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IM583-A
December, 1999
POWER WAVE ™455
For use with machines having Code Numbers:
10372, 10553, 10555
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
R
OPERATOR’S MANUAL
• 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
products.
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.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the 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.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
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
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.
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.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
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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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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
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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vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - Power Wave 455..........................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Stacking ..........................................................................................................A-2
Environmental Protection................................................................................A-2
Lifting...............................................................................................................A-2
Machine Grounding ...............................................................................................A-2
High Frequency Protection ....................................................................................A-2
Input Connection....................................................................................................A-2
Input Fuse and Supply Wire Considerations .........................................................A-3
Input Voltage Reconnect Procedure......................................................................A-3
Output Connections...............................................................................................A-3
Voltage Sensing at the Work Piece.......................................................................A-4
Power Wave / Power Feed Wire Feeder Interconnections....................................A-4
Electrode and Work Leads - Electrode Positive Applications .........................A-4
Electrode and Work Leads - Electrode Negative Applications........................A-4
Control Cable Connections .............................................................................A-4
Power Feed Control Box Mounting .................................................................A-4
Operation .........................................................................................................Section B
Safety Instructions .................................................................................................B-1
Graphic Symbols that appear on this machine or in this manual...........................B-2
General Description...............................................................................................B-3
Recommended Processes and Equipment ...........................................................B-3
Design Features and Advantages .........................................................................B-3
Additional Features................................................................................................B-3
Welding Capability.................................................................................................B-4
Limitations..............................................................................................................B-4
Compatible Lincoln Equipment..............................................................................B-4
Power Source Operation .......................................................................................B-4
Duty Cycle and Time Period ...........................................................................B-4
Case Front Controls........................................................................................B-4
Welding Adjustments ......................................................................................B-5
Detailed Weld Mode Descriptions...................................................................B-5
Accessories.....................................................................................................Section C
Options / Accessories............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Troubleshooting..............................................................................................Section E
Troubleshooting the Power Wave / Power Feed System using the Status LED ...E-1
Safety Precautions.................................................................................................E-2
How to Use Troubleshooting Guide.......................................................................E-2
Troubleshooting Guide ..........................................................................................E-3
Wiring Diagram and Dimension Print............................................................Section F
Parts Lists ....................................................................................................P291 Series
Nov97
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE 455
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
OUTPUT
INPUT
CURRENT
OUTPUT
INPUT
CONDITIONS
CONDITIONS
CURRENT
208V - 60HZ.
230V - 60HZ.
400V - 60HZ.
460V - 60HZ.
575V - 60HZ.
200V - 50HZ.
220V - 50HZ.
400V - 50HZ.
440V - 50HZ.
550V - 50HZ.
