLIDING WORK CONNECTION
electrode and work lead cables can influence the
K1796 COAXIAL CABLE apparent voltage at the studs of the welder. Voltage
MEASURE FROM END
sense leads improve the accuracy of the arc conditions
OF OUTER JACKET OF and can have a dramatic effect on performance.
CABLE
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.
Output connections on some Power Waves are made
via 1/2-13 threaded output studs located beneath the CAUTION
spring loaded output cover at the bottom of the case If the voltage sensing is enabled but the sense
front. leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
Most welding applications run with the electrode being extremely high welding outputs may occur.
positive (+). For those applications, connect the elec- ------------------------------------------------------------------------
trode cable between the wire feeder and the positive
(+) output stud on the power source (located beneath The ELECTRODE sense lead (67) is built into the con-
the spring loaded output cover near the bottom of the trol cable, and is automatically enabled for all semi-
case front). Connect the other end of the electrode automatic processes. The WORK sense lead (21) con-
cable to the wire drive feed plate. The electrode cable nects to the Power Wave 455M (CE) at the four pin
lug must be against the feed plate. Be sure the con- connector located underneath the output stud cover.
nection to the feed plate makes tight metal-to-metal By default the WORK voltage is monitored at the out-
electrical contact. The electrode cable should be sized put stud in the Power Wave 455M (CE). For more
according to the specifications given in the work cable information on the WORK sense lead (21), see "Work
connections section. Connect a work lead from the Voltage Sensing” in the following paragraph.
negative (-) power source output stud to the work
piece. The work piece connection must be firm and All constant current processes sense the voltage at the
secure, especially if pulse welding is planned. output studs of the Power Wave 455M (CE) by default.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-5 INSTALLATION A-5
Enable the voltage sense leads as follows: Electrode Voltage Sensing
TABLE A.2 Enabling or disabling electrode voltage sensing is
Process Electrode Voltage Work Voltage automatically configured through software. The 67
Sensing 67 lead * Sensing 21 lead electrode sense lead is internal to the cable to the
GMAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder
GMAW-P 67 lead required 21 lead optional is present.
FCAW 67 lead required 21 lead optional
GTAW Voltage sense at studs Voltage sense at studs CAUTION
GMAW Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional Important: The electrode polarity must be config-
CAC Voltage sense at studs Voltage sense at studs ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme-
* The electrode voltage 67 sense lead is integral to ly high welding outputs.
the control cable to the wire feeder. ------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMAT-
Work Voltage Sensing
The standard Power Wave 455M’s default to the work IC POWER FEED WIRE FEEDER
stud (work sense lead disabled) INTERCONNECTIONS
For processes requiring work voltage sensing, con- The Power Wave 455M (CE) and semi-automatic
nect the (21) work voltage sense lead (K940) from the POWER FEED family communicate via a 5 conductor
Power Wave work sense lead receptacle to the work control cable (K1543). The control cable consists of two
piece. Attach the sense lead to the work piece as power leads, one twisted pair for digital communication,
close to the weld as practical, but not in the return cur- and one lead for voltage sensing. The cables are
rent path. Enable the work voltage sensing in the designed to be connected end to end for ease of exten-
Power Wave as follows: sion. The output receptacle on the Power Wave 455M
(CE) is located beneath the spring loaded output cover at
WARNING the bottom of the case front. The input receptacle on the
Power Feed is typically located at the back of the feeder,
• Do not touch electrically live or on the bottom of the user interface.
parts or electrodes with your
skin or wet clothing. For convenience sake, the electrode and control cables
can be routed behind the left or right strain reliefs (under
• Insulate yourself from the work
the spring loaded output cover), and along the channels
and ground. formed into the base of the Power Wave 455M (CE), out
• Always wear dry insulating gloves. the back of the channels, and then to the wire feeder.

----------------------------------------------------------- Due to the flexibility of the platform the configuration may

1. Turn off power to the power source at the discon- vary. The following is a general description of the sys-
nect switch. tem. For specific configuration information, consult the
semi-automatic Power Feed instruction manual.
2. Remove the front cover from the power source.
SYSTEM DESCRIPTION
3. The control board is on the left side of
the power source. Locate the 8-position The Power Wave 455M (CE) and Power Feed M family
8

DIP switch and look for switch 8 of the of products utilize a digital communication system called
7

DIP switch. ArcLink. Simply put, ArcLink allows large amounts of

6

information to be passed at very high speeds between

5

components (nodes) in the system. The system requires

4

4. Using a pencil or other small object,

3

slide the switch right to the OFF posi- only two wires for communication, and because of its
2

tion if the work sense lead is NOT con- bus-like structure, the components may be connected to
1

the network in any order, thus simplifying the system set-

nected. Conversely, slide the switch to
O
N

up.
the ON position if the work sense lead
is present.
Each "system" must contain only one power source.
The number of wire feeders is determined by the type
5. Replace the cover and screws. The PC board will
of wire feeder. Refer to the wire feeder instruction
“read” the switch at power up, and configure the
manual for details
work voltage sense lead appropriately.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-6 INSTALLATION A-6
CONFIGURING THE SYSTEM If a system can not be “Auto Mapped” then the status
light on the power source will blink green fast and the
For codes below 11100, consult the semi-automatic welder output will be disabled. If a system is not
Power Feed instruction manual for configuration infor- “Auto-mappable”, then consult the instruction manual
mation about DIP switch settings. for the accessory being used for configuration infor-
mation about DIP switch settings, or consult your local
For codes above 11100 the power source will “Auto Lincoln sales representative.
Map” the system eliminating most of the need to set
DIP switches to configure the system.

