Lincoln Electric Welder 455 M User Manual

RETURN TO MAIN MENU  
IM807-A  
June, 2004  
POWER WAVE  
455 M  
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: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
3.g. Never dip the electrode in water for cooling.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
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  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
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  
can cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
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  
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SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales 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  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
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SAFETY  
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SAFETY  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank 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 www.lincolnelectric.com. 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.  
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TABLE OF CONTENTS  
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  
________________________________________________________________________  
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TABLE OF CONTENTS  
Page  
Troubleshooting..............................................................................................Section E  
How to use Troubleshooting Guide .......................................................................E-1  
Using the Status LED to Troubleshoot System Problems .....................................E-2  
Error Codes For Power Waves..............................................................................E-3  
Troubleshooting Guide.............................................................................E-4 thru E-6  
________________________________________________________________________  
Wiring Diagram ............................................................................................Section F-1  
Connection Diagrams ..................................................................................Section F-2  
Dimension Print............................................................................................Section F-3  
________________________________________________________________________  
Parts Lists ....................................................................................................P438 Series  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - POWER WAVE 455M (CE) (K2202-2)  
INPUT AT RATED OUTPUT - THREE PHASE ONLY  
OUTPUT CONDITIONS  
AMPS / VOLTS / DUTY CYCLE  
INPUT  
VOLTS  
OUTPUT CONDITIONS INPUT CURRENT  
INPUT CURRENT  
AMPS  
AMPS / VOLTS / DUTY CYCLE  
AMPS  
400A@36V. 100%  
400A@36V. 100%  
400A@36V. 100%  
400A@36V. 100%  
500A@40V. 60%  
500A@40V. 60%  
500A@40V. 60%  
500A@40V. 60%  
36A  
36A  
33A  
33A  
48A  
48A  
44A  
44A  
380V - 60HZ.  
380V - 50HZ.  
415V - 60HZ.  
415V - 50HZ.  
OUTPUT  
PULSE  
VOLTAGE  
RANGE  
OPEN  
CIRCUIT  
VOLTAGE  
CURRENT  
RANGE  
AMPS  
PULSE  
FREQUENCY  
PULSE AND  
BACKGROUND  
TIME RANGE  
AUXILIARY  
POWER  
75 VDC  
5 - 570A  
0.15 - 1000 Hz  
5 - 55 VDC  
100 MICRO SEC. -  
3.3 SEC.  
40 VDC AT  
10 AMPS  
220 VAC AT  
5 AMPS  
PROCESS CURRENT RANGE (DC)  
CURRENT  
50-570 Amps  
40-570 Amps  
30-570 Amps  
15-500 Amps  
5-750 Amps  
MIG/MAG  
FCAW  
SMAW  
GTAW  
Pulse  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
TYPE 75°C  
TYPE 75°C  
TYPE 75°C  
INPUT  
VOLTAGE /  
FREQUENCY  
DUTY  
CYCLE  
INPUT AMPERE  
RATING ON  
NAMEPLATE  
COPPER WIRE GROUND WIRE (SUPER LAG)  
IN CONDUIT  
IN CONDUIT  
OR BREAKER  
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)  
2
2
(mm )  
(mm )  
380V HZ.  
415V HZ.  
100%  
100%  
36A  
33A  
40A  
40A  
8 (10)  
8 (10)  
10 (6)  
10 (6)  
PHYSICAL DIMENSIONS  
HEIGHT  
663 mm  
(26.10 in)  
WIDTH  
DEPTH  
835 mm  
(32.88 in)  
WEIGHT  
505 mm  
114 kg.  
(19.86 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)  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS Read this  
entire installation section before you start installa-  
tion.  
LIFTING  
Lift the machine by the lift bail only. The lift bail is  
designed to lift the power source only. Do not attempt  
to lift the Power Wave with accessories attached to it.  
WARNING  
STACKING  
ELECTRIC SHOCK can kill.  
Power Wave machines can be stacked to a maximum  
of 3 high.  
• Only qualified personnel should  
perform this installation.  
• Turn the input power OFF at the  
WARNING  
disconnect switch or fuse box  
before working on this equipment. Turn off the  
input power to any other equipment connected to  
the welding system at the disconnect switch or  
fuse box before working on the equipment.  
• Lift only with equipment of  
adequate lifting capacity.  
• 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  
heavy accessory such as trail-  
er or gas cylinder.  
• Always connect the Power Wave 455M (CE)  
grounding lug (located inside the reconnect input  
access door) to a proper safety (Earth) ground.  
FALLING  
EQUIPMENT can damaged.  
cause injury. • Do not operate machine while  
suspended from lift bail.  
• Do not lift machine if lift bail is  
----------------------------------------------------------  
SELECT SUITABLE LOCATION  
Do not use Power Wave 455M (CE) in outdoor envi-  
ronments. The Power Wave 455M (CE) power source  
should not be subjected to falling water, nor should  
any parts of it be submerged in water. Doing so may  
cause improper operation as well as pose a safety  
hazard. The best practice is to keep the machine in a  
dry, sheltered area.  
Do not stack the Power Wave 455M (CE) on top of  
any other machine.  
