Lincoln Electric Power Wave Im808 A Users Manual

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IEC 60974-1

POWER WAVE 455M/STT

™

OPERATOR’S MANUAL

IM808-A

June, 2004

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However, your

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS MAN-

UAL AND THE SAFETY PRE-

CAUTIONS CONTAINED

THROUGHOUT. And, most

importantly, think before you act

and be careful.

For use with machines having Code Numbers: 11008, 11204

• 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

• World's Leader in Welding and Cutting Products •

NRTL/C

RETURN TO MAIN MENU

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

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

ing arc or when the engine is running. Stop

the engine and allow it to cool before refuel-

ing 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 posi-

tion and in good repair.Keep hands, hair, clothing and tools

away from V-belts, gears, fans and all other moving parts

when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you

purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,

Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the

Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

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.

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

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

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

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

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can

cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate circuits.

This can create fire hazards or overheat lifting chains or

cables until they fail.

6.h. Also see item 1.c.

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

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 met-

allique 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 defonc-

tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le total

de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie du

corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon-

nement 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, pan-

talons sans revers, et chaussures montantes.

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

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de

la zone de travail qu’il est pratique de le faire. Si on place la

masse sur la charpente de la construction ou d’autres endroits

éloignés de la zone de travail, on augmente le risque de voir

passer le courant de soudage par les chaines de levage,

câbles de grue, ou autres circuits. Cela peut provoquer des

risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir

le code “Code for safety in welding and cutting” CSA Standard

W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

SAFETY

viivii

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!

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.

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

this equipment.

CAUTION

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.

viii

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

________________________________________________________________________

ix 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

POWER WAVE 455M/STT (CE)

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE 455M/STT (CE) (K2203-2)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT

VOLTS

380V - 60Hz.

380V - 50Hz.

415V - 60Hz.

415V - 50Hz.

OPEN

CIRCUIT

VOLTAGE

75 VDC

INPUT

VOLTAGE /

FREQUENCY

380V Hz.

415V Hz.

HEIGHT

663 mm

(26.10 in)

WIDTH

505 mm

(19.86 in)

DEPTH

835 mm

(32.88 in)

WEIGHT

121 kg.

(267 lbs.)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

40 A

TYPE 75°C

GROUND WIRE

IN CONDUIT

AWG[IEC] SIZES

(mm2)

10 (6)

TYPE 75°C

COPPER WIRE

IN CONDUIT

AWG[IEC] SIZES

(mm2)

8 (10)

INPUT AMPERE

RATING ON

NAMEPLATE

36 A

33 A

DUTY

CYCLE

100%

MIG/MAG

FCAW

SMAW

Pulse

STT

50-500 A

40-500 A

30-500 A

5-750 A

40-325 A

PULSE

VOLTAGE

RANGE

5 - 55 VDC

AUXILIARY

POWER

40 VDC AT

10 AMPS

220 VAC AT

5 AMPS

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC.

3.3 SEC.

STT PARAMETERS

PEAK & BACK-

GROUND CURRENT

15-450 AMPS

CURRENT

RANGE

AMPS

5 - 570 A

PULSE

FREQUENCY

0.15 - 1000 Hz

INPUT

CURRENT

AMPS

36 A

33 A

INPUT

CURRENT

AMPS

48 A

44 A

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

EXCEPT STT PROCESS

400A@36V. 100%

STT PROCESS ALL VOLTAGES

325A@33V. 100%

OUTPUT CONDITIONS

AMPS / VOLTS / DUTY CYCLE

EXCEPT STT PROCESS

500A@40V. 60%

STT PROCESS ALL VOLTAGES

325A@33V. 100%

OPERATING TEMPERATURE RANGE

-20°C to 40°C

STORAGE TEMPERATURE RANGE

-40°C to 40°C

PROCESS CURRENT RANGE (DC) CURRENT AMPS

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

Power Wave machines can be stacked to a maximum

of 3 high.

The bottom machine must always be placed on a

firm, secure, level surface. There is a danger of

machines toppling over if this precaution is not

taken.

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

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.

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.

SAFETY PRECAUTIONS Read this

entire installation section before you start installa-

tion.

ELECTRIC SHOCK can kill.

• Only qualified personnel should per-

form 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 safe-

ty 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 cir-

culate in through the rear louvers and out through the

case sides and bottom. Dirt, dust, or any foreign mate-

rial 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 oper-

ating temperatures and nuisance shutdowns.