SINGLE HEAD FEEDER DUAL HEAD FEEDER

UP TO 4 FEEDERS
ALLOWED

POWER WAVE POWER WAVE

455M(CE) FEED HEAD
455M(CE)

SINGLE HEAD BOOM FEEDER

UP TO 4 FEED HEADS
ALLOWED

POWER WAVE
455M(CE)
FH 1

Typical Robotic/ Hard Automation

(using Wire Drive Module and PF-10R)

POWER WAVE 455M(CE)

ROBOT
WIRE
PF-10R
PLC CONTROLLER
ANALOG INTERFACE DRIVE
MODULE

etc.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-7 INSTALLATION A-7

ALTERNATE HARD AUTOMATIC APPLICATION

(using a UI, WD Module, and PF-10R)

POWER WAVE 455M (CE)

PF-10R
WIRE
DRIVE
MODULE

(FH1)

COMBINATION HARD AUTOMATION APPLICATION

(w/ Semi-Auto, WD Module, and PF-10R)

POWER WAVE 455M (CE)

WIRE
PF-10R
DRIVE
MODULE
DUAL HEAD
(FH1)

System that is NOT "Auto Mappable"

DUAL HEAD BOOM FEEDER

(using two single heads)

POWER WAVE
455M (CE) DUAL HEAD
FH-1 FH-2

In this case the individual feed heads need to be assigned to the dual head control and the PW455M auto map-
ping disabled and the Equipment Groups set. (See the Feeder documentation for information on setting the
feeder DIP switches)
POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-8 INSTALLATION A-8

WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS

WAVES It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
CAUTION the Power Wave / Power Feed system.
Special care must be taken when more than one
Power Wave is welding simultaneously on a single CAUTION
part. Arc blow and arc interference may occur or
be magnified. The use of non-standard cables, especially in
lengths greater than 7.62 (25 feet), can lead to
Each power source requires a work lead from the communication problems (system shutdowns),
work stud to the welding fixture. Do not combine all of poor motor acceleration (poor arc starting) and
the work leads into one lead. The welding travel direc- low wire driving force (wire feeding problems).
tions should be in the direction moving away from the ------------------------------------------------------------------------
work lead as shown below. Connect all of the work The K1543 series of control cables can be connected
sense leads from each power source to the work end to end for ease of extension. Do not exceed more
piece at the end of the weld. than 100 feet (30.5 m) total control cable length.

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the
pulsing frequency will be the same, helping to stabilize
the arcs.

Every welding gun requires a separate shielding gas

regulator for proper flow rate and shielding gas cover-
age.

Do not attempt to supply shielding gas for two or more

guns from only one regulator.

If an anti-spatter system is in use then each gun must

have its own anti-spatter system. (See Figure A.2)

FIGURE A.2
TWO POWER WAVES
POWER WAVE
POWER WAVE POWERWAVE
POWERWAVE

- +
- +

Travel
Direction

Connect All Work

Sense Leads at the End
of the Joint

Connect All Welding

Work Leads at the
Beginning of the Joint

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-9 INSTALLATION A-9

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 A-10 INSTALLATION A-10
I / O RECEPTACLE SPECIFICATIONS switch 7 auto mapping
TABLE 3 off auto mapping enable-default
WIRE FEEDER RECEPTACLE S1 on auto mapping disabled
PIN LEAD# FUNCTION
A 53 Communication Bus L
B 54 Communication Bus H
C 67A Electrode Voltage Sense switch 8 work sense lead
D 52 0vdc off work sense lead not connected-default
E 51 +40vdc on work sense lead connected

TABLE 4
VOLTAGE SENSE RECEPTACLE S2
PIN LEAD# FUNCTION
3 21A Work Voltage Sense
FIGURE A.3
TABLE 5
CONTROL BOARD (DIP Switch Location)
RS232 RECEPTACLE S3
PIN LEAD# FUNCTION
2 253 RS232 Receive
3 254 RS232 Transmit
4 # S3 Pin5
5 # S3 Pin4
6 ## S3 Pin20
20 ## S3 Pin6
7 251 RS232 Common

DIP SWITCH SETTINGS AND LOCATIONS

DIP switches on the P.C. Boards allow for custom

configuration of the Power Wave. To access the DIP
switches:
• Turn off power at the disconnect switch.
• Remove the top four screws securing the front
WATER FLOW SENSOR
access panel. Water cooled guns can be damaged very quickly if
• Loosen, but do not completely remove, the bottom they are used even momentarily without water flowing.
two screws holding the access panel. A water flow sensor is recommended for those water
• Open the access panel, allowing the weight of the coolers that do not have an integral flow sensor.
panel to be carried by the bottom two screws. Make Recommended practice is to install a water flow sen-
sure to prevent the weight of the access panel from sor such as K1536-1 on the water return line of the
hanging on the harness. torch. When fully integrated into the welding system,
• Adjust the DIP switches as necessary. the sensor will prevent welding if no water flow is pre-
• Replace the panel and screws, and restore power. sent.

CONTROL BOARD DIP SWITCH:

switch 1 = reserved for future use
switch 2 = reserved for future use
switch 3 = equipment group 1 selcted (default=off)
switch 4 = equipment group 2 selcted (default=off)
switch 5 = reserved for future use
switch 6 = reserved for future use
switch 7 = auto mapping
switch 8 = work sense lead

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-1 OPERATION B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.

WARNING

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.
• Do not use AC welder if your cloth-
ing, gloves or work area is damp or
if working on, under or inside work-
piece.
Use the following equipment:
-DC manual (stick) welder.
-AC welder with reduced voltage
control.
• Do not operate with panels
removed.
• Disconnect input power before ser-
vicing.
-------------------------------------------------------------
ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT. READ AND
FOLLOW THE MANUFACTURER’S INSTRUC-
TIONS, EMPLOYER’S SAFETY PRACTICES AND
MATERIAL SAFETY DATA SHEETS (MSDS) FOR
CONSUMABLES.
-----------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases from
your breathing zone and general area.
WELDING SPARKS can cause
fire or explosion.
• Do not weld near flammable material.
• Do not weld on containers which have
held flammable material.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-2 OPERATION B-2