------------------------------------------------------------------------  
The bottom machine must always be placed on a  
firm, secure, level surface. There is a danger of  
machines toppling over if this precaution is not  
taken.  
Do not mount the Power Wave 455M (CE) over com-  
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  
at least .060" (1.6mm) thick, which shall extend not  
less than 5.90" (150mm) beyond the equipment on all  
sides.  
-------------------------------------------------------------  
MACHINE GROUNDING  
The frame of the welder must be grounded. A ground  
terminal marked with the symbol  
is located inside  
the reconnect/input access door for this purpose. See  
your local and national electrical codes for proper  
grounding methods.  
Place the welder where clean cooling air can freely cir-  
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  
a minimum. Do not use air filters on the air intake  
because the air flow will be restricted. Failure to  
observe these precautions can result in excessive  
operating temperatures and nuisance shutdowns.  
HIGH FREQUENCY PROTECTION  
Locate the Power Wave away from radio controlled  
machinery.  
CAUTION  
Machines are equipped with F.A.N. (fan as needed)  
circuitry. The fan runs whenever the output is enabled,  
whether under loaded or open circuit conditions. The  
fan also runs for a period of time (approximately 5 min-  
utes) after the output is disabled, to ensure all compo-  
nents are properly cooled.  
The normal operation of the Power Wave may  
adversely affect the operation of RF controlled  
equipment, which may result in bodily injury or  
damage to the equipment.  
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)  
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A-3  
A-3  
INSTALLATION  
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  
U / L1  
CR1  
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  
CONNECTIONS  
INPUT CONNECTION  
Connect a work lead of sufficient size and length (Per  
Table 1) between the proper output terminal on the  
power source and the work. Be sure the connection to  
the work makes tight metal-to-metal electrical contact. To  
avoid interference problems with other equipment and to  
achieve the best possible operation, route all cables  
directly to the work and wire feeder. Avoid excessive  
lengths and do not coil excess cable.  
WARNING  
Only a qualified electrician should  
connect the input leads to the  
Power  
Wave  
455M  
(CE).  
Connections should be made in  
accordance with all local and  
national electrical codes and the connection dia-  
gram located on the inside of the reconnect/input  
access door of the machine. Failure to do so may  
result in bodily injury or death.  
Minimum work and electrode cable sizes are as follows:  
TABLE A.1  
Current (60% Duty Cycle)  
MINIMUM COPPER  
WORK CABLE SIZE AWG  
Up To-30 m (100 Ft.  
-------------------------------------------------------------  
Use a three-phase supply line. A 45 mm (1.75 inch)  
diameter access hole for the input supply is located on  
the upper left case back next to the input access door.  
Connect L1, L2, L3 and ground according to the Input  
Supply Connection Diagram decal located on the  
2
Length)  
400 Amps  
500 Amps  
600 Amps  
67 mm (2/0)  
85 mm (3/0)  
2
2
85 mm (3/0)  
NOTE: K1796 coaxial welding cable is recommended to  
reduce the cable inductance in long cable lengths. This  
is especially important when Pulse welding up to 350  
amps.  
inside of the input access door or refer to Figure A.1.  
INPUT FUSE AND SUPPLY WIRE  
CONSIDERATIONS  
CAUTION  
Refer to the Technical Specifications at the beginning  
of this Installation section for recommended fuse and  
wire sizes. Fuse the input circuit with the recommend-  
ed super lag fuse or delay type breakers (also called  
“inverse time” or “thermal/magnetic” circuit breakers).  
Choose an input and grounding wire size according to  
local or national electrical codes. Using fuses or circuit  
breakers smaller than recommended may result in  
“nuisance” shut-offs from welder inrush currents, even  
if the machine is not being used at high currents.  
When using inverter type power sources like the  
Power Waves, use the largest welding (electrode and  
2
work) cables that are practical. At least 67 mm 2/0  
copper wire - even if the average output current  
would not normally require it. When pulsing, the  
pulse current can reach very high levels. Voltage  
drops can become excessive, leading to poor weld-  
ing characteristics, if undersized welding cables are  
used.  
POWER WAVE 455M (CE)  
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A-4  
A-4  
INSTALLATION  
For additional Safety information regarding the elec-  
trode and work cable set-up, See the standard "SAFE-  
TY INFORMATION" located in the front of the  
Instruction Manuals.  
CABLE INDUCTANCE, AND ITS AFFECT  
ON PULSE WELDING  
For Pulse Welding processes, cable inductance will  
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  
effects on welding performance. For the total welding  
loop length greater than 15.24m (50 ft.), the K1796  
Coaxial Welding Cables are recommended. The weld-  
ing loop length is defined as the total of electrode  
cable length (A) + work cable length (B) + work length  
(C) (See Figure A.3).  
CAUTION  
Excessive voltage drops caused by poor work  
piece connections often result in unsatisfactory  
welding performance.  
------------------------------------------------------------------------  
NEGATIVE ELECTRODE POLARITY  
When negative electrode polarity is required, such as  
in some Innershield applications, switch the output  
connections at the power source (electrode cable to  
the negative (-) stud, and work cable to the positive (+)  
stud).  