Machines are equipped with F.A.N. (fan as needed) cir-

cuitry. The fan runs whenever the output is enabled,

whether under loaded or open circuit conditions. The

fan also runs for a period of time (approximately 5 min-

utes) after the output is disabled, to ensure all compo-

nents are properly cooled.

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)

A-2

INSTALLATION

POWER WAVE 455M/STT (CE)

A-2

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 trail-

er 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.

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

WARNING

CAUTION

A-3

INSTALLATION

POWER WAVE 455M/STT (CE)

A-3

INPUT CONNECTION

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 con-

nection diagram located on the inside of the

reconnect/input access door of the machine.

Failure to do so may result in bodily injury or death.

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

Use a three-phase supply line. 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.

INPUT FUSE AND SUPPLY WIRE

CONSIDERATIONS

Refer to the Technical Specifications at the beginning

of this Installation section for recommended fuse and

wire sizes. Fuse the input circuit with the recommend-

ed super lag fuse or delay type breakers (also called

“inverse time” or “thermal/magnetic” circuit breakers).

Choose an input and grounding wire size according to

local or national electrical codes. Using fuses or circuit

breakers smaller than recommended may result in

“nuisance” shut-offs from welder inrush currents, even

if the machine is not being used at high currents.

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do

so will result in damage to the machine.

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

ELECTRODE AND WORK CABLE

CONNECTIONS

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.

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)

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.

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.

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

CAUTION

W / L3

V / L2

U / L1

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

S24190

use or service this equipment.

Do not touch electrically live parts.

removed.

Only qualified persons should install,

Do not operate with covers

inspecting or servicing machine.

Disconnect input power before

CR1

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

A-4

INSTALLATION

POWER WAVE 455M/STT (CE)

A-4

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 weld-

ing loop length is defined as the total of electrode cable length

(A) + work cable length (B) + work length (C) (See Figure A.3).

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.)

Output connections on some Power Waves are made via 1/2-

13 threaded output studs located beneath the spring loaded

output cover at the bottom of the case front.

Most welding applications run with the electrode being posi-

tive (+). 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 con-

nections 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 weld-

ing 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 aver-

age 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 avail-

able.

Do Not connect the STT and Power Wave stud together.

Paralleling the connection will bypass the STT circuitry and

severely deteriorate STT welding performance.

For additional Safety information regarding the electrode and

work cable set-up, See the standard "SAFETY INFORMA-

TION" located in the front of the Instruction Manuals.

Excessive voltage drops caused by poor work piece con-

nections often result in unsatisfactory welding perform-

ance.

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

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).

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

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.

If the voltage sensing is enabled but the sense leads are

missing, improperly connected, or if the electrode polar-

ity switch is improperly configured, extremely high weld-

ing 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 locat-

ed 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 para-

graph.

All constant current processes sense the voltage at the out-

put studs of the POWER WAVE 455M/STT (CE) by default.

CAUTION

FIGURE A.3

POWER

WAVE

WORK

POWER

WAVE

FIGURE A.4

K1796 COAXIAL CABLE

MEASURE FROM END

OF OUTER JACKET OF

CABLE

WORK

SLIDING WORK CONNECTION

FIGURE A.4

A-5

INSTALLATION

POWER WAVE 455M/STT (CE)

A-5

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.

Important: The electrode polarity must be config-

ured at the feed head for all semi-automatic

processes. Failure to do so may result in extreme-

ly high welding outputs.

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

POWER WAVE TO SEMI-AUTOMAT-

IC 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 exten-

sion. The output receptacle on the Power Wave

455M/STT (CE) is located beneath the spring loaded out-

put cover at the bottom of the case front. The input recep-

tacle 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.

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 semi-

automatic 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 bus-

like 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 man-

ual for details

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.

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.

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.

5. Replace the cover and screws. The PC board will

“read” the switch at power up, and configure the work

voltage sense lead appropriately.

N12 3456 78

CAUTION

A-6

INSTALLATION

POWER WAVE 455MSTT (CE)

A-6

CONFIGURING THE SYSTEM

For codes below 11100, consult the semi-automatic

Power Feed instruction manual for configuration infor-

mation about DIP switch settings.

For codes above 11100 the power source will “Auto

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 “Auto-

mappable”, then consult the instruction manual for the

accessory being used for configuration information

about DIP switch settings, or consult your local Lincoln

sales representative.