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER SMAW

ON GMAW

OFF FCAW

HIGH TEMPERATURE GTAW

MACHINE STATUS U0 OPEN CIRCUIT

VOLTAGE

CIRCUIT BREAKER U1 INPUT VOLTAGE

WIRE FEEDER U2 OUTPUT VOLTAGE

POSITIVE OUTPUT I1 INPUT CURRENT

NEGATIVE OUTPUT I2 OUTPUT CURRENT

3 PHASE INVERTER PROTECTIVE

GROUND

INPUT POWER

THREE PHASE WARNING OR

CAUTION

DIRECT CURRENT

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-3 OPERATION B-3
DEFINITION OF WELDING TERMS SMAW
• Shielded Metal Arc welding
NON-SYNERGIC WELDING MODES SW
• Stud Arc Welding
• A Non-synergic welding mode requires all welding
process variables to be set by the operator. SAW
• Submerged Arc Welding
SYNERGIC WELDING MODES
SAW-S
• A Synergic welding mode offers the simplicity of • Submerged Arc Welding-(Series)
single knob control. The machine will select the cor-
rect voltage and amperage based on the wire feed FCAW
speed (WFS) set by the operator. • Flux Core Arc Welding
455M CAC
•455Modular • Carbon Arc Cutting
WFS
• Wire Feed Speed

CC
• Constant Current

CV
• Constant Voltage

GMAW
• Gas Metal Arc welding

GMAW-P
• Gas Metal Arc welding-(Pulse Arc)

GMAW-S
• Gas Metal Arc welding-(Short Circuiting Arc)

GTAW
• Gas Tungsten Arc welding

GTAW-P
• Gas Tungsten Arc welding-(Pulse Arc)

PAW
• Plasma Arc welding

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-4 OPERATION B-4
GENERAL DESCRIPTION DeviceNet Interface Module
The Power Wave 455M (CE) semi-automatic power This module can be used for DeviceNet capability. It
source is designed to be a part of a modular, multi- will be a 5 pin sealed mini connector per ANSI
process welding system. Depending on configuration, B93.55M-1981.
it can support constant current, constant voltage, and
pulse welding modes. EtherNet/DeviceNet Module
This module includes the DeviceNet and EtherNet
The Power Wave 455M (CE) power source is capability. The DeviceNet uses a 5 pin sealed mini
designed to be used with the semi automatic family of connector per ANSI B93.55M-1981. The EtherNet
Power Feed wire feeders, operating as a system. uses a RJ5 connector.
Each component in the system has special circuitry to
"talk with" the other system components, so each RECOMMENDED EQUIPMENT
component (power source, wire feeder, user interface)
knows what the other is doing at all times. These com- Power Wave 455M (CE) – Semi-Automatic
ponents communicate with ArcLink Operation
Semi Automatic Power Waves can only be used with
The Power Wave 455M (CE) is a high performance, ArcLink compatible Power Feed semi-automatic wire
digitally controlled inverter welding power source feeders and modules. In addition, the Power Feed
capable of complex, high-speed waveform control. semi-automatic wire feeders may require optional
Properly equipped, it can support the GMAW, GMAW- equipment to access certain weld modes in the Power
P, FCAW, SMAW, GTAW, and CAC processes. It car- Wave. Other models of Lincoln feeders, or any mod-
ries an output rating of 400 amps, 36 volts (at 100% els of non-Lincoln wire feeders, cannot be used.
duty cycle).
All welding programs and procedures are selected
RECOMMENDED PROCESSES AND through the Power Feed M semi-automatic user inter-
face
EQUIPMENT
RECOMMENDED PROCESSES
REQUIRED EQUIPMENT
Any ArcLink compatible semi-automatic wire feeding
The Power Wave 455M (CE) can be set up in a num-
equipment. Specifically, the semi-automatic Power
ber of configurations, some requiring optional equip-
Feed M family.
ment or welding programs. Each machine is factory
preprogrammed with multiple welding procedures, typ-
ically including GMAW, GMAW-P, FCAW, GTAW, and WARNING
CAC for a variety of materials, including mild steel,
stainless steel, cored wires, and aluminum. LIMITATIONS
• The Power Waves are not to be used in outdoor
The Power Wave 455M (CE) is recommended for environments.
semi-automatic welding with ArcLink compatible ------------------------------------------------------------------------
equipment like the Power Feed M series of feeders. • Only ArcLink compatible Power Feed semi-automat-
The Power Wave 455M (CE) can have a number of ic wire feeders and users interfaces may be used.
modules installed that allow the machine to be used in Other Lincoln wire feeders or non-Lincoln wire feed-
Robotic and hard automation applications. ers cannot be used.

Wire Drive Interface Module • Power Wave 455M (CE) Output Limitations
For Robotic platforms the Wire Drive Control Module The Power Wave 455M (CE) will support maximum
is required to drive the Power Feed-10R wire drive. average output current of 500 Amps @ 60% duty
This module can be factory installed through our cycle.
automation division or field installed for robotic appli-
cations. DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding
The Wire Drive Control Module is also be equipped at a 100% duty cycle (continuous welding). The power
with a terminal strip for making simple input signal source will be the limiting factor in determining system
connections. It can be used to externally control the duty cycle capability. Note that the duty cycle is based
basic wire drive function. It is divided into three upon a ten minute period. A 60% duty cycle repre-
groups: Trigger group, Cold Inch group, and sents 6 minutes of welding and 4 minutes of idling in a
Shutdown group. ten minute period.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-5 OPERATION B-5
CASE FRONT CONTROLS FIGURE B.1
All operator controls and adjustments are located on
the case front of the Power Wave 455m (CE). (See
Figure B.1) 2 3
1
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates 6
system errors. Normal operation is a steady green
light. Error conditions are indicated, per table 3. 8
13
NOTE: The Power Wave 455M (CE) status light will
flash green, and sometimes red and green, for up to 12 14
one minute when the machine is first turned on. This
is a normal situation as the machine goes through a
self test at power up.
15
TABLE 3 10
Light Meaning 9 4 5
Condition 7 11
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components. CASE FRONT LAYOUT
POWER WAVE 455M (CE)
Blinking Occurs during a reset, and indicates the
Green Power Wave 455M (CE) is mapping (identi-
fying) each component in the system.
5. 5 AMP AUXILIARY POWER CIRCUIT BREAKER:
Normal for first 1-10 seconds after power is
Protects 220 volt AC case front receptacle
turned on, or if the system configuration is auxiliary supply.
changed during operation
6. LEAD CONNECTOR S2 (SENSE LEAD)
A l t e r n a t i n g Non-recoverable system fault. If the PS
Green and Status light is flashing any combination of 7. DIAGNOSTIC CONNECTOR (RS-232)
Red red and green, errors are present in the
Power Wave 455M (C E). Read the error 8. WIRE FEEDER RECEPTACLE (S1 5-PIN)
code before the machine is turned off.
9. NEGATIVE STUD
Error Code interpretation through the Status
light is detailed in the Service Manual. 10. POSITIVE STUD
Individual code digits are flashed in red with
a long pause between digits. If more than 11. AUXILIARY OUTPUT
one code is present, the codes will be sepa-
rated by a green light. 12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)