FIGURE A.3  
POWER  
WAVE  
A
C
WORK  
When operating with electrode polarity negative the  
"Electrode Sense Polarity" DIP switch must be set to  
the "Negative" position on the Wire Drive Feed Head  
PC Board. The default setting of the switch is positive  
electrode polarity. Consult the Power Feed instruction  
manual for further details.  
B
For long work piece lengths, a sliding ground should  
be considered to keep the total welding loop length  
less than 15.24m (50 ft.). (See Figure A.4.)  
FIGURE A.4  
POWER  
WAVE  
VOLTAGE SENSING  
A
A
The best arc performance occurs when the Power  
Waves have accurate data about the arc conditions.  
Depending upon the process, inductance within the  
electrode and work lead cables can influence the  
apparent voltage at the studs of the welder. Voltage  
sense leads improve the accuracy of the arc conditions  
and can have a dramatic effect on performance.  
Sense Lead Kits (K940-10, -25 or -50) are available for  
this purpose.  
C
WORK  
C
B
B
SLIDING WORK CONNECTION  
K1796 COAXIAL CABLE  
MEASURE FROM END  
OF OUTER JACKET OF  
CABLE  
Output connections on some Power Waves are made  
via 1/2-13 threaded output studs located beneath the  
spring loaded output cover at the bottom of the case  
front.  
CAUTION  
If the voltage sensing is enabled but the sense  
leads are missing, improperly connected, or if the  
electrode polarity switch is improperly configured,  
extremely high welding outputs may occur.  
Most welding applications run with the electrode being  
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 spring loaded output cover near the bottom of the  
case front). Connect the other end of the electrode  
cable to the wire drive feed plate. The electrode cable  
lug must be against the feed plate. Be sure the con-  
nection to the feed plate makes tight metal-to-metal  
electrical contact. The electrode cable should be sized  
according to the specifications given in the work cable  
connections section. Connect a work lead from the  
negative (-) power source output stud to the work  
piece. The work piece connection must be firm and  
secure, especially if pulse welding is planned.  
------------------------------------------------------------------------  
The ELECTRODE sense lead (67) is built into the con-  
trol cable, and is automatically enabled for all semi-  
automatic processes. The WORK sense lead (21) con-  
nects to the Power Wave 455M (CE) at the four pin  
connector located underneath the output stud cover.  
By default the WORK voltage is monitored at the out-  
put stud in the Power Wave 455M (CE). For more  
information on the WORK sense lead (21), see "Work  
Voltage Sensingin the following paragraph.  
All constant current processes sense the voltage at the  
output studs of the Power Wave 455M (CE) by default.  
POWER WAVE 455M (CE)  
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A-5  
A-5  
INSTALLATION  
Electrode Voltage Sensing  
Enable the voltage sense leads as follows:  
Enabling or disabling electrode voltage sensing is  
automatically configured through software. The 67  
electrode sense lead is internal to the cable to the  
wire feeder and always connected when a wire feeder  
is present.  
TABLE A.2  
Process Electrode Voltage  
Sensing 67 lead *  
GMAW 67 lead required  
GMAW-P 67 lead required  
FCAW 67 lead required  
Work Voltage  
Sensing 21 lead  
21 lead optional  
21 lead optional  
21 lead optional  
GTAW Voltage sense at studs Voltage sense at studs  
GMAW Voltage sense at studs Voltage sense at studs  
CAUTION  
Important: The electrode polarity must be config-  
ured at the feed head for all semi-automatic  
processes. Failure to do so may result in extreme-  
ly high welding outputs.  
SAW  
CAC  
67 lead required  
Voltage sense at studs Voltage sense at studs  
21 lead optional  
* The electrode voltage 67 sense lead is integral to  
the control cable to the wire feeder.  
------------------------------------------------------------------------  
POWER WAVE TO SEMI-AUTOMAT-  
IC POWER FEED WIRE FEEDER  
INTERCONNECTIONS  
Work Voltage Sensing  
The standard Power Wave 455Ms default to the work  
stud (work sense lead disabled)  
For processes requiring work voltage sensing, con-  
nect the (21) work voltage sense lead (K940) from the  
Power Wave work sense lead receptacle to the work  
piece. Attach the sense lead to the work piece as  
close to the weld as practical, but not in the return cur-  
rent path. Enable the work voltage sensing in the  
Power Wave as follows:  
The Power Wave 455M (CE) and semi-automatic  
POWER FEED family communicate via a 5 conductor  
control cable (K1543). The control cable consists of two  
power leads, one twisted pair for digital communication,  
and one lead for voltage sensing. The cables are  
designed to be connected end to end for ease of exten-  
sion. The output receptacle on the Power Wave 455M  
(CE) is located beneath the spring loaded output cover at  
the bottom of the case front. The input receptacle on the  
Power Feed is typically located at the back of the feeder,  
or on the bottom of the user interface.  
WARNING  
• Do not touch electrically live  
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  
the spring loaded output cover), and along the channels  
formed into the base of the Power Wave 455M (CE), out  
the back of the channels, and then to the wire feeder.  
• Insulate yourself from the work  
and ground.  
• Always wear dry insulating gloves.  
-----------------------------------------------------------  
Due to the flexibility of the platform the configuration may  
vary. The following is a general description of the sys-  
tem. For specific configuration information, consult the  
semi-automatic Power Feed instruction manual.  
1. Turn off power to the power source at the discon-  
nect switch.  