POWER WAVE

455M/STT (CE)

ROBOT

PLC CONTROLLER

ANALOG INTERFACE

etc.

POWER WAVE

455M/STT (CE)

POWER WAVE

455M/STT (CE)

POWER WAVE

455M/STT (CE) FEED HEAD

SINGLE HEAD FEEDER DUAL HEAD FEEDER

SINGLE HEAD BOOM FEEDER

FH 1

PF-10R

UP TO 4 FEEDERS

ALLOWED

UP TO 4 FEED HEADS

ALLOWED

WIRE

DRIVE

MODULE

Typical Robotic/ Hard Automation

(using Wire Drive Module and PF-10R)

A-7

INSTALLATION

POWER WAVE 455M/STT (CE)

A-7

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)

System that is NOT "Auto Mappable"

POWER WAVE 455M/STT (CE)

POWER WAVE

455M/STT (CE)

DUAL HEAD

ALTERNATE HARD AUTOMATIC APPLICATION

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

COMBINATION HARD AUTOMATION APPLICATION

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

DUAL HEAD BOOM FEEDER

(using two single heads)

PF-10R

FH-1 FH-2

PF-10R

WIRE

DRIVE

MODULE

(FH1)

WIRE

DRIVE

MODULE

(FH1)

A-8

INSTALLATION

POWER WAVE 455M/STT (CE)

A-8

WELDING WITH MULTIPLE POWER

WAVES

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.

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 puls-

ing frequency will be the same, helping to stabilize the

arcs.

Every welding gun requires a separate shielding gas

regulator for proper flow rate and shielding gas cover-

age.

Do not attempt to supply shielding gas for two or more

guns from only one regulator.

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

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

FIGURE A.2

POWERWAVE

Connect All Work

Sense Leads at the End

of the Joint

Connect All Welding

Work Leads at the

Beginning of the Joint

Travel

Direction

POWER WAVE

POWERWAVE

POWER WAVE

TWO POWER WAVES

CONTROL CABLE SPECIFICATIONS

It is recommended that genuine Lincoln control cables

be used at all times. Lincoln cables are specifically

designed for the communication and power needs of

the Power Wave / Power Feed system.

The use of non-standard cables, especially in

lengths greater than 7.6m(25 ft)., can lead to com-

munication 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.

CAUTION

A-9

INSTALLATION

POWER WAVE 455M/STT (CE)

A-9

MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

A-10

INSTALLATION

POWER WAVE 455M/STT (CE)

A-10

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 con-

figuration 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.

CONTROL BOARD DIP SWITCH:

switch 1 = reserved for future use

switch 2 = reserved for future use

switch 3 = reserved for future use

switch 4 = reserved for future use

switch 5 = reserved for future use

switch 6 = reserved for future use

switch 7 = reserved for future use

switch 8 = work sense lead

switch 8

work sense lead

off work sense lead not connected

on work sense lead connected

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 sen-

sor will prevent welding if no water flow is present.

CONTROL BOARD (DIP Switch Location)

FIGURE A.3

B-1

OPERATION

B-1

POWER WAVE 455M/STT (CE)

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet

clothing.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

• Do not use AC welder if your cloth-

ing, gloves or work area is damp or if

working on, under or inside work-

piece.

Use the following equipment:

-DC manual (stick) welder.

-AC welder with reduced voltage

control.

• Do not operate with panels removed.

• Disconnect input power before serv-

icing.

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

ONLY QUALIFIED PERSONS SHOULD INSTALL,

USE OR SERVICE THIS EQUIPMENT. READ AND

FOLLOW THE MANUFACTURER’S INSTRUC-

TIONS, EMPLOYER’S SAFETY PRACTICES AND

MATERIAL SAFETY DATA SHEETS (MSDS) FOR

CONSUMABLES.

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

READ THIS WARNING, PROTECT YOURSELF &

OTHERS.

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust at the arc,

or both,to keep fumes and gases from

your breathing zone and general area.

WELDING SPARKS can cause fire or

explosion.

• Do not weld near flammable material.

• Do not weld on containers which have

held flammable material.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

WARNING

B-2

OPERATION

B-2

POWER WAVE 455M/STT (CE)

INPUT POWER

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

GMAW

FCAW

GTAW

OPEN CIRCUIT

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE

GROUND

WARNING OR

CAUTION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

SMAW

B-3

OPERATION

B-3

POWER WAVE 455M/STT (CE)

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

•ANon-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

•ASynergic welding mode offers the simplicity of

single knob control. The machine will select the cor-

rect voltage and amperage based on the wire feed

speed (WFS) set by the operator.