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
450A@38V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
400A@36V. 100%
70
65
39
35
29
72
67
40
36
29
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
570A@43V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
500A@40V. 60%
87
82
50
48
38
79
74
45
41
33
OUTPUT
PULSE
VOLTAGE
RANGE
OPEN
CIRCUIT
VOLTAGE
CURRENT
RANGE
PULSE
FREQUENCY
PULSE AND
BACKGROUND
TIME RANGE
AUXILIARY
POWER
75 VDC
5 - 570
0.15 - 1000 Hz
5 - 55 VDC
100 MICRO SEC. -
3.3 SEC.
40 VDC AT
10 AMPS
115 VAC AT
10 AMPS
PROCESS CURRENT RANGES (DC)
CURRENT
MIG/MAG
FCAW
SMAW
Pulse
50-570 Amps
40-570 Amps
30-570 Amps
5-750 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75°C
TYPE 75°C
TYPE 75°C
INPUT
VOLTAGE /
FREQUENCY
OUTPUT AMPS/ INPUT AMPERE
COPPER WIRE GROUND WIRE (SUPER LAG)
DUTY
RATING ON
IN CONDUIT
IN CONDUIT
OR BREAKER
CYCLE
NAMEPLATE
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)
(MM2)
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
4 (25)
4 (25)
8 (10)
8 (10)
8 (10)
(MM2)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
8 (10)
8 (10)
10 (6)
10 (6)
10 (6)
208/60
230/60
400/60
460/60
575/60
200/50
220/50
400/50
440/50
550/50
450/100%
450/100%
450/100%
450/100%
450/100%
400/100%
400/100%
400/100%
400/100%
400/100%
70
65
39
35
29
72
67
35
31
29
80 AMP
70 AMP
50 AMP
40 AMP
40 AMP
80 AMP
80 AMP
50 AMP
40 AMP
40 AMP
PHYSICAL DIMENSIONS
HEIGHT
26.10 in
663 mm
WIDTH
DEPTH
32.88 in
835 mm
WEIGHT
250 lbs.
114 kg.
19.86 in
505 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
STORAGE TEMPERATURE RANGE
0°C to 40°C
-50°C to 85°C
POWER WAVE 455
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A-2
A-2
INSTALLATION
Read this entire installation section before you
start installation.
ENVIRONMENTAL PROTECTION
The Power Wave power source is rated IP21S and
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.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
LIFTING
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
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.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) to
a proper safety (Earth) ground.
MACHINE GROUNDING
-------------------------------------------------------------
The frame of the welder must be grounded. A ground
terminal marked with the symbol
is located inside
SELECT SUITABLE LOCATION
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
circulate in through the rear louvers and out through
the case sides and bottom. Dirt, dust, or any foreign
material that can be drawn into the welder should be
kept at a minimum. Using filters on the air intake to
prevent dirt from building up restricts air flow. Do
not use such filters. Failure to observe these precau-
tions can result in excessive operating temperatures
and nuisance shutdowns.
HIGH FREQUENCY PROTECTION
If possible, locate the Power Wave away from radio
controlled machinery. The normal operation of the
Power Wave may adversely affect the operation of RF
controlled equipment, which may result in bodily injury
or damage to the equipment.
This machine (above code 10500 only) is equipped
with F.A.N. (fan as needed) circuitry. The fan runs
whenever the output is enabled, whether under
loaded or open circuit conditions. The fan also runs for
a period of time (approximately 5 minutes) after the
output is disabled, to ensure all components are prop-
erly cooled.
INPUT CONNECTION
WARNING
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, locat-
ed on the back of the Control PC board enclosure.
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be
made in accordance with all local and national electri-
cal codes and the connection diagram located on the
inside of the reconnect/input access door of the
machine. Failure to do so may result in bodily injury
or death.
STACKING
Power Wave machines can be stacked to a maximum
of 3 high. The bottom machine must always be
placed on a firm, secure, level surface. There is a
danger of machines toppling over if this precaution is
not taken.
-------------------------------------------------------------
Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1
following.
POWER WAVE 455
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A-3
A-3
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
INPUT SUPPLY CONNECTION DIAGRAM
W / L3
INPUT SUPPLY CONNECTION DIAGRAM
VOLTAGE=200-208V
V / L2
U / L1
CR1
W / L3
V / L2
U / L1
.
.
.
Disconnect input power before
inspecting or servicing machine.
200-208V
220-230V
380-415V
440-460V
CR1
Do not operate with covers
removed.
.
.
.
Disconnect input power before
inspecting or servicing machine.
’A’
Do not touch electrically live parts.
Do not operate with covers
removed.
.
Only qualified persons should install,
use or service this equipment.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=440-460V
VOLTAGE=550-575V
VOLTAGE=220-230V
VOLTAGE=380-415V
VOLTAGE=440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
200-208V
220-230V
380-415V
440-460V
’A’
’A’
’A’
’A’
’A’
440-460V
550-575V
440-460V
550-575V
NOTE: Turn main input power to the machine OFF before performing reconnect procedure. Failure to do
so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON.
instructions located on the inside of the input access
INPUT FUSE AND SUPPLY WIRE
door or in Figure A.1. If the main reconnect switch is
CONSIDERATIONS
placed in the wrong position, the welder will not pro-
duce output power. If the Auxiliary (“A”) lead is placed
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
in the wrong position, there are two possible results.
