Lincoln Electric Power Wave Im808 A Users Manual

IM808-A to the manual 02ab140f-5b26-4c53-ad99-803182bff2ae

2015-02-09

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IM808-A

POWER WAVE 455M/STT
™

For use with machines having Code Numbers:

June, 2004

11008, 11204

Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And,
most
importantly, think before you act
and be careful.

IEC 60974-1
NRTL/C

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

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

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

FOR ENGINE
powered equipment.

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

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

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

Mar ‘95

SAFETY
ELECTRIC SHOCK can kill.

ARC RAYS can burn.

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.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.

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.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.

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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.

CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

SAFETY

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 suivantes:

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:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Mar. ‘93

SAFETY

vii

Thank You

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!

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.

viii

TABLE OF CONTENTS
Page

Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 455M/STT .........................................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
STT Welding ...................................................................................................B-9
________________________________________________________________________
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
________________________________________________________________________

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-7
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagrams...........................................................................Section F-2, F-3
Dimension Print............................................................................................Section F-4
________________________________________________________________________
Parts Lists ....................................................................................................P450 Series
________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
OUTPUT CONDITIONS
AMPS / VOLTS / DUTY CYCLE
EXCEPT STT PROCESS

INPUT
VOLTS
380V
380V
415V
415V

400A@36V.
400A@36V.
400A@36V.
400A@36V.

60Hz.
50Hz.
60Hz.
50Hz.

INPUT
CURRENT
AMPS

100%
100%
100%
100%

36 A
36 A
33 A
33 A

STT PROCESS ALL VOLTAGES
325A@33V. 100%

INPUT
CURRENT
AMPS

OUTPUT CONDITIONS
AMPS / VOLTS / DUTY CYCLE
EXCEPT STT PROCESS
500A@40V.
500A@40V.
500A@40V.
500A@40V.

48 A
48 A
44 A
44 A

60%
60%
60%
60%

STT PROCESS ALL VOLTAGES
325A@33V. 100%

OUTPUT
OPEN
CURRENT
PULSE
PULSE
CIRCUIT
RANGE
FREQUENCY VOLTAGE
VOLTAGE
AMPS
RANGE
75 VDC

5 - 570 A

PULSE AND
BACKGROUND
TIME RANGE

STT PARAMETERS
PEAK & BACKGROUND CURRENT

AUXILIARY
POWER

15-450 AMPS

40 VDC AT
10 AMPS

0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC.
3.3 SEC.

220 VAC AT
5 AMPS

PROCESS CURRENT RANGE (DC)

CURRENT AMPS

MIG/MAG
FCAW
SMAW
Pulse
STT

50-500 A
40-500 A
30-500 A
5-750 A
40-325 A

RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE /
FREQUENCY

DUTY
CYCLE

INPUT AMPERE
RATING ON
NAMEPLATE

380V Hz.
415V Hz.

100%
100%

36 A
33 A

TYPE 75°C
TYPE 75°C
TYPE 75°C
COPPER WIRE GROUND WIRE (SUPER LAG)
IN CONDUIT
IN CONDUIT
OR BREAKER
AWG[IEC] SIZES AWG[IEC] SIZES SIZE (AMPS)
(mm2)
(mm2)
8 (10)
8 (10)

10 (6)
10 (6)

40 A
40 A

PHYSICAL DIMENSIONS
HEIGHT
663 mm
(26.10 in)

WIDTH
505 mm
(19.86 in)

DEPTH
835 mm
(32.88 in)

WEIGHT
121 kg.
(267 lbs.)

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

STORAGE TEMPERATURE RANGE
-40°C to 40°C

POWER WAVE 455M/STT (CE)

A-2

INSTALLATION

SAFETY PRECAUTIONS Read this
entire installation section before you start installation.
WARNING

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.

STACKING

ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box before
working on this equipment. Turn off
the input power to any other equipment connected
to the welding system at the disconnect switch or
fuse box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave 455M/STT (CE)
grounding lug (located inside the reconnect input
access door) to a proper safety (Earth) ground.
----------------------------------------------------------

SELECT SUITABLE LOCATION
Do not use Power Wave 455M/STT (CE) in outdoor
environments. The Power Wave 455M/STT (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 mount the Power Wave 455M/STT (CE) over
combustible surfaces. Where there is a combustible
surface directly under stationary or fixed electrical
equipment, that surface shall be covered with a steel
plate at least 1.6mm (.060") thick, which shall extend
not less than 150mm (5.90") beyond the equipment on
all sides.
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. 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.
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 minutes) after the output is disabled, to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing the
fan to run whenever the power source is on). To disable
F.A.N., connect leads 444 and X3A together at the output
of the solid state fan control relay, located on the back of
the Control PC board enclosure. (See Wiring Diagram)

Power Wave machines can be stacked to a maximum
of 3 high.

WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trailer or gas cylinder.
FALLING
• Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury.
• Do not operate machine while
suspended from lift bail.
Do not stack the Power Wave 455M/STT (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.
-------------------------------------------------------------

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.

HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.

CAUTION
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.

POWER WAVE 455M/STT (CE)

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

CR1

U / L1

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

S24190

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.