To clear the error, turn power source off, 13. ROBOTIC WIRE FEEDER RECEPTACLE
and back on to reset. See Troubleshooting (OPTIONAL)
Section.
14. I/O CONNECTOR (OPTIONAL)
Steady Red Non recoverable hardware fault. Generally
indicates nothing is connected to the Power 15. ETHERNET CONNECTOR (OPTIONAL)
Wave 455M (CE) wire feeder receptacle.
See Trouble Shooting Section.

Blinking Red Not applicable.

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

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:

Protects 40 volt DC wire feeder power supply.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-6 OPERATION B-6

NOMINAL PROCEDURES
WELDING ADJUSTMENTS
The Power Wave 455M (CE) is designed to operate
with 19.1mm (3/4") electrode stick-out for CV and All adjustments are made on the system component
Pulse processes. known as the User Interface (Control Box), which con-
tains the switches, knobs, and digital displays neces-
FRINGE PROCEDURES sary to control both the Power Wave 455M (CE) and a
Power Feed wire feeder. Typically, the Control Box is
Excessively short or long electrode stick-outs may supplied as part of the wire feeder. It can be mounted
function only on a limited basis, if at all. directly on the wire feeder itself, the front of the power
source, or mounted separately, as might be done in a
welding boom installation.
MAKING A WELD
Because the Control Box can be configured with many
WARNING different options, your system may not have all of the
following adjustments. Regardless of availability, all
controls are described below. For further information,
The serviceability of a product or structure utiliz- consult the Power Feed wire feeder instruction manu-
ing the welding programs is and must be the sole al.
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric • WFS / AMPS:
Company affect the results obtained in applying In synergic welding modes (synergic CV, pulse
these programs. These variables include, but are GMAW) WFS (wire feed speed) is the dominant con-
not limited to, welding procedure, plate chemistry trol parameter, controlling all other variables. The user
and temperature, weldment design, fabrication adjusts WFS according to factors such as weld size,
methods and service requirements. The available penetration requirements, heat input, etc. The Power
range of a welding program may not be suitable Wave then uses the WFS setting to adjust its output
for all applications, and the build/user is and must characteristics (output voltage, output current) accord-
be solely responsible for welding program selec- ing to pre-programmed settings contained in the
tion. Power Wave 455M (CE). In non-synergic modes, the
------------------------------------------------------------------------ WFS control behaves more like a conventional CV
power source where WFS and voltage are indepen-
The steps for operating the Power Wave 455M (CE) dent adjustments. Therefore to maintain the arc char-
will vary depending upon the options installed in the acteristics, the operator must adjust the voltage to
user interface (control box) of the welding system. The compensate for any changes made to the WFS.
flexibility of the Power Wave system lets the user cus-
tomize operation for the best performance. In constant current modes (stick, TIG) this control
adjusts the output current, in amps.
First, consider the desired welding process and the
part to be welded. Choose an electrode material, • VOLTS / TRIM:
diameter, shielding gas and process (GMAW, GMAW- In constant voltage modes (synergic CV, standard
P, etc.) CV) the control adjusts the welding voltage.
Second, find the program in the welding software that In pulse synergic welding modes (pulse GMAW only)
best matches the desired welding process. The stan- the user can change the Trim setting to adjust the arc
dard software shipped with the Power Waves 455M length. It is adjustable from 0.500 to 1.500. A Trim set-
(CE) encompasses a wide range of common process- ting of 1.000 is a good starting point for most condi-
es and will meet most needs. If a special welding pro- tions.
gram is desired, contact the local Lincoln Electric
sales representative.

To make a weld, the Power Wave needs to know the

desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicat-
ed digitally via the control cable.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-7 OPERATION B-7

• WELDING MODE Non Synergic CV:

May be selected by name (CV/MIG, CC/Stick Crisp, This type of CV mode behaves more like a conven-
Gouge, etc.) or by a mode number (10, 24, 71, etc.) tional CV power source. Voltage and WFS are inde-
depending on the Control Box options. Selecting a pendent adjustments. Therefore to maintain the arc
welding mode determines the output characteristics of characteristics, the operator must adjust the voltage to
the Power Wave power source. For a more complete compensate for any changes made to the WFS.
description of the welding modes available in the
Power Wave, see the explanation below.

• ARC CONTROL All CV Modes:

Also known as Inductance or Wave Control. Allows Arc Control, often referred to as wave control, adjusts
operator to vary the arc characteristics from "soft" to the inductance of the wave shape. The wave control
"harsh" in all weld modes. It is adjustable from -10.0 to adjustment is similar to the "pinch" function in that it is
+10.0, with a nominal setting of 00.0 (The nominal set- inversely proportional to inductance. Therefore,
ting of 00.0 may be displayed as OFF on some Power increasing wave control greater than 0.0 results in a
Feed wire feeder control panels). See the Welding harsher, colder arc while decreasing the wave control
Mode descriptions, below, for detailed explanations of to less than 0.0 provides a softer, hotter arc.
how the Arc Control affects each mode. (See Figure A.5)

CONSTANT VOLTAGE WELDING

Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The nominal preprogrammed volt-
age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automati-
cally adjusts the voltage level correspondingly to
maintain similar arc characteristics throughout the
WFS range.
FIGURE A.5
CURRENT WAVE FORM (CV)