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  
DIP switch and look for switch 8 of the  
DIP switch.  
The Power Wave 455M (CE) and Power Feed M family  
of products utilize a digital communication system called  
ArcLink. Simply put, ArcLink allows large amounts of  
information to be passed at very high speeds between  
components (nodes) in the system. The system requires  
only two wires for communication, and because of its  
bus-like structure, the components may be connected to  
the network in any order, thus simplifying the system set-  
up.  
4. Using a pencil or other small object,  
slide the switch right to the OFF posi-  
tion if the work sense lead is NOT con-  
nected. Conversely, slide the switch to  
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  
of wire feeder. Refer to the wire feeder instruction  
manual for details  
5. Replace the cover and screws. The PC board will  
readthe switch at power up, and configure the  
work voltage sense lead appropriately.  
POWER WAVE 455M (CE)  
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A-6  
A-6  
INSTALLATION  
If a system can not be Auto Mappedthen the status  
light on the power source will blink green fast and the  
welder output will be disabled. If a system is not  
Auto-mappable, then consult the instruction manual  
for the accessory being used for configuration infor-  
mation about DIP switch settings, or consult your local  
Lincoln sales representative.  
CONFIGURING THE SYSTEM  
For codes below 11100, consult the semi-automatic  
Power Feed instruction manual for configuration infor-  
mation about DIP switch settings.  
For codes above 11100 the power source will Auto  
Mapthe 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  
PLC CONTROLLER  
ANALOG INTERFACE  
PF-10R  
WIRE  
DRIVE  
MODULE  
etc.  
POWER WAVE 455M (CE)  
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A-7  
A-7  
INSTALLATION  
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)  
PF-10R  
WIRE  
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)  
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A-8  
A-8  
INSTALLATION  
WELDING WITH MULTIPLE POWER  
WAVES  
CONTROL CABLE SPECIFICATIONS  
It is recommended that genuine Lincoln control cables  
be used at all times. Lincoln cables are specifically  
designed for the communication and power needs of  
the Power Wave / Power Feed system.  
CAUTION  
Special care must be taken when more than one  
Power Wave is welding simultaneously on a single  
part. Arc blow and arc interference may occur or  
be magnified.  
CAUTION  
The use of non-standard cables, especially in  
lengths greater than 7.62 (25 feet), can lead to  
communication problems (system shutdowns),  
poor motor acceleration (poor arc starting) and  
low wire driving force (wire feeding problems).  
------------------------------------------------------------------------  
The K1543 series of control cables can be connected  
end to end for ease of extension. Do not exceed more  
than 100 feet (30.5 m) total control cable length.  
Each power source requires a work lead from the  
work stud to the welding fixture. Do not combine all of  
the work leads into one lead. The welding travel direc-  
tions should be in the direction moving away from the  
work lead as shown below. Connect all of the work  
sense leads from each power source to the work  
piece at the end of the weld.  
For the best results when pulse welding, set the wire  
size and wire feed speed the same for all the Power  
Waves. When these parameters are identical, the  
pulsing frequency will be the same, helping to stabilize  
the arcs.  
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  
-
+
-
+
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)  
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A-9  
A-9  
INSTALLATION  
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES  
POWER WAVE 455M (CE)  
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A-10  
A-10  
INSTALLATION  
switch 7  
auto mapping  
auto mapping enable-default  
I / O RECEPTACLE SPECIFICATIONS  
off  
TABLE 3  
WIRE FEEDER RECEPTACLE S1  
on  
auto mapping disabled  
PIN  
A
B
C
D
LEAD#  
53  
54  
67A  
52  
FUNCTION  
Communication Bus L  
Communication Bus H  
Electrode Voltage Sense  
0vdc  
switch 8  
work sense lead  
work sense lead not connected-default  
off  
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  
RS232 RECEPTACLE S3  
CONTROL BOARD (DIP Switch Location)  
PIN  
2
3
LEAD#  
253  
254  
#
FUNCTION  
RS232 Receive  
RS232 Transmit  
S3 Pin5  
4
5
#
S3 Pin4  
6
20  
7
# #  
# #  
251  
S3 Pin20  
S3 Pin6  
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  
access panel.  
Loosen, but do not completely remove, the bottom  
two screws holding the access panel.  
Open the access panel, allowing the weight of the  
panel to be carried by the bottom two screws. Make  
sure to prevent the weight of the access panel from  
hanging on the harness.  
Adjust the DIP switches as necessary.  
Replace the panel and screws, and restore power.  
WATER FLOW SENSOR  
Water cooled guns can be damaged very quickly if  
they are used even momentarily without water flowing.  
A water flow sensor is recommended for those water  
coolers that do not have an integral flow sensor.  