ELECTRODE AND WORK CABLE
CONNECTIONS

INPUT CONNECTION
WARNING
Only a qualified electrician should connect the
input leads to the Power Wave 455M/STT (CE).
Connections should be made in accordance with
all local and national electrical codes and the connection diagram located on the inside of the
reconnect/input access door of the machine.
Failure to do so may result in bodily injury or death.

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.

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
inside of the input access door or refer to Figure A.1.

Minimum work and electrode cables sizes are as follows:
TABLE A.1
Current (60% Duty Cycle)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To-30 m Length (100 Ft.)
400 Amps
67 mm2 (2/0)
500 Amps
85 mm2 (3/0)
600 Amps
85 mm2 (3/0)

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

NOTE: K1796 coaxial welding cable is recommended to
reduce the cable inductance in long cable lengths. This is
especially important in Pulse and STT applications.

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

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

CAUTION
When using inverter type power sources like the
Power Waves, use the largest welding (electrode and
ground) cables that are practical. At least 67 mm2
(2/0) copper wire - even if the average output current
would not normally require it. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor welding
characteristics, if undersized welding cables are
used.
------------------------------------------------------------------------

POWER WAVE 455M/STT (CE)

A-4

INSTALLATION

CABLE INDUCTANCE, AND ITS EFFECTS
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.), traditional 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 welding loop length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See Figure A.3).
FIGURE A.3

POWER
WAVE

For additional Safety information regarding the electrode and
work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the Instruction Manuals.

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, reverse the output connections at
the power source (electrode cable to the negative (-) stud,
and work cable to the positive (+) stud).

A
C
WORK
B

For long work piece lengths, a sliding work connection should
be considered to keep the total welding loop length less than
50 feet. (See Figure A.4.)

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.

VOLTAGE SENSING
FIGURE A.4A.4
FIGURE

POWER
WAVE

A
C
B

WORK

C
B

SLIDING WORK CONNECTION
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE

Output connections on some Power Waves are made via 1/213 threaded output studs located beneath the spring loaded
output cover at the bottom of the case front.
Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable
between the wire feeder and the positive (+) output stud on
the power source (located beneath the spring loaded output
cover near the bottom of the case front). 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 connection 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.
When welding with the STT process, use the positive output
connection labeled “STT” for STT welding. (If desired ,other
welding modes can be used on this stud; however, the average output current will be limited to 325 amps.) For non-STT
processes, use the positive output connection labeled “Power
Wave”, so that the full output range of the machine is available.

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 voltage apparent 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.

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.

-----------------------------------------------------------------------The ELECTRODE sense lead (67) is built into the control
cable, and is automatically enabled for all semi-automatic
processes. The WORK sense lead (21) connects to the
Power Wave 455M/STT (CE) at the four pin connector located underneath the output stud cover. By default the WORK
voltage is monitored at the output stud in the Power Wave
455M/STT (CE). For more information on the WORK sense
lead (21), see "Work Voltage Sensing” in the following paragraph.
All constant current processes sense the voltage at the output studs of the POWER WAVE 455M/STT (CE) by default.

Do Not connect the STT and Power Wave stud together.
Paralleling the connection will bypass the STT circuitry and
severely deteriorate STT welding performance.

POWER WAVE 455M/STT (CE)

A-5

INSTALLATION

Enable the voltage sense leads as follows:
TABLE A.2
Process Electrode Voltage Work Voltage
Sensing 67 lead *
Sensing 21 lead
GMAW 67 lead required
21 lead optional
GMAW-P 67 lead required
21 lead optional
FCAW 67 lead required
21 lead optional
STT
67 lead required
21 lead required
GTAW Voltage sense at studs Voltage sense at studs
GMAW Voltage sense at studs Voltage sense at studs
SAW
67 lead required
21 lead optional
CAC
Voltage sense at studs Voltage sense at studs
* The electrode voltage 67 sense lead is integral to the
control cable to the wire feeder.
Work Voltage Sensing
The standard Power Wave 455M/STT (CE) is shipped
with the work voltage sense lead enabled.
For processes requiring work voltage sensing, connect
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 current path.
Enable the work voltage sensing in the Power Wave as
follows:
1. Turn off power to the power source at the disconnect
switch.
2. Remove the front cover from the power
source.

CAUTION
Important: The electrode polarity must be configured at the feed head for all semi-automatic
processes. Failure to do so may result in extremely high welding outputs.
------------------------------------------------------------------------

POWER WAVE TO SEMI-AUTOMATIC POWER FEED WIRE FEEDER
INTERCONNECTIONS
The Power Wave 455M/STT (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 extension. The output receptacle on the Power Wave
455M/STT (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.
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, out the back of
the channels, and then to the wire feeder.

2
1

O
N

4. Using a pencil or other small object, slide
the switch right to the OFF position if the
work sense lead is NOT connected.
Conversely, slide the switch to the ON
position if the work sense lead is present.

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.

Electrode Voltage Sensing
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.

5. Replace the cover and screws. The PC board will
“read” the switch at power up, and configure the work
voltage sense lead appropriately.

Due to the flexibility of the platform the configuration may
vary. The following is a general description of the system.
For specific configuration information, consult the semiautomatic Power Feed instruction manual.

SYSTEM DESCRIPTION
The Power Wave 455M/STT (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 buslike structure, the components may be connected to the
network in any order, thus simplifying the system set-up.