455M

•455Modular

WFS

• Wire Feed Speed

•Constant Current

•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

SMAW

•Shielded Metal Arc welding

•Stud Arc Welding

SAW

•Submerged Arc Welding

SAW-S

•Submerged Arc Welding-(Series)

STT

•Surface Tension Transfer

FCAW

•Flux Core Arc Welding

CAC

•Carbon Arc Cutting

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 semi-

automatic wire feeders may require optional equipment to

access certain weld modes in the Power Wave. Other mod-

els 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 inter-

face

REQUIRED EQUIPMENT

Any ArcLink compatible semi-automatic wire feeding

equipment. Specifically, the semi-automatic Power

Feed M family.

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.

B-4

OPERATION

B-4

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 configura-

tion, 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 compo-

nent (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 perform-

ance, 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 car-

ries 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

RECOMMENDED PROCESSES

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 fac-

tory 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.

The POWER WAVE 455M/STT (CE) is recommended

for semi-automatic welding with ArcLink compatible

equipment like the Power Feed M/STT series of feed-

ers. 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 connec-

tions. 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.

POWER WAVE 455M/STT (CE)

WARNING

B-5

OPERATION

POWER WAVE 455M/STT (CE)

B-5

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.

2. STATUS LIGHT: A two color light that indicates sys-

tem 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

Light

Condition

Steady Green

Blinking

Green

Alternating

Green and

Red

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-

ly with wire feeder and its components.

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

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 sepa-

rated by a green light.

To clear the error, turn power source off, and

back on to reset. See Troubleshooting

Section.

Non recoverable hardware fault. Generally

indicates nothing is connected to the Power

Wave 455M 455M/STT (CE) wire feeder

receptacle. See Trouble Shooting Section.

Not applicable.

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

11. AUXILIARY OUTPUT

12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)

13. ROBOTIC WIRE FEEDER RECEPTACLE

(OPTIONAL)

14. I/O CONNECTOR (OPTIONAL)

15. STT STUD

16. ETHERNET CONNECTOR (OPTIONAL)

FIGURE B.1

3. HIGH TEMPERATURE LIGHT (thermal overload):

A yellow light that comes on when an over temper-

ature situation occurs. Output is disabled and the

fan continues to run, until the machine cools down.

When cool, the light goes out and output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:

Protects 40 volt DC wire feeder power supply.

CASE FRONT LAYOUT

POWER WAVE 455M/STT (CE)

11 10

B-6

OPERATION

B-6

NOMINAL PROCEDURES

The Power Wave is designed to operate with 3/4" elec-

trode stick-out for CV and Pulse processes.

FRINGE PROCEDURES

Excessively short or long electrode stick-outs may

function only on a limited basis, if at all.

MAKING A WELD

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 inter-

face (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, GMAW-

P, etc.)

Second, find the program in the welding software that

best matches the desired welding process. The stan-

dard software shipped with the Power Waves encom-

passes a wide range of common processes and will

meet most needs. If a special welding program is

desired, contact the local Lincoln Electric sales repre-

sentative.

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.

WELDING ADJUSTMENTS

All adjustments are made on the system component

known as the User Interface (Control Box), which con-

tains the switches, knobs, and digital displays neces-

sary to control both the Power Wave 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.

Because the Control Box can be configured with many

different options, your system may not have all of the

following adjustments. Regardless of availability, all

controls are described below. For further information,

consult the Power Feed wire feeder instruction manu-

al.

•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) accord-

ing to pre-programmed settings contained in the

POWER WAVE 455M/STT (CE). In non-synergic

modes, the WFS control behaves more like a conven-

tional CV power source where WFS and voltage are

independent adjustments. Therefore to maintain the

arc characteristics, the operator must adjust the volt-

age 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 set-

ting of 1.000 is a good starting point for most condi-

tions.

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)

WARNING

ave Control 0.00

Wave Control +10.0

ave Control -10.0

Current

Time

CURRENT WAVE FORM (CV)

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.

• 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 set-

ting of 00.0 may be displayed as OFF on some Power

Feed wire feeder control panels). See the Welding

Mode descriptions, below, for detailed explanations of

how the Arc Control affects each mode.