Recommended practice is to install a water flow sen-  
sor such as K1536-1 on the water return line of the  
torch. When fully integrated into the welding system,  
the sensor will prevent welding if no water flow is pre-  
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)  
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B-1  
B-1  
OPERATION  
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)  
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B-2  
B-2  
OPERATION  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
SMAW  
INPUT POWER  
ON  
GMAW  
FCAW  
GTAW  
OFF  
HIGH TEMPERATURE  
MACHINE STATUS  
CIRCUIT BREAKER  
WIRE FEEDER  
POSITIVE OUTPUT  
NEGATIVE OUTPUT  
3 PHASE INVERTER  
INPUT POWER  
THREE PHASE  
DIRECT CURRENT  
OPEN CIRCUIT  
VOLTAGE  
U
U
U
I
0
1
2
INPUT VOLTAGE  
OUTPUT VOLTAGE  
INPUT CURRENT  
OUTPUT CURRENT  
1
I
2
PROTECTIVE  
GROUND  
WARNING OR  
CAUTION  
POWER WAVE 455M (CE)  
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B-3  
B-3  
OPERATION  
SMAW  
Shielded Metal Arc welding  
DEFINITION OF WELDING TERMS  
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  
single knob control. The machine will select the cor-  
rect voltage and amperage based on the wire feed  
speed (WFS) set by the operator.  
Submerged Arc Welding-(Series)  
FCAW  
Flux Core Arc Welding  
455M  
455Modular  
CAC  
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)  
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B-4  
B-4  
OPERATION  
DeviceNet Interface Module  
GENERAL DESCRIPTION  
This module can be used for DeviceNet capability. It  
will be a 5 pin sealed mini connector per ANSI  
B93.55M-1981.  
The Power Wave 455M (CE) semi-automatic power  
source is designed to be a part of a modular, multi-  
process welding system. Depending on configuration,  
it can support constant current, constant voltage, and  
pulse welding modes.  
EtherNet/DeviceNet Module  
This module includes the DeviceNet and EtherNet  
capability. The DeviceNet uses a 5 pin sealed mini  
connector per ANSI B93.55M-1981. The EtherNet  
uses a RJ5 connector.  
The Power Wave 455M (CE) power source is  
designed to be used with the semi automatic family of  
Power Feed wire feeders, operating as a system.  
Each component in the system has special circuitry to  
"talk with" the other system components, so each  
component (power source, wire feeder, user interface)  
knows what the other is doing at all times. These com-  
ponents communicate with ArcLink  
RECOMMENDED EQUIPMENT  
Power Wave 455M (CE) Semi-Automatic  
Operation  
Semi Automatic Power Waves can only be used with  
ArcLink compatible Power Feed semi-automatic wire  
feeders and modules. In addition, the Power Feed  
semi-automatic wire feeders may require optional  
equipment to access certain weld modes in the Power  
Wave. Other models of Lincoln feeders, or any mod-  
els of non-Lincoln wire feeders, cannot be used.  
The Power Wave 455M (CE) is a high performance,  
digitally controlled inverter welding power source  
capable of complex, high-speed waveform control.  
Properly equipped, it can support the GMAW, GMAW-  
P, FCAW, SMAW, GTAW, and CAC processes. It car-  
ries an output rating of 400 amps, 36 volts (at 100%  
duty cycle).  
All welding programs and procedures are selected  
through the Power Feed M semi-automatic user inter-  
face  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
REQUIRED EQUIPMENT  
Any ArcLink compatible semi-automatic wire feeding  
equipment. Specifically, the semi-automatic Power  
Feed M family.  
RECOMMENDED PROCESSES  
The Power Wave 455M (CE) can be set up in a num-  
ber of configurations, some requiring optional equip-  
ment or welding programs. Each machine is factory  
preprogrammed with multiple welding procedures, typ-  
ically including GMAW, GMAW-P, FCAW, GTAW, and  
CAC for a variety of materials, including mild steel,  
stainless steel, cored wires, and aluminum.  
WARNING  
LIMITATIONS  
The Power Waves are not to be used in outdoor  
environments.  
------------------------------------------------------------------------  
Only ArcLink compatible Power Feed semi-automat-  
ic wire feeders and users interfaces may be used.  
Other Lincoln wire feeders or non-Lincoln wire feed-  
ers cannot be used.  
The Power Wave 455M (CE) is recommended for  
semi-automatic welding with ArcLink compatible  
equipment like the Power Feed M series of feeders.  
The Power Wave 455M (CE) can have a number of  
modules installed that allow the machine to be used in  
Robotic and hard automation applications.  
Power Wave 455M (CE) Output Limitations  
The Power Wave 455M (CE) will support maximum  
average output current of 500 Amps @ 60% duty  
cycle.  
Wire Drive Interface Module  
For Robotic platforms the Wire Drive Control Module  
is required to drive the Power Feed-10R wire drive.  
This module can be factory installed through our  
automation division or field installed for robotic appli-  
cations.  
DUTY CYCLE AND TIME PERIOD  
The Power Feed wire feeders are capable of welding  
at a 100% duty cycle (continuous welding). The power  
source will be the limiting factor in determining system  
duty cycle capability. Note that the duty cycle is based  
upon a ten minute period. A 60% duty cycle repre-  
sents 6 minutes of welding and 4 minutes of idling in a  
ten minute period.  
The Wire Drive Control Module is also be equipped  
with a terminal strip for making simple input signal  
connections. It can be used to externally control the  
basic wire drive function. It is divided into three  
groups: Trigger group, Cold Inch group, and  
Shutdown group.  