Wave Control +10.0

Wave Control 0.00

Wave Control -10.0

Current

Time

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 B-8 OPERATION B-8
PULSE WELDING The Power Wave 455M (CE) utilizes "adaptive con-
trol" to compensate for changes in electrical stick-out
Pulse welding procedures are set by controlling an while welding. (Electrical stick-out is the distance from
overall "arc length" variable. When pulse welding, the the contact tip to the work piece.) The Power Wave
arc voltage is highly dependent upon the waveform. waveforms are optimized for a 0.75" (19mm) stick-out.
The peak current, back ground current, rise time, fall The adaptive behavior supports a range of stickouts
time and pulse frequency all affect the voltage. The from 0.50" (13mm) to 1.25" (32mm). At very low or
exact voltage for a given wire feed speed can only be high wire feed speeds, the adaptive range may be
predicted when all the pulsing waveform parameters less due to reaching physical limitations of the welding
are known. Using a preset voltage becomes impracti- process.
cal, and instead the arc length is set by adjusting
"trim". Arc Control, often referred to as wave control, in pulse
programs usually adjusts the focus or shape of the
Trim adjusts the arc length and ranges from 0.50 to arc. Wave control values greater than 0.0 increase the
1.50, with a nominal value of 1.00. Trim values greater pulse frequency while decreasing the background cur-
than 1.00 increase the arc length, while values less rent, resulting in a tight, stiff arc best for high speed
than 1.00 decrease the arc length. sheet metal welding. Wave control values less than
0.0 decrease the pulse frequency while increasing the
Most pulse welding programs are synergic. As the background current, for a soft arc good for out-of-posi-
wire feed speed is adjusted, the Power Wave 455M tion welding.
(CE) will automatically recalculate the waveform para- (See Figure A.6)
meters to maintain similar arc properties.

FIGURE A.6
CURRENT WAVE FORM (PULSE)

Current

Wave Control -10.0

Wave Control 0.0
Wave Control +10.0

Time

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 C-1 ACCESSORIES C-1
OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED
Work Voltage Sense Lead Kit, K940
Dual Cylinder Undercarriage, K1570-1.
Gas Guard Regulator, K659-1
Coaxial welding Cable, K1796
Cool-Arc 40 K2187-1 (230V AC)
Water Flow Sensor, K1536-1
Wire Drive Interface Module, K2205-1
DeviceNet interface Module, K2206-1
Ethernet Interface Module, K2207-1

COMPATIBLE LINCOLN EQUIPMENT

Any Arc-Link compatible semi-automatic wire feeding

equipment. Specifically, the semi-automatic Power
Feed M family. If the wire drive interface module is
installed the machine is compatible with the Power
Feed 10R wire feeder.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 D-1 MAINTENANCE D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.

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

PERIODIC MAINTENANCE
Calibration of the Power Wave 455M (CE) is critical to
its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improper-
ly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali-
bration of output Voltage and Current should be
checked yearly.

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

The calibration procedure itself requires the use of a

resistive load bank, and certified actual meters for volt-
age and current. The accuracy of the calibration will be
directly affected by the accuracy of the measuring
equipment you use. Detailed instructions are available
with the utility.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

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

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-2 TROUBLESHOOTING E-2
charts for both machine and weld performance.
USING THE STATUS LED TO The STATUS LIGHT is a two color light that indicates
TROUBLESHOOT SYSTEM PROBLEMS system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
The Power Wave / Power Feed are best diagnosed as chart.
a system. Each component (power source, user inter-
face, and feed head) has a status light, and when a NOTE: The Power Wave 455M (CE) status light will
problem occurs it is important to note the condition of flash green, and sometimes red and green, for up to
each. In addition, errors displayed on the user inter- one minute when the machine is first turned on. This
face in most cases indicate only that a problem exists is a normal situation as the machine goes through a
in the power source, not what the problem may be. self test at power up.
Therefore, prior to cycling power to the system,
check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays "Err 006"
or "Err 100" .

Included in this section is information about the power

source Status LED, and some basic troubleshooting

LIGHT CONDITION MEANING

Status LED is solid green (no blinking). 1. System OK. Power source communicating normally
with wire feeder and its components.

Status LED is blinking green. 2. Occurs during a reset, and indicates the Power
Wave 455M (CE) is mapping (identifying) each com-
ponent in the system. Normal for first 1-10 seconds
after power is turned on, or if the system configura-
tion is changed during operation.

Status LED is blinking red and green. 3. Non-recoverable system fault. If the PS Status light
is flashing any combination of red and green, errors
are present in the Power Wave 455M (CE). Read
the error code before the machine is turned off.

Error Code interpretation through the Status light is

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

To clear the error, turn power source off, and back

on to reset.

Status LED is solid red (no blinking). Non recoverable hardware fault. Generally indicates
nothing is connected to the Power Wave 455M (CE)
wire feeder receptacle. See Trouble Shooting Section.

Status LED is blinking red. Not applicable.

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWER WAVE

The following is a list of possible error codes that the Power Wave 455M (CE) can output via the status light (see
"Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11
these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.
Error Code # Indication
11 CAN communication bus off. Probably due to excessive number of communication errors.
12 User Interface time out error. UI is no longer responding to the Power Source. The most likely
cause is a fault/bad connection in the communication leads or con-
trol cable.

21 Unprogrammed Weld Mode. Contact the Service Department for instructions on reloading the
Welding Software.
22 Empty Weld Table. Contact the Service Department for instructions on reloading the
Welding Software.
23 Weld Table checksum error. Contact the Service Department for instructions on reloading the
Welding Software.
31 Primary overcurrent error. Excessive Primary current present. May be related to a short in the
main transformer or output rectifier.
32 Capacitor "A" under voltage Low voltage on the main capacitors. May be caused by improper
(Left side facing machine) input configuration.
33 Capacitor "B" under voltage When accompanied by an overvoltage error on the same side, it
(Right side facing machine) indicates no capacitor voltage present on that side, and is usually
the result of an open or short in the primary side of the machine.
34 Capacitor "A" over voltage Excess voltage on the main capacitors. May be caused by improp-
(Left side facing machine) er input configuration.

35 Capacitor "B" over voltage When accompanied by an under voltage error on the same side, it
indicates no capacitor voltage present on that side, and is usually
(Right side facing machine) the result of an open or short in the primary side of the machine.