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

POWER WAVE 455M/STT (CE)

A-6

INSTALLATION

CONFIGURING THE SYSTEM
For codes below 11100, consult the semi-automatic
Power Feed instruction manual for configuration information about DIP switch settings.
For codes above 11100 the power source will “Auto
Map” the system eliminating most of the need to set
DIP switches to configure the system.

If a system can not be “Auto Mapped” then the status
light on the power source will blink green fast and the
welder output will be disabled. If a system is not “Automappable”, then consult the instruction manual for the
accessory being used for configuration information
about DIP switch settings, or consult your local Lincoln
sales representative.

SINGLE HEAD FEEDER

DUAL HEAD FEEDER

UP TO 4 FEEDERS
ALLOWED

POWER WAVE
455M/STT (CE)

FEED HEAD

SINGLE HEAD BOOM FEEDER
UP TO 4 FEED HEADS
ALLOWED

POWER WAVE
455M/STT (CE)

FH 1

Typical Robotic/ Hard Automation
(using Wire Drive Module and PF-10R)

ROBOT
PLC CONTROLLER
ANALOG INTERFACE

POWER WAVE
455M/STT (CE)

etc.

POWER WAVE 455MSTT (CE)

WIRE
DRIVE
MODULE

PF-10R

A-7

INSTALLATION
ALTERNATE HARD AUTOMATIC APPLICATION
(using a UI, WD Module, and PF-10R)

POWER WAVE 455M/STT (CE)

PF-10R
WIRE
DRIVE
MODULE
(FH1)

COMBINATION HARD AUTOMATION APPLICATION
(w/ Semi-Auto, WD Module, and PF-10R)

POWER WAVE 455M/STT (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/STT (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/STT (CE)
auto mapping disabled and the Equipment Groups set. (See the Feeder documentation for information on setting
the feeder DIP switches)
POWER WAVE 455M/STT (CE)

A-8

INSTALLATION

WELDING WITH MULTIPLE POWER
WAVES
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.
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 directions
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.

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
The use of non-standard cables, especially in
lengths greater than 7.6m(25 ft)., 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 30.5 m(100 ft.) total control cable length.

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the
arcs.
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas coverage.
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

POWERWAVE

POWER WAVE

POWERWAVE

Travel
Direction

Connect All Work
Sense Leads at the End
of the Joint

Connect All Welding
Work Leads at the
Beginning of the Joint

POWER WAVE 455M/STT (CE)

A-9

INSTALLATION

A-9

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

POWER WAVE 455M/STT (CE)

A-10

INSTALLATION

I / O RECEPTACLE SPECIFICATIONS
TABLE 3
WIRE FEEDER RECEPTACLE S1
PIN
LEAD#
FUNCTION
A
53
Communication Bus L
B
54
Communication Bus H
C
67A
Electrode Voltage Sense
D
52
0vdc
E
51
+40vdc
TABLE 4
VOLTAGE SENSE RECEPTACLE S2
PIN
LEAD#
FUNCTION
3
21A
Work Voltage Sense
TABLE 5
RS232 RECEPTACLE S3
PIN
LEAD#
FUNCTION
2
253
RS232 Receive
3
254
RS232 Transmit
4
#
S3 Pin5
5
#
S3 Pin4
6
##
S3 Pin20
20
##
S3 Pin6
7
251
RS232 Common

DIP SWITCH SETTINGS AND LOCATIONS
DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP
switches:
• Turn off power at the disconnect switch.
• Remove the top four screws securing the front
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.

switch 8
off
on

FIGURE A.3
CONTROL BOARD (DIP Switch Location)

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 sensor
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 present.

CONTROL BOARD DIP SWITCH:
switch
switch
switch
switch
switch
switch
switch
switch

1
2
3
4
5
6
7
8

=
=
=
=
=
=
=
=

reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
reserved for future
work sense lead

work sense lead
work sense lead not connected
work sense lead connected

use
use
use
use
use
use
use

POWER WAVE 455M/STT (CE)

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 clothing, gloves or work area is damp or if
working on, under or inside workpiece.
Use the following equipment:
-DC manual (stick) welder.
-AC welder with reduced voltage
control.
• Do not operate with panels removed.
• Disconnect input power before servicing.
------------------------------------------------------------ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT. READ AND
FOLLOW THE MANUFACTURER’S INSTRUCTIONS, 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/STT (CE)

B-1

B-2

OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
INPUT POWER

SMAW

GMAW

OFF

FCAW

HIGH TEMPERATURE

GTAW

MACHINE STATUS

OPEN CIRCUIT
VOLTAGE

CIRCUIT BREAKER

INPUT VOLTAGE

WIRE FEEDER

OUTPUT VOLTAGE

POSITIVE OUTPUT

INPUT CURRENT

NEGATIVE OUTPUT

OUTPUT CURRENT

3 PHASE INVERTER

PROTECTIVE
GROUND

INPUT POWER

THREE PHASE

DIRECT CURRENT

POWER WAVE 455M/STT (CE)

WARNING OR
CAUTION

B-2

B-3

OPERATION

DEFINITION OF WELDING TERMS

SMAW
• Shielded Metal Arc welding

NON-SYNERGIC WELDING MODES

SW
• Stud Arc Welding

• A Non-synergic welding mode requires all welding
process variables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity of
single knob control. The machine will select the correct voltage and amperage based on the wire feed
speed (WFS) set by the operator.