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B-5  
B-5  
OPERATION  
FIGURE B.1  
CASE FRONT CONTROLS  
All operator controls and adjustments are located on  
the case front of the Power Wave 455m (CE). (See  
Figure B.1)  
3
2
1
1. POWER SWITCH: Controls input power to the  
Power Wave.  
2. STATUS LIGHT: A two color light that indicates  
system errors. Normal operation is a steady green  
light. Error conditions are indicated, per table 3.  
6
8
13  
14  
10  
NOTE: The Power Wave 455M (CE) status light will  
flash green, and sometimes red and green, for up to  
one minute when the machine is first turned on. This  
is a normal situation as the machine goes through a  
12  
15  
self test at power up.  
TABLE 3  
Light  
Condition  
Meaning  
9
4
5
11  
7
Steady Green System OK. Power source communicating normal-  
ly with wire feeder and its components.  
CASE FRONT LAYOUT  
POWER WAVE 455M (CE)  
Blinking  
Green  
Occurs during a reset, and indicates the  
Power Wave 455M (CE) is mapping (identi-  
fying) each component in the system.  
Normal for first 1-10 seconds after power is  
turned on, or if the system configuration is  
changed during operation  
5. 5 AMP AUXILIARY POWER CIRCUIT BREAKER:  
Protects 220 volt AC case front receptacle  
auxiliary supply.  
6. LEAD CONNECTOR S2 (SENSE LEAD)  
7. DIAGNOSTIC CONNECTOR (RS-232)  
8. WIRE FEEDER RECEPTACLE (S1 5-PIN)  
9. NEGATIVE STUD  
Alternating Non-recoverable system fault. If the PS  
Green and Status light is flashing any combination of  
Red  
red and green, errors are present in the  
Power Wave 455M (C E). 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 sepa-  
rated by a green light.  
10. POSITIVE STUD  
11. AUXILIARY OUTPUT  
12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)  
13. ROBOTIC WIRE FEEDER RECEPTACLE  
(OPTIONAL)  
To clear the error, turn power source off,  
and back on to reset. See Troubleshooting  
Section.  
14. I/O CONNECTOR (OPTIONAL)  
Non recoverable hardware fault. Generally  
indicates nothing is connected to the Power  
Wave 455M (CE) wire feeder receptacle.  
See Trouble Shooting Section.  
Steady Red  
Blinking Red  
15. ETHERNET CONNECTOR (OPTIONAL)  
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.  
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B-6  
B-6  
OPERATION  
NOMINAL PROCEDURES  
WELDING ADJUSTMENTS  
The Power Wave 455M (CE) is designed to operate  
with 19.1mm (3/4") electrode stick-out for CV and  
Pulse processes.  
All adjustments are made on the system component  
known as the User Interface (Control Box), which con-  
tains the switches, knobs, and digital displays neces-  
sary to control both the Power Wave 455M (CE) and a  
Power Feed wire feeder. Typically, the Control Box is  
supplied as part of the wire feeder. It can be mounted  
directly on the wire feeder itself, the front of the power  
source, or mounted separately, as might be done in a  
welding boom installation.  
FRINGE PROCEDURES  
Excessively short or long electrode stick-outs may  
function only on a limited basis, if at all.  
MAKING A WELD  
Because the Control Box can be configured with many  
different options, your system may not have all of the  
following adjustments. Regardless of availability, all  
controls are described below. For further information,  
consult the Power Feed wire feeder instruction manu-  
al.  
WARNING  
The serviceability of a product or structure utiliz-  
ing the welding programs is and must be the sole  
responsibility of the builder/user. Many variables  
beyond the control of The Lincoln Electric  
Company affect the results obtained in applying  
these programs. These variables include, but are  
not limited to, welding procedure, plate chemistry  
and temperature, weldment design, fabrication  
methods and service requirements. The available  
range of a welding program may not be suitable  
for all applications, and the build/user is and must  
be solely responsible for welding program selec-  
tion.  
WFS / AMPS:  
In synergic welding modes (synergic CV, pulse  
GMAW) WFS (wire feed speed) is the dominant con-  
trol parameter, controlling all other variables. The user  
adjusts WFS according to factors such as weld size,  
penetration requirements, heat input, etc. The Power  
Wave then uses the WFS setting to adjust its output  
characteristics (output voltage, output current) accord-  
ing to pre-programmed settings contained in the  
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-  
dent adjustments. Therefore to maintain the arc char-  
acteristics, the operator must adjust the voltage to  
compensate for any changes made to the WFS.  
------------------------------------------------------------------------  
The steps for operating the Power Wave 455M (CE)  
will vary depending upon the options installed in the  
user interface (control box) of the welding system. The  
flexibility of the Power Wave system lets the user 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,  
diameter, shielding gas and process (GMAW, GMAW-  
P, etc.)  
VOLTS / TRIM:  
In constant voltage modes (synergic CV, standard  
CV) the control adjusts the welding voltage.  
Second, find the program in the welding software that  
best matches the desired welding process. The stan-  
dard software shipped with the Power Waves 455M  
(CE) encompasses a wide range of common process-  
es and will meet most needs. If a special welding pro-  
gram is desired, contact the local Lincoln Electric  
sales representative.  
In pulse synergic welding modes (pulse GMAW only)  
the user can change the Trim setting to adjust the arc  
length. It is adjustable from 0.500 to 1.500. A Trim set-  
ting of 1.000 is a good starting point for most condi-  
tions.  