If the lead is placed in a position higher than the
applied line voltage, the welder may not come on at
all. If the Auxiliary (“A”) lead is placed in a position
“inverse time” or “thermal/magnetic” circuit breakers).
lower than the applied line voltage, the welder will not
Choose an input and grounding wire size according to
come on, and the two circuit breakers in the reconnect
local or national electrical codes. Using fuses or cir-
area will open. If this occurs, turn off the input volt-
cuit breakers smaller than recommended may result in
age, properly connect the “A” lead, reset the breakers,
“nuisance” shut-offs from welder inrush currents, even
and try again.
if the machine is not being used at high currents.
OUTPUT CONNECTIONS
INPUT VOLTAGE RECONNECT
PROCEDURE
Use the largest welding (electrode and ground) cables
possible — at least 2/0, 4/0 preferred, copper wire —
even if the average output current would not normally
require it. When pulsing, the pulse current can
exceeds 650 amps. Voltage drops can become
excessive, leading to poor welding characteristics, if
undersized welding cables are used.
WARNING
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be
made in accordance with all local and national electri-
cal codes and the connection diagram located on the
inside of the reconnect/input access door of the
machine. Failure to do so may result in bodily injury or
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths, bundle the electrode and ground
cables together where practical, and do not coil
excess cable.
death.
------------------------------------------------------------------------
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this con-
nection to a different input voltage, refer to reconnect
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A-4
A-4
INSTALLATION
VOLTAGE SENSING AT THE
WORKPIECE
POWER WAVE / POWER FEED WIRE
FEEDER INTERCONNECTIONS
A four-pin work piece voltage sense lead connector is
located beneath the output stud cover. The use of a
work piece sense lead is optional for most welding
modes, but may be used if desired.
ELECTRODE & WORK LEADS —
ELECTRODE POSITIVE APPLICATIONS
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).
Sense Lead Kits (K490-10, -25 or -50) are available
for this purpose.
To enable the work piece voltage sensing lead, a
jumper must be removed from the Control PC Board
as follows:
A work lead must be run from the negative (-) power
source output stud to the work piece. The work piece
connection must be firm and secure, especially if
pulse welding is planned. Excessive voltage drops at
the work piece connection often result in unsatisfacto-
ry pulse welding performance.
1) Turn the Power Wave 455 power OFF.
2) Remove the front nameplate from the Power Wave
455 by removing the six screws from the name-
plate. Save the screws for re-use.
3) Locate P26, located on the upper right edge of the
Control PC Board. It is a 16 pin connector with
only two wires going into it. Unplug P26. It should
remain attached to the main harness.
ELECTRODE & WORK LEADS —
ELECTRODE NEGATIVE APPLICATIONS
When negative electrode polarity is required, such as
in some Innershield™ applications, install as above,
except reverse the output connections at the power
source (electrode cable to the negative (-) stud, and
work cable to the positive (+) stud).
4) Install the front nameplate on the Power Wave 455
by replacing the six screws saved in Step 2.
5) Plug a Sense Lead into the Sense Lead
Receptacle. Note: Only the lead marked ‘WORK’
is used. The lead marked ‘ELECT’ can be cut off
and discarded.
CONTROL CABLE CONNECTIONS
6) Connect the WORK sense lead clamp to the piece
being welded.
Connect the control cable between the wire feeder
and power source. The power source wire feeder
connection is located under the spring loaded output
cover, near the bottom of the case front. The control
cable is keyed and polarized, so it can be installed in
only one way.
The Power Wave 455 will now use the external work
piece Sense Lead to sense arc voltage in all welding
modes. If the Sense Lead is enabled but not connect-
ed to the work piece, extremely high welding output
currents may result.