SAW
• Submerged Arc Welding
SAW-S
• Submerged Arc Welding-(Series)
STT
• Surface Tension Transfer

455M
•455Modular

FCAW
• Flux Core Arc Welding

WFS
• Wire Feed Speed

CAC
• Carbon Arc Cutting

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/STT (CE)

B-3

B-4

OPERATION

GENERAL DESCRIPTION
The Power Wave 455M/STT (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,
STT and pulse welding modes.
The Power Wave 455M/STT (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 components
communicate with ArcLink
The POWER WAVE 455M/STT (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, STT and CAC processes. It carries an output rating of 400 amps, 36 volts (at 100%
duty cycle). The STT process is supported at currents
up to 325 amps at 100% duty cycle.

RECOMMENDED PROCESSES AND
EQUIPMENT

DeviceNet Interface Module
This module can be used for DeviceNet capability. It
will be a 5 pin sealed mini connector per ANSI
B93.55M-1981.
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.

RECOMMENDED EQUIPMENT
Power Wave 455M/STT (CE) – Semi-Automatic
Operation
Semi Automatic Power Waves 455M/STT (CE) can only be
used with ArcLink compatible Power Feed semi-automatic
wire feeders and modules. In addition, the Power Feed semiautomatic wire feeders may require optional equipment to
access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non-Lincoln wire
feeders, cannot be used.
All welding programs and procedures are selected
through the Power Feed M semi-automatic user interface

RECOMMENDED PROCESSES

REQUIRED EQUIPMENT

The POWER WAVE 455M/STT (CE) can be set up in a
number of configurations, some requiring optional
equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures,
typically including GMAW, GMAW-P, FCAW, SMAW,
GTAW, STT and CAC-A for a variety of materials,
including mild steel, stainless steel, cored wires, and
aluminum.

Any ArcLink compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed M family.

The POWER WAVE 455M/STT (CE) is recommended
for semi-automatic welding with ArcLink compatible
equipment like the Power Feed M/STT series of feeders. The POWER WAVE 455M/STT (CE) can have a
number of modules installed that allow the machine to
be used in Robotic and hard automation applications.
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 applications.
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.

WARNING
LIMITATIONS
• The Power Waves are not to be used in outdoor
environments.
-----------------------------------------------------------------------• Only ArcLink compatible Power Feed semi-automatic wire
feeders and users interfaces may be used. Other Lincoln
wire feeders or non-Lincoln wire feeders cannot be used.
• POWER WAVE 455M/STT (CE) Output Limitations
The POWER WAVE 455M/STT (CE) will support maximum
average output current of 500 Amps (@ 60% duty cycle) on
the standard Power Wave stud, and a maximum average
output current of 325 amps (100% duty cycle) on the STT
stud.

DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding at
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 represents 6 minutes of
welding and 4 minutes of idling in a ten minute period.

POWER WAVE 455M/STT (CE)

B-5

OPERATION
FIGURE B.1

CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)

1. POWER SWITCH: Controls input power to the
Power Wave.

1
6

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.
NOTE: The POWER WAVE 455M/STT (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.
TABLE 3
Meaning
Light
Condition
Steady Green System OK. Power source communicating normally with wire feeder and its components.
Blinking
Green

Occurs during a reset, and indicates the
POWER WAVE 455M/STT (CE) is mapping
(identifying) 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

A l t e r n a t i n g Non-recoverable system fault. If the PS
Green
and Status light is flashing any combination of
red and green, errors are present in the
Red
POWER WAVE 455M/STT (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.

9
7

CASE FRONT LAYOUT
POWER WAVE 455M/STT (CE)

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
10. POSITIVE STUD

To clear the error, turn power source off, and
back on to reset. See Troubleshooting
Section.

11. AUXILIARY OUTPUT

Steady Red

Non recoverable hardware fault. Generally
indicates nothing is connected to the Power
Wave 455M 455M/STT (CE) wire feeder
receptacle. See Trouble Shooting Section.

13. ROBOTIC WIRE FEEDER RECEPTACLE
(OPTIONAL)

Blinking Red

Not applicable.

12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)

14. I/O CONNECTOR (OPTIONAL)
15. STT STUD

3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature 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.

16. ETHERNET CONNECTOR (OPTIONAL)

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
POWER WAVE 455M/STT (CE)

B-6

OPERATION

B-6

NOMINAL PROCEDURES

WELDING ADJUSTMENTS

The Power Wave is designed to operate with 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 contains the switches, 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, 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

WARNING
The serviceability of a product or structure utilizing
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 selection.
-----------------------------------------------------------------------The steps for operating the Power Wave 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 customize
operation for the best performance.
First, consider the desired welding process and the
part to be welded. Choose an electrode material,
diameter, shielding gas and process (GMAW, GMAWP, etc.)
Second, find the program in the welding software that
best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales representative.
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicated
digitally via the control cable.