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.  
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B-7  
B-7  
OPERATION  
WELDING MODE  
Non Synergic CV:  
May be selected by name (CV/MIG, CC/Stick Crisp,  
Gouge, etc.) or by a mode number (10, 24, 71, etc.)  
depending on the Control Box options. Selecting a  
welding mode determines the output characteristics of  
the Power Wave power source. For a more complete  
description of the welding modes available in the  
Power Wave, see the explanation below.  
This type of CV mode behaves more like a conven-  
tional CV power source. Voltage and WFS are inde-  
pendent adjustments. Therefore to maintain the arc  
characteristics, the operator must adjust the voltage to  
compensate for any changes made to the WFS.  
ARC CONTROL  
All CV Modes:  
Also known as Inductance or Wave Control. Allows  
operator to vary the arc characteristics from "soft" to  
"harsh" in all weld modes. It is adjustable from -10.0 to  
+10.0, with a nominal setting of 00.0 (The nominal set-  
ting of 00.0 may be displayed as OFF on some Power  
Feed wire feeder control panels). See the Welding  
Mode descriptions, below, for detailed explanations of  
how the Arc Control affects each mode.  
Arc Control, often referred to as wave control, adjusts  
the inductance of the wave shape. The wave control  
adjustment is similar to the "pinch" function in that it is  
inversely proportional to inductance. Therefore,  
increasing wave control greater than 0.0 results in a  
harsher, colder arc while decreasing the wave control  
to less than 0.0 provides a softer, hotter arc.  
(See Figure 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  
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B-8  
B-8  
OPERATION  
The Power Wave 455M (CE) utilizes "adaptive con-  
trol" to compensate for changes in electrical stick-out  
while welding. (Electrical stick-out is the distance from  
the contact tip to the work piece.) The Power Wave  
waveforms are optimized for a 0.75" (19mm) stick-out.  
The adaptive behavior supports a range of stickouts  
from 0.50" (13mm) to 1.25" (32mm). At very low or  
high wire feed speeds, the adaptive range may be  
less due to reaching physical limitations of the welding  
process.  
PULSE WELDING  
Pulse welding procedures are set by controlling an  
overall "arc length" variable. When pulse welding, the  
arc voltage is highly dependent upon the waveform.  
The peak current, back ground current, rise time, fall  
time and pulse frequency all affect the voltage. The  
exact voltage for a given wire feed speed can only be  
predicted when all the pulsing waveform parameters  
are known. Using a preset voltage becomes impracti-  
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  
arc. Wave control values greater than 0.0 increase the  
pulse frequency while decreasing the background cur-  
rent, resulting in a tight, stiff arc best for high speed  
sheet metal welding. Wave control values less than  
0.0 decrease the pulse frequency while increasing the  
background current, for a soft arc good for out-of-posi-  
tion welding.  
Trim adjusts the arc length and ranges from 0.50 to  
1.50, with a nominal value of 1.00. Trim values greater  
than 1.00 increase the arc length, while values less  
than 1.00 decrease the arc length.  
Most pulse welding programs are synergic. As the  
wire feed speed is adjusted, the Power Wave 455M  
(CE) will automatically recalculate the waveform para-  
meters to maintain similar arc properties.  
(See Figure A.6)  
FIGURE A.6  
CURRENT WAVE FORM (PULSE)  
Current  
Wave Control -10.0  
Wave Control 0.0  
Wave Control +10.0  
Time  
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C-1  
C-1  
ACCESSORIES  
OPTIONAL EQUIPMENT  
FACTORY INSTALLED  
None Available.  
FIELD INSTALLED  
Work Voltage Sense Lead Kit, K940  
Dual Cylinder Undercarriage, K1570-1.  
Gas Guard Regulator, K659-1  
Coaxial welding Cable, K1796  
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.  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Only Qualified personnel should  
perform this maintenance.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this equipment.  
Do not touch electrically hot parts.  
ROUTINE MAINTENANCE  
Routine maintenance consists of periodically blowing  
out the machine, using a low pressure airstream, to  
remove accumulated dust and dirt from the intake and  
outlet louvers, and the cooling channels in the  
machine.  
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.  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled PROBLEM (SYMP-  
TOMS). This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled POSSIBLE CAUSElists  
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.  
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E-2  
E-2  
TROUBLESHOOTING  
charts for both machine and weld performance.  
USING THE STATUS LED TO  
TROUBLESHOOT SYSTEM PROBLEMS  
The STATUS LIGHT is a two color light that indicates  
system errors. Normal operation is a steady green  
light. Error conditions are indicated in the following  
chart.  
The Power Wave / Power Feed are best diagnosed as  
a system. Each component (power source, user inter-  
face, and feed head) has a status light, and when a  
problem occurs it is important to note the condition of  
each. In addition, errors displayed on the user inter-  
face in most cases indicate only that a problem exists  
in the power source, not what the problem may be.  
Therefore, prior to cycling power to the system,  
check the power source status light for error  
sequences as noted below. This is especially  
important if the user interface displays "Err 006"  
or "Err 100" .  