For neatness and convenience sake, both the elec-
trode 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, out the back of the channels, and
then to the wire feeder.
To restore normal work piece sensing (at the output
terminals) reconnect P26 to the Control PC board.
The Sense Lead can then be disconnected.
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A-5
A-5
INSTALLATION
POWER FEED CONTROL BOX
MOUNTING
In some installations, it may be desirable to mount the
Wire Feeder control box directly to the front of the
Power Wave power source. (The control box is the
box containing the knobs, switches and displays nec-
essary to control the Power Wave / Power Feed weld-
ing system.) Complete details for separating the con-
trol box from the wire drive are contained in the Power
Feed Instruction Manual. Once separated, mounting
instructions are as follows:
1. Disconnect the input power from the Power Wave.
2. Separate the control box from the wire drive on the
Power Feed wire feeder, and remove the control
panels (see the Power Feed Instruction Manual for
details).
3. Remove the front nameplate from the Power Wave
by removing six screws from the metal nameplate.
Save the screws for re-use.
4. Connect the 6-pin connector that comes out the
back of the control box to the 6-pin receptacle that
is tie-wrapped to the harnessing inside the rectan-
gular opening in the power source. It will be nec-
essary to remove one or two of the wire ties in
order to give enough slack to the power source
connector and leads.
5. Position the control box over the rectangular hole
in the Power Wave case front, being careful not to
pinch any leads between the control box and the
case front. Align the four holes in the back of the
control box with the four threaded mounting holes
in the case front. Secure the control box in place
with four of the screws saved from the previous
step.
6. Reassemble the control box.
The Power Feed Wire Drive can now be connected to
the power source wire feeder connector. This con-
nector is located under the spring loaded output
cover, near the bottom of the case front. The control
cable is keyed and polarized, so it can be installed in
only one way. (To ensure proper electrode voltage
sensing, always connect the Wire Drive to the Power
Source wire feeder connector. Do not connect it to
the optional Output Receptacle which may be present
on the Power Feed Control Box.)
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B-1
B-1
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com-
bustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.
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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
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B-3
B-3
OPERATION
Parameter
Examples
GENERAL DESCRIPTION
Welding
Mode
Stick Crisp, Stick Soft, Flux Cored with Gas,
Flux Cored without Gas, CV, Synergic CV,
.035 Stainless Pulse, .045 Steel Pulse, 5356
Aluminum Pulse
The Power Wave 455 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-A processes.
Output
Current (CC modes), Voltage (CV modes),
Wire Feed Speed (synergic modes)
Trim
.500 to 1.500 (only in Pulse modes)
-10.0 to +10.0
RECOMMENDED PROCESSES AND
EQUIPMENT
Arc Control
ADDITIONAL DESIGN FEATURES AND
ADVANTAGES
RECOMMENDED PROCESSES
The Power Wave can be set up in a number of config-
urations, some requiring optional equipment. Each
machine is factory preprogrammed with multiple weld-
ing procedures, typically including GMAW, GMAW-P,
FCAW, SMAW, GTAW and CAC-A, for a variety of
materials, including mild steel, stainless steel, cored
wires, and aluminum.
• Designed to NEMA EW-1, IEC 974-1 and CSA
Standards.
• Qualifies for “S” mark on nameplate, which means it
can be used in areas where there is increased risk
of electric shock.
RECOMMENDED EQUIPMENT
• Multiple process output ranges: 5 - 570 amps.
• Easy access for input connections. Connections
are simple strip and clamp (no lugs required).
The Power Wave 455 must be used with the Power
Feed family of wire feeders. These feeders are
required to access and make use of the many of the
welding features contained in the Power Wave 455.
• F.A.N. (fan as needed). (On codes above 10500
only) Cooling fan runs only when necessary.
DESIGN FEATURES AND ADVANTAGES
• Modular construction for easy servicing.