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.
• WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW,
STT), 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, output current) according to pre-programmed settings contained in the
POWER WAVE 455M/STT (CE). In non-synergic
modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are
independent adjustments. Therefore to maintain the
arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
In constant current modes (stick, TIG) this control
adjusts the output current, in amps.
• VOLTS / TRIM:
In constant voltage modes (synergic CV, standard CV)
the control adjusts the welding voltage.
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.
Power Wave 455M/STT (CE) Only: In STT modes, the
user can adjust the Trim setting to change the overall
heat input to the weld.

POWER WAVE 455M/STT (CE)

B-7

OPERATION

B-7

• 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 available in the
Power Wave, see the explanation below.

Non Synergic CV:
This type of CV mode behaves more like a conventional CV power source. Voltage and WFS are independent adjustments. Therefore to maintain the arc
characteristics, the operator must adjust the voltage to
compensate for any changes made to the WFS.

• 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 -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.

All CV Modes:
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 software at the factory. The nominal preprogrammed voltage 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 automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS
range.

FIGURE A.5
CURRENT WAVE FORM (CV)

Wave Control +10.0
Wave Control 0.00

Wave Control -10.0

Current

Time
POWER WAVE 455M/STT (CE)

B-8

OPERATION

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 impractical, and instead the arc length is set by adjusting "trim".
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 will automatically recalculate the waveform parameters to maintain
similar arc properties.

B-8

The Power Wave utilizes "adaptive control" 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.
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 current, 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-position welding.
(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

POWER WAVE 455M/STT (CE)

B-9
STT WELDING

B-9

OPERATION

The pictures illustrate the wave shape of current for the
process. They are not drawn to scale, and are intended only for the purpose of showing how the variables
effect the waveform.
Trim in the STT mode adjusts the tail out and background portion of the waveform. For open root
processes, the tail out is fixed, and the trim affects only
the background level. Trim values greater than 1.0 add
more energy to the weld and make the weld puddle
hotter; trim values less than 1.0 reduce energy to weld
A nominal value of 1.0 will work for most applications.
(See Figure A.7)

For most programs, peak current is adjusted by arc
control, also referred to as wave control. A wave control value of +10.0 maximizes the peak current, while a
wave control of -10.0 minimizes peak current. In general, the peak current is proportional to the arc length.
(See Figure A.8)
NOTE: The ranges on Wave Control and Trim are
dependent on the weld programs. The values shown
are typical ranges.

FIGURE A.7

Trim
Trim 1.50
Current

Trim
1.00
Trim 1.00
Trim 0.50
Time

FIGURE A.8

Wave Control +10.0
Wave Control 0.0
Wave Control -10.0

Current

Time

POWER WAVE 455M/STT (CE)

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

POWER WAVE 455M/STT (CE)

C-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/STT (CE) is critical to its operation. Generally speaking the calibration
will not need adjustment. However, neglected or
improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance,
the calibration of output Voltage and Current should be
checked yearly.

CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the factory. 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 voltage and current. The accuracy of the calibration will be
directly affected by the accuracy of the measuring
equipment you use. Detailed instructions are available
with the utility.

POWER WAVE 455M/STT (CE)

D-1

E-1

TROUBLESHOOTING

E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

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 (SYMPTOMS)”. 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 CAUSE” lists
the obvious external possibilities that may contribute to
the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

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

POWER WAVE 455M/STT (CE)

E-2

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user interface, 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 interface
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" .

E-2

charts for both machine and weld performance.
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.
NOTE: The POWER WAVE 455M/STT (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
Status LED is solid green (no blinking).

MEANING
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/STT (CE) is mapping (identifying) 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.

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/STT (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/STT
(CE) wire feeder receptacle. See Trouble Shooting
Section.
Not applicable.

POWER WAVE 455M/STT (CE)

E-3

TROUBLESHOOTING

E-3

Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWERWAVE
The following is a list of possible error codes that the POWER WAVE 455M/STT (CE) can output via the status
light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.
11
12

Error Code # Description
CAN communication bus off.
User Interface time out error.

Indication
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 control cable.

Unprogrammed Weld Mode.

Empty Weld Table.

Weld Table checksum error.

Primary overcurrent error.

Capacitor "A" under voltage
(Left side facing machine)
Capacitor "B" under voltage
(Right side facing machine)

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.
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 improper input configuration.

Capacitor "A" over voltage
(Left side facing machine)

Capacitor "B" over voltage
(Right 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.

Thermal error

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.

Soft start error

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

Capacitor delta error

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

Single phase error

Indicates machine is running on single phase input power. Usually
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

E-4

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS

Major physical or electrical damage is evident when the sheet
metal covers are removed.

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

Input fuses keep blowing, or input
breaker keeps tripping.

Make certain that fuses or
breakers are properly sized.
See Installation section of this
manual for recommended fuse
and breaker sizes.
Welding procedure is drawing
too much output current, or
duty cycle is too high. Reduce
output current, duty cycle, or
both.
There is internal damage to
the power source. Contact an
authorized Lincoln Electric
Service facility.

Machine will not power up (no
lights, no fan, etc.)

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.

Make certain that the Power
Switch (SW1) is in the “ON”
position.
Circuit breaker CB4 (in reconnect area) may have opened.
Reset. Also, check input voltage selection, below.
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, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 455M/STT (CE)

E-5

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS

Thermal LED is lit.