36 Thermal error Indicates over temperature. Usually accompanied by Thermal LED.

Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.

37 Soft start error Capacitor precharge failed. Usually accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this
41 Secondary overcurrent error
occurs the machine output will phase back to 100 amps, typically
resulting in a condition referred to as "noodle welding"

NOTE: The secondary limit is 570 amps for the standard stud, and
325 amps.

43 Capacitor delta error The maximum voltage difference between the main capacitors has
been exceeded. May be accompanied by errors 32-35.

49 Single phase error Indicates machine is running on single phase input power. Usually
caused by the loss of the middle leg (L2).
Other Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the PS
Control Board. If cycling the input power on the machine does not
clear the error, try reloading the operating system. If this fails,
replace the control board.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal Lincoln Electric Field Service
covers are removed. facility for technical assistance.
Input fuses keep blowing, or input 1. Make certain that fuses or
breaker keeps tripping. breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.
2. Welding procedure is drawing
too much output current, or
duty cycle is too high.
Reduce output current, duty
cycle, or both.
3. There is internal damage to
the power source. Contact an
authorized Lincoln Electric
Service facility.
Machine will not power up (no 1. Make certain that the Power
lights, no fan, etc.) Switch (SW1) is in the “ON”
position.
2. Circuit breaker CB4 (in recon-
nect area) may have opened. If all recommended possible areas
Reset. Also, check input volt- of misadjustments have been
age selection, below. checked and the problem persists,
3. Input voltage selection made contact your local Lincoln
improperly. Power down, Authorized Field Service Facility.
check input voltage reconnect
according to diagram on
reconnect cover.
Thermal LED is lit. 1. Fan thermostat has opened.
Check for proper fan opera-
tion. (Fan should run whenev-
er output power is on.) Check
for material blocking intake or
exhaust louvers, or for exces-
sive dirt clogging cooling chan-
nels in machine.
2. Secondary rectifier or Choke
thermostat has opened. After
machine has cooled, reduce
load, duty cycle, or both.
Check for material blocking
intake or exhaust louvers.
3. DC Bus PC board thermostat
has opened check for exces-
sive load on 40VDC supply.

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

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-5 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine won’t weld, can’t get any 1. Input voltage is too low or too
output. (CR1 will not pull in.) high. Make certain that input
voltage is proper, according to
the Rating Plate located on the
rear of the machine.
2. If the Thermal LED is also lit,
see “Yellow Thermal LED is Lit”
section.
3. Primary current limit has been
exceeded. Possible short in out-
put circuit. Turn machine off.
Remove all loads from the out-
put of the machine. Turn back
on. If condition persists, turn
power off, and contact an autho-
rized Lincoln Electric Field
Service facility.
4. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes by If all recommended possible areas
the status light. See of misadjustments have been
"Troubleshooting the Power Wave checked and the problem persists,
/ Power Feed System Using the contact your local Lincoln
Status LED" section of this text. Authorized Field Service Facility.

Machine often “noodle welds” (out- [Link] current limit has been
put is limited to approximately 100 exceeded, and the machine has
amps) when running a particular phased back to protect itself.
procedure, especially a procedure 2. Adjust procedure or reduce load
with high WFS. to lower current draw from the
machine.
3. A single phase input (loss of L2)
will reduce the secondary cur-
rent limit from 570 Amps to 325
Amps.

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

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 E-6 TROUBLESHOOTING E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine won’t produce full output. 1. Input voltage may be too low,
limiting output capability of the
power source. Make certain that
the input voltage is proper,
according to the Rating Plate
located on the rear of the
machine.
2. Input may be “single phased”.
Make certain the input voltage is
proper on all three Input lines.
3. Secondary current or voltage not
be properly calibrated. Check
values displayed on the Power
Feed 10/11 verses readings on
an external meter.

Auxiliary receptacle is “dead” no 1. Circuit breaker CB2 (on case

auxiliary voltage . front) may have opened. Reset.
2. Circuit breaker CB4 (in recon-
nect area) may have opened.
Reset. If all recommended possible areas
General degradation of the weld [Link] for feeding problems, bad of misadjustments have been
performance connections, excessive loops in checked and the problem persists,
cabling, etc. contact your local Lincoln
2. Verify weld mode is correct for Authorized Field Service Facility.
processes.
3. The power source may require
calibration.
4. Check the actual current dis-
played on the Power Feed 10
vs. actual current measured via
external meter.
5. Check the actual voltage dis-
played on the Power Feed 10
vs. actual voltage measured via
external meter.
6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.

Excessively long and erratic arc. 1. Check for proper configuration

and implementation of voltage
sensing circuits.