• Thermostatically protected.
A unique feature of the Power Wave is the ability to
function without any controls, when used with Power
Feed wire feeders. All power source control informa-
tion comes to the Power Wave from a Power Feed
wire feeder.
• Electronic over current protection.
• Input over voltage protection.
The following chart lists the power source parameters
that can be changed from the Power Feed wire feed-
er, and gives examples of each. (Optional equipment
may be required to access some of the following para-
meters.)
• Utilizes digital signal processing and microprocessor
control.
• Simple, reliable input voltage change over.
• All system components communicate and transfer
information.
• Auto device recognition simplifies accessory cable
connections.
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B-4
B-4
OPERATION
CASE FRONT CONTROLS
WELDING CAPABILITY
All operator controls and adjustments are located on
the case front of the Power Wave.
The POWER WAVE 455 is rated at 60 Hz. 450A@
38V. 100% duty cycle or 570A@ 43V 60% duty cycle -
50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V
60% duty cycle. The machine is capable of higher out-
puts at lower duty cycles.
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated as follows:
If the duty cycle is exceeded, a thermostat will shut off
the output until the machine cools to a reasonable
operating temperature.
NOTE: The Power Wave 455 status light will flash
green, and sometimes red and green, for up to one
minute when the Power Wave 455 is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
LIMITATIONS
• The Power Wave is not recommended for process-
es other than those listed.
Light
Meaning
Condition
• The Power Wave can only be used with Power
Feed wire feeders. Other models of Lincoln feed-
ers, or any models of non-Lincoln wire feeders, can-
not be used.
Steady Green System OK. Power source communicating nor-
mally with wire feeder and its components.
Blinking
Green
Nothing connected to Wire Feeder
Receptacle.
Alternating Recoverable system fault.See
Green and Troubleshooting Section.
Red
COMPATIBLE LINCOLN EQUIPMENT
All Lincoln Power Feed™ Wire Feeders.
Steady Red
Non-recoverable system fault. Must turn
power source off, find source of error, and
turn power back on to reset. See
Troubleshooting Section.
POWER SOURCE OPERATION
See Troubleshooting Section.
Blinking Red
DUTY CYCLE AND TIME PERIOD
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper-
ature situation occurs. Output is disabled until the
machine cools down. When cool, the light goes
out and output is enabled.
The POWER WAVE 455 is rated at 60 Hz. 450A@
38V. 100% duty cycle or 570A@ 43V 60% duty cycle -
50 Hz. 400A@ 36V, 100% duty cycle or 500A@40V
60% duty cycle. The duty cycle is based upon a ten
minute period. A 60% duty cycle represents 6 minutes
of welding and 4 minutes of idling in a ten minute peri-
od.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAK-
ER: Protects 110 volt AC case front receptacle
auxiliary supply.
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B-5
B-5
OPERATION
10.0 to +10.0, with a nominal setting of 00.0. (The
nominal setting 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.
WELDING ADJUSTMENTS
All adjustments are made on the system component
known as the control box, which contains the switch-
es, knobs and digital displays necessary to control
both the Power Wave 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, or mounted separately, as might be done
in a welding boom installation.
DETAILED WELD MODE DESCRIPTIONS
CONSTANT VOLTAGE (CV/WELD, CV/MIG,
CV/FLUX CORED) PROCEDURES
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 manual.
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
wares at the factory. This preprogrammed voltage is
the best average voltage for the procedure at the
given wire feed speed. If the wire feed speed is
changed on the wire feeder, the voltage automatically
changes with it.
1. WFS / AMPS:
In synergic welding modes (synergic CV, pulse
GMAW) WFS (wire feed speed) is the dominant
control 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, out-
put current) according to pre-programmed settings
contained in the Power Wave. In non-synergic
modes, the WFS control changes the wire feed
speed according to the desired procedure.