1. Fan thermostat has opened.
Check for proper fan operation.
(Fan should run whenever output
power is on.) Check for material
blocking intake or exhaust louvers, or for excessive dirt clogging cooling channels in
machine.
2. Secondary rectifier or Choke
thermostat has opened. After
machine has cooled, reduce
load, duty cycle, or both. Check
for material blocking intake or
exhaust louvers.
3. DC Bus PC board thermostat
has opened check for excessive
load on 40VDC supply.

Machine won’t weld, can’t get any
output. (CR1 will not pull in.)

1. 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.
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 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 authorized
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
the
status
light.
See
"Troubleshooting the Power Wave
/ Power Feed System Using the
Status LED" section of this text.

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.

E-6

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS

Machine often “noodle welds” (output 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 current
limit from 570 Amps to 325
Amps.

Machine won’t produce full output.

1. Input voltage may be too low,
limiting output capability of the
power source. Make certain that
the input voltage is proper,
according to the Rating Plate
located on the rear of the
machine.
2. Input may be “single phased”.
Make certain the input voltage is
proper on all three Input lines.
3. STT machines only: May be
exceeding the 325 amp limit on
the STT output terminal.
4. Secondary current or voltage not
be properly calibrated. Check
values displayed on the Power
Feed 10/11 verses readings on
an external meter.

RECOMMENDED
COURSE OF ACTION

If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.

Auxiliary receptacle is “dead” no 1. Circuit breaker CB2 (on case
front) may have opened. Reset.
auxiliary voltage .
2. Circuit breaker CB4 (in reconnect area) may have opened.
Reset.

E-7

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)
General degradation of the weld
performance

Excessively long and erratic arc.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

1.Check for feeding problems, bad
connections, excessive loops in
cabling, etc.
2. Verify weld mode is correct for
processes.
3. The power source may require calibration.
4. Check the actual current displayed
on the Power Feed 10 vs. actual
current measured via external
meter.
5. Check the actual voltage displayed 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.
If all recommended possible areas
1. Check for proper configuration and
of misadjustments have been
implementation of voltage sensing
checked and the problem persists,
circuits.
contact your local Lincoln
Authorized Field Service Facility.

In the STT mode, the arc is excessively long and erratic.

1. Check that the (21) work sense
lead is connected, and configured
properly.

In the STT mode, the spatter is
higher than normal and the arc is
inconsistent.

1. Check that the (21) work sense
lead is connected, and configured
properly. (Dip Switch Set)
2. Verify that the electrode lead is
connected to the STT stud and
not the “POWER WAVE” stud.
3 Check that the “POWER WAVE”
stud is not electrically connected
to the STT stud.

POWER WAVE 455M/STT (CE)

GND-A
RED
BLACK
GREEN
67C

L8
539
541
521 L9
522
BLACK
847
WHITE
BLACK

851
852
853
854
855
856
857
858
859
860
861
862

1
2

+40VDC
DIODE

1
2
3
4
5
6

886

880

TO
J83

67B

67C
511

512

VOLTAGE SENSE
SELECT
BOARD

1
2
3
4
5
6
7
8
9
10
11
12

I/O
RECEPTACLE

3 CONDUCTOR
TWISTED/SHIELDED
SHIELD GROUND TO CASE

J
K
L
M
N

A
B
C
D
E
F
G
H

830

891
894

6B
6W
892
893

1
2
1
2
3
4
5
6
1
2
3
4

1
2
3
4
1
2
3
4

J76

J75

J74

J70 & J71
ARE NOT USED

J710

ETHERNET
PORT

J73

J72

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

851
852
853
854
855
856
857
858
859
860
861
862
512
511
5W
5B

CASEFRONT
PANEL

1
2
3
4
5
6
7
8

1
2
3
4
5
6

N.D.

J85

J84

J83

153B
154B
51B
52B

1
2
3
4

WHITE
RED
BLACK
BLACK
BLACK
GREEN

847

539
541
521
522
886
880

J82

J81

743
741
800
840

1
2
3
4

FEEDHEAD
BOARD

743
741
800
840
153B
154B
51B
52B

DEVICENET MODULE

WIRE DRIVE INTERFACE
MODULE

ROBOTIC/WIREDRIVE
INTERFACE RECEPTACLE

CASEFRONT

GND-B

L10

J16

1
3
4
5
6

J16

CB2

1
2
3
4

CB1

1
2
3
4
5
6
7

52A

54A

53A

251

253
254

21A

CB2

351

TO J47

202

R1
50Y

TP3

C1
.05/600V

202A

206A

202A

TO ELECTRODE

TP2

C2
.05/600V

206A
TO TP3

TO R1

206 TO J9

CE Model

TO R1

TO J9

TO WORK

TO TP3

220V RECEPTACLE

ELECTRODE

352A

5A CIRCUIT
BREAKER

TO
J2

51A
C11
.0047/3KV

67A
67
52

C
D

53
54

A
B

RS232
CONNECTOR

10A CIRCUIT
BREAKER

ARCLINK
RECEPTACLE

VOLTAGE
SENSE
RECEPTACLE

115V
RECEPTACLE

51A

67A
52A

53A
54A

10A CIRCUIT
BREAKER

1
3
4
5
6

MODULE
INTERFACE
CONNECTOR
153B
154B
51B
67B
52B

52B

153B
154B
51B

ONLY PRESENT IF FEEDHEAD
MODULE IS NOT PRESENT

ONLY PRESENT IF FEEDHEAD
MODULE IS PRESENT

TP1

WORK

TO TP6

POWER

TO
J43

TO
J40
J50

SW1

J11

J10B

J10A

1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8

TO CB4
612B

TO J61
H1D

211
212
213
813
811
216
816
812

4W
4R
3R
3W

2W
2B

1W
1B

506
403
404

604

504
503
406
405
238
505

231
232

224
220

222
223
225

228
226
227
221

267
266
268

TO
P90
P91

TO
SSR

TO
THERMAL
LED

TO
STATUS
LED

TO
J20
J40
J50

TO
RECT
THERM

TO
J42
J43
R5

TO CONTACTOR
L1A

LOAD LINE TO CONTACTOR
L3A

(TOP)