NOTE: The Power Wave 455M (CE) status light will  
flash green, and sometimes red and green, for up to  
one minute when the machine is first turned on. This  
is a normal situation as the machine goes through a  
self test at power up.  
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).  
Status LED is blinking red.  
Non recoverable hardware fault. Generally indicates  
nothing is connected to the Power Wave 455M (CE)  
wire feeder receptacle. See Trouble Shooting Section.  
Not applicable.  
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E-3  
E-3  
TROUBLESHOOTING  
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 #  
CAN communication bus off.  
User Interface time out error.  
Indication  
11  
12  
Probably due to excessive number of communication errors.  
UI is no longer responding to the Power Source. The most likely  
cause is a fault/bad connection in the communication leads or con-  
trol cable.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
21  
22  
23  
Unprogrammed Weld Mode.  
Empty Weld Table.  
Weld Table checksum error.  
Excessive Primary current present. May be related to a short in the  
main transformer or output rectifier.  
Low voltage on the main capacitors. May be caused by improper  
input configuration.  
When accompanied by an overvoltage error on the same side, it  
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.  
Excess voltage on the main capacitors. May be caused by improp-  
er input configuration.  
31  
32  
33  
Primary overcurrent error.  
Capacitor "A" under voltage  
(Left side facing machine)  
Capacitor "B" under voltage  
(Right side facing machine)  
34  
35  
Capacitor "A" over voltage  
(Left side facing machine)  
When accompanied by an under voltage error on the same side, it  
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.  
Capacitor "B" over voltage  
(Right side facing machine)  
Indicates over temperature. Usually accompanied by Thermal LED.  
Check fan operation. Be sure process does not exceed duty cycle  
limit of the machine.  
36  
Thermal error  
37  
41  
Soft start error  
Capacitor precharge failed. Usually accompanied by codes 32-35.  
The secondary (weld) current limit has been exceeded. When this  
occurs the machine output will phase back to 100 amps, typically  
resulting in a condition referred to as "noodle welding"  
Secondary overcurrent error  
NOTE: The secondary limit is 570 amps for the standard stud, and  
325 amps.  
The maximum voltage difference between the main capacitors has  
been exceeded. May be accompanied by errors 32-35.  
43  
Capacitor delta error  
Single phase error  
Indicates machine is running on single phase input power. Usually  
49  
caused by the loss of the middle leg (L2).  
Error codes that contain three or four digits are defined as fatal  
errors. These codes generally indicate internal errors on the 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.  
Other  
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.  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
1. Contact your local authorized  
Lincoln Electric Field Service  
facility for technical assistance.  
1. Make certain that fuses or  
breakers are properly sized.  
See Installation section of this  
manual for recommended  
fuse and breaker sizes.  
Major physical or electrical damage  
is evident when the sheet metal  
covers are removed.  
Input fuses keep blowing, or input  
breaker keeps tripping.  
2. Welding procedure is drawing  
too much output current, or  
duty cycle is too high.  
Reduce output current, duty  
cycle, or both.  
3. There is internal damage to  
the power source. Contact an  
authorized Lincoln Electric  
Service facility.  
1. Make certain that the Power  
Switch (SW1) is in the ON”  
position.  
Machine will not power up (no  
lights, no fan, etc.)  
2. Circuit breaker CB4 (in recon-  
nect area) may have opened.  
Reset. Also, check input volt-  
age selection, below.  
3. Input voltage selection made  
improperly. Power down,  
check input voltage reconnect  
according to diagram on  
reconnect cover.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Authorized Field Service Facility.  
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.  
Thermal LED is lit.  
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.  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine wont weld, cant 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  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
the  
status  
light.  
See  
"Troubleshooting the Power Wave  
/ Power Feed System Using the  
Status LED" section of this text.  
Authorized Field Service Facility.  
Machine often noodle welds(out-  
put is limited to approximately 100  
amps) when running a particular  
procedure, especially a procedure  
with high WFS.  
1.Secondary current limit has been  
exceeded, and the machine has  
phased back to protect itself.  
2. Adjust procedure or reduce load  
to lower current draw from the  
machine.  
3. 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.  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine wont 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 deadno 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  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
General degradation of the weld  
performance  
1.Check for feeding problems, bad  
connections, excessive loops in  
cabling, etc.  
2. Verify weld mode is correct for  
processes.  
Authorized Field Service Facility.  
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)  
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F-1  
F-1  
DIAGRAMS  
REAR OF MACHINE  
5 0 6  
6
5
4
3
2
5 0 5  
5 0 4  
5 0 3  
6 0 4  
5 0 4  
4 0 4  
3 0 4  
6
5
4
3
2
1
8 1 5  
4 1 5  
1
8 1 4  
4 1 4  
+
C A H I M N E O F O R N F T  
POWER WAVE 455M (CE)  
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F-2  
F-2  
CONNECTION DIAGRAM  
Connection Diagram Semi-automatic "Simple System"  
(Electrode Positive, CV/Pulse Configuration shown)  
POWER WAVE  
WIRE  
FEEDER  
TO  
WORK  
CONTROL CABLE K1543  
POWER WAVE 455M (CE)  
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F-3  
F-3  
DIAGRAMS  
POWER WAVE 455M (CE)  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
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.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre- N’opérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
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.  
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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: www.lincolnelectric.com  
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