In some cases, the operator may want to change the
preprogrammed voltages; for example, to compensate
for cable and fixture voltage drops. The preset volt-
ages can be adjusted on the wire feeder’s Voltage
display. When a change is made to the voltage at
one wire feed speed, this change is applied to all
other wire feed speed settings. For example, if the
operator turns up the voltage by 10 percent, the
machine automatically increases the preset voltages
at all the other wire feed speeds by 10 percent. The
preset voltage, programmed at the factory, may be
changed with the wire feeder VOLTS adjustment.
In constant current modes (stick, TIG) this control
adjusts the output current, in amps.
2. VOLTS / TRIM:
In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.
The Arc Control adjusts the inductance. (This adjust-
ment is often referred to as “pinch”. Inductance is
inversely proportional to pinch.) Increasing the Arc
Control setting decreases the inductance, which
results in the arc getting colder and pinched tighter.
Decreasing the Arc Control setting increases the
inductance, which results in the arc getting wider
(reduced pinch).
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 setting of 1.000 is a good starting point for
most conditions.
3. WELDING MODE:
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 avail-
able in the Power Wave, see the explanation
below.
GMAW PULSE PROCEDURES
In these procedures, the actual voltage greatly
depends on the waveform used. The peak currents,
background currents, rise times, fall times, and pulse
times all affect the actual voltage. The actual voltage
for a given wire feed speed is not directly predictable
unless the waveform is known. In this case, it is not
practical to preset an actual voltage for the procedure.
Instead, an arc length adjustment is provided. The
machine “knows” what the best arc length is at the
given wire feed speed but allows the operator to
change it.
4. ARC CONTROL:
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 -
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B-6
B-6
OPERATION
The arc length trim (usually referred to simply as
“trim”) can be adjusted between 0.500 and 1.500 on
the control box’s Volts/Trim display. A Trim of 1.000
means that no adjustments will be made to the preset
arc lengths. A Trim greater than 1.000 increases the
preset arc lengths. A Trim setting less than 1.000
decreases the preset arc lengths. The arc length trim
adjustment is factored in at all wire feed speed set-
tings. Increasing the Trim by 10 percent at a given
wire feed speed also increases all the other arc length
trim settings of the procedure by 10 percent.
ARC GOUGING PROCEDURES
Arc gouging can be performed by choosing the arc
gouging weld mode. Doing so automatically ener-
gizes the output terminals on the Power Wave, mak-
ing the power source immediately ready to weld. The
output current is set by the Amps control on the
Power Weld wire feeder. The Volts/Trim adjustment
has no effect in this mode.
The Arc Control adjusts the arc force. Increasing the
Arc Control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the Arc Control setting decreases the arc force, mak-
ing the arc softer and smoother.
The Power Wave utilizes a control scheme known as
adaptive control in all pulse modes. Because the
Power Wave utilizes adaptive control, it can adjust the
pulsing parameters based on changes in the arc due
to changes in the electrical stickout of the electrode.
(Electrical stickout is the distance from the contact to
to the workpiece.) The Power Wave is optimized
for use with a .75” stickout. The adaptive behavior
is programmed to support a stickout range from .5” to
1.25”. In the low and high end of the wire feed speed
ranges of most processes, the adaptive behavior may
be restricted. This is a physical restriction due to
reaching the edge of the operating range for the
process.
The Arc Control adjustment allows the pulse frequen-
cy to be varied. Increasing the Arc Control causes the
frequency setting to increase, while decreasing the
Arc Control causes the frequency to decrease.
Varying the Arc Control, and hence, the pulse fre-
quency, affects the droplet transfer and allows fine-
tuning for different welding positions.
CONSTANT CURRENT (CC/STICK, CC/TIG)
PROCEDURES
Stick welding can be performed by choosing one of
the stick welding modes. Check the Power Feed wire
feeder Operator’s Manual for instructions on how to
energize the output terminals on the Power Wave.