N.A.
THERMAL LED (Y)
TO J7

N.D.
STATUS LED (R/G)
TO J7

J1 & J3
ARE NOT USED

1
2
3
4
5
6
1
2
1
2
1
2
3
4

1
2
3
4

TO RECONNECT PANEL
A

21A
414
418
514
518
54
53
273
274

202
67

206

253
254

251

CONTROL BOARD

292

220A

1
2
3
4
1
2
3
4
5
6
7
8
475
476
477
478

POS
POS
NEG
NEG
51

TO C3

228
273
267
262

268A
226
274
266
345

346

475
477
476
478

225
223
221
227
222

4R
346

345

C3 2400oF
100V

POS
POS
POS

NEG

TO
CHOKE
THERM

TO
C3
AUX. #1

TO
J4
J43

289B
TO C10

TO C8
289A

TO D5
287

TO RECT
THERM

TO
CB1
J41
J82
S1

224A

224

TO
J4
J11
R5

TO
J47

TO
J4

812
813
811
816

TP5

STT

TP6

TO WORK

TO J8

288E

288D

TO J8

289F

289E

289D

287

2.7 10W

220A

220

TO J5

X3A

3W
4

P91
4
3
2
1

291

288B
TO C10

.022
800V

SEC
(TOP
LEFT)

20 F
400V

C10

TO
SWITCH
BD #2

X1
X2

PRI
(TOP
RIGHT)

H6
H5

TO J6,J10B

J40

J50

4
2
352

P52
1
33A

350

TO
RECONNECT
SWITCH

3500oF
500V

W
(115V) R
(230V)
H1

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR
INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V
OPERATION.

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 440-575V
OPERATION.

N.L. 10 AMP CIRCUIT BREAKER IS USED IN PLACE OF FUSE ON CODES
BELOW 11150.

N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.

N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD
LEAD H4B CONNECTS H4 TO SW1.

N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD
CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS
(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5.

N.G. ONLY PRESENT ON NON-CE MODELS.

N.F. ONLY PRESENT ON "CE" MODELS.

H1A

H6A

H1D

612

231

601
X3
238
604
232

TO SW 1

N.E. LEAD 33 IS PRESENT IN MODELS WITH 115V RECEPTACLE
ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN
MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.

N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET.

P50

1
2
3
4
5
6
7
8
9
10

TO
CB3
AUX #1

H6
(550-575)

J61

J60

1
2
3
4
5
6
7
8

N.F.
SWITCH LEAD
FILTER

L3B

’A
’

AC
3

NEG
AC
2

WATER
COOLER
RECEPTACLE

CASE
FRONT

REAR
UPPER
BASE

AUX.
2

AUX.
1

ELECTRICAL SYMBOLS PER E1537

COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS

LEAD COLOR CODING
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE

" = STT MACHINE ONLY
" = OPTION

COMPONENT VALUE UNITS:

N.F.

6
12

LATCH

G4420

VIEW OF CONNECTOR ON PC BOARD

1 2

EX. 12 PIN CONNECTOR

CONNECTOR PIN NUMBERS:

CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS

PROTECTIVE BONDING CIRCUIT

LEGEND
DASHED "
PHANTOM "

FRONT
UPPER
BASE

L1B

TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.

AC
1

POS

3
4

1
2

TO SUPPLY LINES

TO
RECONNECT
SWITCH

33A

350
352

200-208V
220-230V
440-460V
550-575V

TO SW1

FAN

N.L.

INPUT
RECTIFIER

NEG

TO
AUX #2

N.C.
N.J.

CR1
TO AUX #1

601

TO J60

TO J61

INPUT
LINE
FILTER

N.F.

TO AUX #1
H2
H3
H5
H6

RECONNECT
PANEL

X5
TO AUX#1

H1B

FUSE

10A

FRONT
REAR
FAN
RECONNECT RECONNECT
HORIZONTAL HORIZONTAL SHROUD SHELL
BRACKET
BAFFLE
BAFFLE

L1A

.0047 oF
440

L3A

TO
CR1
SW1
CB4

TO
CR1
J6
AUX #1

19D

N.G.

TO
SWITCH BD #1
NEG

19C

TO
SWITCH BD #1

TO
20
HARMONIC
FILTER

HARMONIC
FILTER 19

20C

20D
TO
SWITCH BD #2

TO
HARMONIC
FILTER

TO AUX #1

TO J61

CB3
3.5A

CIRCUIT
BREAKER

TO SOLID STATE RELAY
444

612

N.B., N.G., N.H.