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

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 F-1

TM
POWER WAVE 455M (CE) WIRING DIAGRAM
LEFT SIDE OF MACHINE

ETHERNET / DEVICENET OR DEVICENET MODULE TO CB3

SOLID 3R 3W
DIGITAL POWER J7 3.5A
MODULE STATE CIRCUIT
SUPPLY BOARD
6W
RELAY + 3 4 - BREAKER
TO AUX #2
1 225 TO AUXILIARY TRANSFORMER #1 H1A
TO TP6 J4
2 223 W H6
TO J9 X1 H6A H1B
202 J42 3 221 (550-575) TO INPUT SWITCH N.L.
6B 4 227 (51V) H5 H6 612B
CONTROL BOARD X2 U H5
TO TP3 5 222 (440-460)
1 743 6 2 1 H4 TO J61 10A
TO R1 (380-415) H4 H4B 612
J72 2 741 202A 1 475 TO POWER BD. TO FUSE
N.D. 3 800 TO RECTIFIER AUX #2
WORK - 2 477 J47
840 J41 444 X3A X3 N.J. CB3
4 3 476 TP4 W H3 TO AUX #1
1 153B 478 X3 (220-230) H3 RECONNECT PANEL H1
S5 251 1 4
L2 J73 2 154B 2 TO FAN TO AUX #1 224A (24V) N H2
DEVICENET J2 1 346 X4 (200-208) H2
3 51B 253 3 CHOKE
2 (115V) R H1
CONNECTOR 4 52B 254 4 268A TO RECT THERM X5 H1
6B 1 3 THERM
J74 4 226 TO TO FAN TO SOLID STATE RELAY
1 6W 2 C1 1 J4 MAIN CHOKE 291 444
1 267 5 274 J11 TO
+24V 2 894 892 .05/600V 2 266 6 266 R5 CR1
+24V GND 3 893 893 2 TP1 J43
892 3 268 7 345 P91 J60 FAN
CAN_H 4 3 4 TO J8
891 4 J75 8 216 4 CURRENT
CAN_L 5 891 5 228
5 9 228 211 X3A X5
894 6 226 3 TO SOLID STATE RELAY TO AUX#1
6 J4 10 273 213 2 + TRANSDUCER
1 7 227 TO 11 267 212 1
S9 8 221 J42 12 262 THIS AREA VIEWED FROM
830 2 J43
J76 9 TO J5
ETHERNET 3 10 R5 REAR OF MACHINE
222
CONNECTOR 4 224 MAIN
11 223 TO J6,J10B N.B., N.G., N.H.
12 225 DC BUS BOARD 220 TRANSFORMER
RJ 45 TYPE TO C3 224A OUTPUT
1 TO LEFT SIDE
ETHERNET 1 POS 220A RECT RECONNECT SWITCH
L10 2 224 RECT
PORT J5 THERM J46 2 POS TO
3 220 SWITCH BD #2 TO
3 NEG 292 16
J710 4 13 SWITCH BD #1
RECONNECT

414
418
403
405
406

404
4 NEG RECT 14 POS PANEL
1 231 TO THERM
1 51 CHOKE 19C N.C. TO SW1
2 232 THERM
3 2 291 SEC PRI TO
J70 & J71 TO (TOP (TOP SWITCH N.J.
4 J20 3 50 TO 19

1
ONLY PRESENT IF FEEDHEAD

3
6

2
4
4 CB1 LEFT) LEFT) BD #2
THE ETHERNET CONNECTION ARE NOT USED 5 504 J40 J47 TO TO AUX #1 200-208V
MODULE IS PRESENT J50 5 475 J41
IS ONLY PRESENT IN THE 6 503 J82 D4 HARMONIC H2 220-230V
7 406 6 476 440-460V
ETHERNET / DEVICENET MODULE ONLY PRESENT IF FEEDHEAD S1 FILTER TO H3
8 405 7 477 F4 18 SWITCH BD #1
’A 550-575V
MODULE IS NOT PRESENT J6 8 478 J40 H5
9 238 ’
10 505 NEG H6
F4 20D

Downloaded from [Link] manuals search engine

11 220A TO RECT SWITCH BOARD TO
12 604 THERM #1 SWITCH BD #2
13 12 TO 20
292
14 506 + HARMONIC
15 403 CHOPPER BOARD 2.7 10W 3500oF FILTER
J16 16 404 PRI TO C4 500V
COLLECTOR
SEC (BOTTOM SWITCH
1 LEFT) BD #1 350 1 S8
153B 1 TO D5 .022 (BOTTOM
2 345 1 LEFT) 352 2
154B 3 TO 287 800V 20C 19C TO WATER
3 1W 2 D3
51B 4 STATUS TO AUX #2 3
4 1B LED 4R 3 TO C8 MAIN TRANSFORMER
COOLER
5 J10 F3 33A 4
OR 52B 5 346 4 289A 14 RECEPTACLE
6 6 5
7 2W TO 11 12
4W 6 289B F3 TO
OR J16 8 2B THERMAL TO C10 RECONNECT
J7 LED EMITTER HARMONIC
MODULE 9 N.G. SWITCH
INTERFACE 10 TO RECONNECT 20 FILTER 19
CONNECTOR 11 SWITCH
262 TO 2.7 15
WIRE DRIVE INTERFACE 12
153B 1 53A 13 J4 10W NEG POS
4W J43 .022
154B 3 54A 14 4R R5 268
MODULE TO 268A 800V PRI TO
51B 4 51A 15 3R (BOTTOM SWITCH
67B 67A SSR SEC INPUT
5 16 3W (BOTTOM RIGHT) BD #2
ROBOTIC/WIREDRIVE 52B 6 52A 1 RIGHT)

FRONT OF MACHINE
211 POWER BD RECTIFIER
INTERFACE RECEPTACLE 2 212 RECTIFIER D2 20C 19D
3 213 TO F2
L8 S1 P90 POS
S6 4 813 17
ARCLINK J8 P91 TO TO J6, J10B
A 539 FEEDHEAD 5 811 NEG POS
RECEPTACLE 6 216 AC AC X2 C3
B 541 BOARD F2
7 816 AUX. #1
C 521 L9 53A
1 743 8 812 AC AC AC
D 522 11 INPUT BOARD 3 2 1
E 2 741 A 53 206 1 NEG
BLACK J81 2.7
F 3 800 B 54 TP7 1 601
514
503

847
518
504
505
506

54A 2 10W 17
G WHITE 4 840 L6 202 X1 2 X3 C B A
3 PRI 18
C 67A 67 J9 SEC TO 3 TO
REAR OF MACHINE

H BLACK 67 4 .022 (TOP SWITCH 238 N.F.