(Certain options energize the terminals automatically
while other options require a manual adjustment to
energize the terminals.) The output current is set by
the Amps control on the Power Feed wire feeder. The
Volts/Trim adjustment has no effect in this mode.
The Arc Control adjusts the arc force. Increasing the
Arc Control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the Arc Control setting decreases the arc force, mak-
ing the arc softer and smoother.
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C-1
C-1
ACCESSORIES
OPTIONS / ACCESSORIES
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave machines.
FIELD INSTALLED
The following options/accessories are available for
your Power Wave from your local Lincoln Distributor.
K1570-1 Dual Cylinder Undercarriage
K940-10 Voltage Sense Lead Kit- 10 foot voltage
sense lead kit.
K940-25 Voltage Sense Lead Kit- 25 foot voltage
sense lead kit, if additional length is required.
K940-50 Voltage Sense Lead Kit- 50 foot voltage
sense lead kit, if additional length is required.
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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.
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E-1
E-1
TROUBLESHOOTING
color of the Status LED, and refer to the following
chart to help you determine which system compo-
nent (power source, wire feeder, wire drive, etc.)
may be faulty. Replace the components identified
as potentially faulty with known good compo-
nents, and the system should operate normally.
USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS
The Status LED on the power source case front
can help diagnose problems down to the system
component (power source, wire feeder, wire drive,
etc.) level. If, for any reason, the system does not
appear to be working properly, always check the
Status LED is solid green (no blinking).
Status LED is blinking green.
System operating normally.
1. Normal condition for the first few seconds after the
power is turned on.
2. Wire feeder and/or its components are not prop-
erly configured and/or connected together. Refer
to wire feeder instruction manual(s) for wire feeder
configuration information.
Status LED is solid red (no blinking).
1. Indicates that nothing is connected to the Wire
Feeder Receptacle. Connect a Power Feed Wire
Feeder to the wire feeder receptacle.
2. Power source cannot communicate with the wire
feeder and/or its components due to a problem
within the power source. Contact an authorized
Lincoln Electric Service facility.
Status LED is blinking red and green.
1. If the Thermal LED is also lit, see “Yellow Thermal
LED Lit” in the Main Troubleshooting Chart.
2. Input voltage is too high or too low. Make certain
that input voltage is proper, according to the
Rating Plate located on the rear of the machine.
3. Power source is having trouble communicating
with wire feeder or its components. Turn machine
off. Disconnect control cable from the Wire
Feeder Receptacle. Turn power back on. If
Status LED then blinks green, the problem is with
the wire feeder. If light is still blinking red and
green, contact an authorized Lincoln Field Service
facility.
Status LED is blinking red.
1. Error code display. Contact an authroized Lincoln
Field Service Shop.
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E-2
E-2
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized
repairs per-formed on this equipment may result in danger to the technician and machine operator and
will invalidate your factory warranty. For your safety, please observe all safety notes and precautions
detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting
this equipment.
This Troubleshooting Guide is provided to help
you locate and correct possible machine misad-
justments. Simply follow the three-step procedure
listed below.
Step 3. CONSULT LOCAL AUTHORIZED
FIELD SERVICE FACILITY
If you have exhausted all of the recommended
tests in step 2, consult your local Authorized
Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM)
Look under the column labeled “PROBLEM
(SYMPTOMS).” This column describes possible
symptoms that your machine may exhibit. Find
the listing that best describes the symptom that
your machine is exhibiting.
Step 2. PERFORM EXTERNAL RECOMMEND-
ED TESTS
The second column labeled “POSSIBLE AREAS
OF MISADJUSTMENT(S)” lists the obvious
external possibilities that may contribute to the
machine symptom. Perform these tests/checks in
the order listed. In general, these tests can be
conducted without removing the case wrap-
around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs
safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your local authorized
is evident when the sheet metal
covers are removed.
Lincoln Electric Field Service facili-
ty for technical assistance.
Input fuses keep blowing, or input
breaker keeps tripping.