RECONNECT SWITCH

TO
SWITCH BD #2
POS

TO AUX #2

TO INPUT SWITCH
612B

H1A

THIS AREA VIEWED FROM
REAR OF MACHINE

TO
AUX #2
CB3
RECONNECT PANEL

INPUT BOARD

AUXILIARY TRANSFORMER #2

6
TO
S4
CB2

P51
1

N.E.

352A

TO J6, J10B

TO RECONNECT
SWITCH

20D 19D

TO MAIN
TRANSFORMER

15 16

H4B

TO
MAIN TRANSFORMER

20C 19C

SWITCH BOARD
#2

11 12

3500oF
500V

SWITCH BOARD
#1

13
14

N.J.

H6A

X3A
TO SOLID STATE RELAY

TO FAN

H3
(220-230)
H2
(200-208)
H1

H6
(550-575)
H5
(440-460)
H4
(380-415)

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)
ALIGNS WITH BLACK LEAD OF LED SOCKET.

NOTES:

TO
SWITCH
BD #1

PRI
TO
(BOTTOM SWITCH
RIGHT) BD #2

(51V)
U

AUXILIARY TRANSFORMER #1

TO POWER BD.
RECTIFIER
X3
W
X3
(24V) N
X4
(115V) R
X5

TO
PRI
(BOTTOM SWITCH
LEFT)
BD #1

PRI
(TOP
LEFT)

RIGHT SIDE

SEC
(TOP
RIGHT)

SEC
(BOTTOM
RIGHT)

STT SNUBBER
CAPACITOR BANK

20 F
400V

STT SNUBBER
DIODE

F3
F3

TO
CR1
J60

CHOKE
THERM

MAIN
TRANSFORMER
LEFT SIDE

SEC
.022 (BOTTOM
LEFT)
800V

291

224A

CURRENT
TRANSDUCER

TO RECT
THERM

.022
800V

2.7
10W

RIGHT SIDE OF MACHINE

289A
289C
288B
288C
288D
288E
289B
289C
289D
289E

288A
288C

TO D5

288A
TO C8

TP7

2.7
10W

RECT
THERM

292

OUTPUT
RECT

216
211
213
212

MAIN CHOKE

TO AUX #1

TP4

TO
J7

TO FAN

444

SOLID 3R
STATE
RELAY + 3

STT SNUBBER
RESISTOR BANK

288F
C6
.05/600V

P90
1
2
3
4

STT CURRENT
TRANSDUCER

TO J46
POWER BD RECT

NEG
NEG
NEG

POS

268
268A

POWER BD
RECTIFIER

262

EMITTER

COLLECTOR
1
2
3
J10
4
5
6

CHOPPER BOARD

J47

J46

DC BUS BOARD

J43

J41

J42

1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12

DIGITAL POWER
SUPPLY BOARD

LEFT SIDE OF MACHINE

N.K.

DIAGRAMS

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

GND-A

ETHERNET
CONNECTOR
RJ 45 TYPE

4
5

894
893
892
891

THE ETHERNET CONNECTION
IS ONLY PRESENT IN THE
ETHERNET / DEVICENET MODULE

CAN_H
CAN_L

+24V GND 3

1
+24V 2

DEVICENET
CONNECTOR

N.D.

ETHERNET / DEVICENET
MODULE

REAR OF MACHINE

FRONT OF MACHINE

POWER WAVE 455M/STT (CE) WIRING DIAGRAM

514
518
503
504
505
506

414
418
403
404
405
406
1
2
3
4
5
6

+
1
2
3
4
5
6

F-1
F-1

F-2

CONNECTION DIAGRAM

Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, CV/Pulse Configuration shown)

POWER WAVE / STT
STT STUD

WIRE
FEEDER

TO
WORK

WORK SENSE

CONTROL CABLE K1543

POWER WAVE 455M/STT (CE)

F-3

CONNECTION DIAGRAM

Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, STT Configuration shown)

POWER WAVE / STT
STT STUD

WIRE
FEEDER

TO
WORK

WORK SENSE

CONTROL CABLE K1543

POWER WAVE 455/STT

POWER WAVE 455M/STT (CE)

19.00

12.35

19.16

19.90

9.48

22.63

23.12

23.51

26.10

DIMENSION PRINT - POWER WAVE 455M

32.88

14.62

11-14-97
M18241

F-4

DIAGRAMS
F-4

NOTES

● Do not touch electrically live parts or

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

● Keep flammable materials away.

● Wear eye, ear and body protection.

● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Mantenha inflamáveis bem guarda-

dos.

● Use proteção para a vista, ouvido e

corpo.

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.
● Use ventilation or exhaust to

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

remove fumes from breathing zone.
● Los humos fuera de la zona de res-

piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von

Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Strom vor Wartungsarbeiten

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

oder Innenschutzverkleidung in
Betrieb setzen!

● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer

● Mantenha-se afastado das partes

serviço.
● Não toque as partes elétricas nuas.

● Não opere com os paineis abertos

moventes.

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

ou guardas removidas.
Japanese

Chinese

Korean

Arabic

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

• 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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Lincoln Electric Power Wave Im808 A Users Manual

IM808-A to the manual 02ab140f-5b26-4c53-ad99-803182bff2ae

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