1 153B 67 (TOP 4 604 CR1
L5 5 800V RIGHT) RIGHT) BD #1
2 154B D 52 21A 6 NEG J60 5 232 J6
1

J
6

GND-A
2
3
5
4

J82 51B INPUT

K RED 3 52A TO 414 1 NEG D1 6 AUX #1
52B 51 J10A NEG
4 E 418 2 LINE

+
L BLACK L7 J40 POS 7
M GREEN 51A J50 514 1 J10B POS F1 231 FILTER
518 2 13 8
N 67C 539 1 C11
541 2 54 1 POS J50
.0047/3KV F1 1
521 3 53 2 C3 2400oF TO J46 287
J83 J11
522 4 TO 273 3 100V SWITCH BOARD 2 T1
TO WORK POWER BD RECT #2
886 5 J43 274 4 RIGHT SIDE 3
880 6 4 T2
J1 & J3 5 TO
3 CONDUCTOR TP3 J61 CR1 TO J61
WHITE 1 CB1 52 ARE NOT USED +
3500oF 6 612 SW1
TWISTED/SHIELDED RED 2 10A CIRCUIT TO ELECTRODE STT CURRENT C5 500V 7 CB4 N.K.
BLACK 3 BREAKER 8 H1D TO J60 T3 T2 T1
SHIELD GROUND TO CASE 50 TRANSDUCER
BLACK 4 TO J47 202A 15 16 9 601
J84
BLACK 5 S2 TO J8 P90 10 T3
R1 20D 19D
S7 GREEN 6 VOLTAGE 812 1 CR1
847 7 SENSE 50Y 813
I/O 2
RECEPTACLE 8 RECEPTACLE 811 3 + - X4
D5 TO
206A 816 4 STT SNUBBER TO AUX #1 L3 L2 L1
851 851 1 1 + TO MAIN RECONNECT
1 DIODE
852 852 2 2 L4 TRANSFORMER SWITCH
2
3 853 853 3 3 21A 288B
854 4 P50
4 854 4 TO C10
855 5 288A H6
5 855 N.E. 5 H6A
856 6 TO C8 (550-575)
6 856 1W 1B
857 857 7 N.D. P52
7 STATUS LED (R/G) W
8 858 858 8 P51 1
J85 S3 TO J7 350
9 859 859 9 RS232 1 TO
32 L1B
DIAGRAMS

860 2W (115V) R L3B

10 860 10 CONNECTOR 2B 33A 4 CB3
861 11 N.A.
11 861 THERMAL LED (Y) 33 4 (230V) AUX #1
862 12 1 352 2
12 862 TO J7 6
512 13 352A
2 253 H1 L3A
511 14 3 254 TO 1 H1A C6 L3
W V U
5W 15 TO RECONNECT PANEL TO SUPPLY LINES
4 TO S4
5B 16 A (TOP) AUXILIARY TRANSFORMER #2
VOLTAGE SENSE 5 CB2 .0047 oF
6 J2 LOAD LINE TO CONTACTOR

POWER WAVE 455M (CE)

SELECT TO J61 440
7 251 H1D L3A
BOARD
20 C7 N.F.
L1A
1 512 SW1 TO SW 1 G
2 POWER
3 67C TO CB4 TO CONTACTOR
J1 4 511
S4 SWITCH LEAD
612B L1A
5 115V TO A SYSTEM GROUND PER
FILTER
6 RECEPTACLE NATIONAL ELECTRICAL CODE.
1 67B
J2 2
NOTES:
D6 32 S4 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
+40VDC
DIODE 220V RECEPTACLE ALIGNS WITH BLACK LEAD OF LED SOCKET.
880 31
TO N.D. 351
J83 TO WORK N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
AC AC 886
CB2 VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
5A CIRCUIT OPERATION. FRONT REAR FAN RECONNECT RECONNECT
CB2 BREAKER 32 TP6 HORIZONTAL HORIZONTAL SHROUD SHELL BRACKET
10A CIRCUIT BAFFLE BAFFLE
GND-A GND-B BREAKER N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
CE Model INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
33
352A
OPERATION.
CASEFRONT CASEFRONT
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) CASE FRONT REAR AUX. AUX. N.F.
PANEL
TO D5 ALIGNS WITH WHITE LEAD OF LED SOCKET. FRONT UPPER UPPER 2 1
288D 289D C8
288A BASE BASE
206 TO J9 20 F N.E. LEAD 33 IS PRESENT IN MODELS WITH 115V RECEPTACLE
R2 288C 400V
OR STT +
288E 2Y 289E
ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN PROTECTIVE BONDING CIRCUIT
TO R1 289A
206A MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.
R3 289C LEGEND
288B STT SNUBBER COMPONENT VALUE UNITS:
TO TP3 288F 2Y 289F CAPACITOR BANK DASHED " " = STT MACHINE ONLY
288C N.F. ONLY PRESENT ON "CE" MODELS.
C6 288D PHANTOM " " = OPTION
R4 CAPACITOR: MFD/VOLTS
.05/600V 288E
2Y C10 RESISTOR: OHMS/WATTS
+ 289B N.G. ONLY PRESENT ON NON-CE MODELS. LEAD COLOR CODING
ELECTRODE TP5 STT SNUBBER 289C 20 F B=BLACK
RESISTOR BANK 289D 400V G=GREEN CONNECTOR PIN NUMBERS:
C2 289E N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD N=BROWN
.05/600V
TP2 CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS R=RED EX. 12 PIN CONNECTOR
U=BLUE
(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5. W=WHITE 1 2 6
N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD COMPONENT VALUES:
LEAD H4B CONNECTS H4 TO SW1. CAPACITORS=MFD/VOLTS
RIGHT SIDE OF MACHINE RESISTORS=OHMS/WATTS 7 12
LATCH
N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT ELECTRICAL SYMBOLS PER E1537 VIEW OF CONNECTOR ON PC BOARD
RECTIFIER TERMINALS RATHER THAN CR1.

N.L. 10 AMP CIRCUIT BREAKER IS USED IN PLACE OF FUSE ON CODES

BELOW 11150.
E

G4420
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-1
 F-2 CONNECTION DIAGRAM F-2
Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, CV/Pulse Configuration shown)

POWER WAVE

TO WIRE
WORK FEEDER

CONTROL CABLE K1543

POWER WAVE 455M (CE)

Downloaded from [Link] manuals search engine

 F-3

DIMENSION PRINT - POWER WAVE 455M

19.90

19.16

9.48 14.62

Downloaded from [Link] manuals search engine

22.63

26.10

23.12 23.51
DIAGRAMS

POWER WAVE 455M (CE)

12.35

19.00 32.88

11-14-97
M18241
F-3
 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION ● Aislese del trabajo y de la tierra.

French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.

German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

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

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

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

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

Downloaded from [Link] manuals search engine

 ● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

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

Downloaded from [Link] manuals search engine

 • World's Leader in Welding and Cutting Products •
• 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: [Link]
Downloaded from [Link] manuals search engine