1. Make certain that fuses or
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.
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.
Machine will not power up (no
lights, no fan, etc.)
1. Make certain that the Power
Switch (SW1) is in the “ON”
position.
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.
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-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Wire feeder won’t work. No lights, 1. Circuit breaker CB1 (on case
apparently no power to wire feeder.
front) may have opened.
Reset.
2. Control cable between the
power source and wire feeder
is “open”. Check continuity on
all 5 leads from end to end in
the control cable.
3. Check for 40 volts DC on pins
D (+40) and E (common) of
the Wire Feeder Receptacle.
If 40 volts DC is not present,
and CB1 is reset, contact an
authorized Lincoln Electric
Service facility.
Thermal LED is lit.
1.
2.
1.
Fan thermostat has opened. Check
for proper fan operation. (Fan should
run whenever main power is on.)
Check for material blocking intake or
exhaust louvers, or for excessive dirt
clogging cooing channels in machine.
Secondary rectifier thermostat has
opened. After machine has cooled,
reduce load, duty cycle, or both.
Check for material blocking intake or
exhaust louvers.
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.
Machine won’t weld, can’t get any
output. (CR1 will not pull in.)
Input voltage is too low or too high.
Make certain that input voltage is
proper, according to the Rating Plate
located on the rear of the machine.
If the Thermal LED is also lit, see
“Yellow Thermal LED is Lit” section.
Primary current limit has been
exceeded. Possible short in output
circuit. Turn machine off. Remove all
loads from the output of the machine.
Turn back on. If condition persists,
turn power off, and contact an autho-
rized Lincoln Electric Field Service
facility.
2.
3.
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 455
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine often “noodle welds” (out- Secondary current limit has been
put is limited to approximately 100
amps) when running a particular
procedure
exceeded, and the machine has
phased back to protect itself.
Adjust procedure or reduce load to
lower current draw from the
machine.
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 prop-
er, 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.
For no apparent reason, the weld- 1. Check for proper Wire Feed
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
ing characteristics have changed.
Speed setting. In CV MIG
and FCAW modes, check for
proper Voltage setting. In the
MIG/MAG pulse modes,
check the Trim setting. These
controls are on the wire feed-
er.
Authorized Field Service Facility.
2. Check for proper shielding
gas mix and flow.
3. Check for loose or faulty weld
cables and cable connections.
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.
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 455
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F-1
F-1
DIAGRAMS
REAR OF MACHINE
4 0 6
4 0 5
4 0 4
4 0 3
6
5
4
3
5 0 6
2 3 9
2 3 5
5 0 3
6
5
4
3
2
1
2
2 3 3
1
2 3 4
+
F R O N T O F M A C H I N E
POWER WAVE 455
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F-2
F-2
DIAGRAMS
REAR OF MACHINE
F R O N T O F M A C H I N E
POWER WAVE 455
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F-3
F-3
DIAGRAMS
POWER WAVE 455
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects,
such as distortion; and supplemental information on arc
welding applications, speeds and costs. Practice materials,
exercises, questions and answers are suggested for each
lesson.
With over 500,000 copies of previous editions published
since 1933, the Procedure Handbook is considered by many to
be the “Bible” of the arc welding industry.
This printing will go fast so don’t delay. Place your
order now using the coupon below.
528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
The hardbound book contains over 750 pages of welding
information, techniques and procedures. Much of this material
has never been included in any other book.
$5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
“hands on”
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and
draftsmen use the “short-cut” language of symbols to pass
on assembly and welding information to shop personnel.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.
187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
Lincoln Welding School
BASIC COURSE
$700.00
$4.50 postage paid U.S.A. Mainland
5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
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Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
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USE THIS FORM TO ORDER:
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Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
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How to Read Shop Drawings
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Seminar Information
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(ED-93)
A New Approach to Industrial Economics $5.00
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Foundation Book Information
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$3.00
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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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