CONSTANT VOLTAGE WELDING

Synergic CV:

For each wire feed speed, a corresponding voltage is

preprogrammed into the machine through special soft-

ware at the factory. The nominal preprogrammed volt-

age is the best average voltage for a given wire feed

speed, but may be adjusted to preference. When the

wire feed speed changes, the Power Wave automati-

cally adjusts the voltage level correspondingly to main-

tain similar arc characteristics throughout the WFS

range.

Non Synergic CV:

This type of CV mode behaves more like a conven-

tional CV power source. Voltage and WFS are inde-

pendent adjustments. Therefore to maintain the arc

characteristics, the operator must adjust the voltage to

compensate for any changes made to the WFS.

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)

POWER WAVE 455M/STT (CE)

FIGURE A.5

B-8

OPERATION

B-8

PULSE WELDING

Pulse welding procedures are set by controlling an

overall "arc length" variable. When pulse welding, the

arc voltage is highly dependent upon the waveform.

The peak current, back ground current, rise time, fall

time and pulse frequency all affect the voltage. The

exact voltage for a given wire feed speed can only be

predicted when all the pulsing waveform parameters

are known. Using a preset voltage becomes impracti-

cal, and instead the arc length is set by adjusting "trim".

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 automati-

cally recalculate the waveform parameters to maintain

similar arc properties.

POWER WAVE 455M/STT (CE)

Wave Control 0.0

Wave Control +10.0

Wave Control -10.0

FIGURE A.6

Current

Time

CURRENT WAVE FORM (PULSE)

The Power Wave utilizes "adaptive control" to com-

pensate for changes in electrical stick-out while weld-

ing. (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 reach-

ing 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 cur-

rent, resulting in a tight, stiff arc best for high speed

sheet metal welding. Wave control values less than 0.0

decrease the pulse frequency while increasing the

background current, for a soft arc good for out-of-posi-

tion welding.

(See Figure A.6)

B-9

OPERATION

B-9

STT WELDING

The pictures illustrate the wave shape of current for the

process. They are not drawn to scale, and are intend-

ed only for the purpose of showing how the variables

effect the waveform.

Trim in the STT mode adjusts the tail out and back-

ground 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 con-

trol value of +10.0 maximizes the peak current, while a

wave control of -10.0 minimizes peak current. In gen-

eral, 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.

POWER WAVE 455M/STT (CE)

Wave Control 0.0

Wave Control +10.0

Wave Control -10.0

rim 1.00

rim 1.50

Trim 0.50

Current

Time

Current

FIGURE A.7

FIGURE A.8

Trim 1.50

Trim 1.00

Trim 0.50

C-1

ACCESSORIES

C-1

OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED

Work Voltage Sense Lead Kit, K940

Dual Cylinder Undercarriage, K1570-1.

Gas Guard Regulator, K659-1

Coaxial welding Cable, K1796

Cool Arc 40

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)

D-1

MAINTENANCE

D-1

POWER WAVE 455M/STT (CE)

SAFETY PRECAUTIONS

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 criti-

cal to its operation. Generally speaking the calibration

will not need adjustment. However, neglected or

improperly calibrated machines may not yield satisfac-

tory 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 facto-

ry. Generally speaking the machine calibration will not

need adjustment. However, if the weld performance

changes, or the yearly calibration check reveals a prob-

lem, contact the Lincoln Electric Company for the cali-

bration software utility.

The calibration procedure itself requires the use of a

resistive load bank, and certified actual meters for volt-

age and current. The accuracy of the calibration will be

directly affected by the accuracy of the measuring

equipment you use. Detailed instructions are available

with the utility.

WARNING

E-1

TROUBLESHOOTING

E-1

POWER WAVE 455M/STT (CE)

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.

CAUTION

This Troubleshooting Guide is provided to help you

locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP-

TOMS)”. This column describes possible symptoms

that the machine may exhibit. Find the listing that best

describes the symptom that the machine is exhibiting.

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

This column provides a course of action for the

Possible Cause, generally it states to contact your

local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your

local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

WARNING

E-2

TROUBLESHOOTING

E-2

POWER WAVE 455M/STT (CE)

USING THE STATUS LED TO

TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed as

a system. Each component (power source, user inter-

face, and feed head) has a status light, and when a

problem occurs it is important to note the condition of

each. In addition, errors displayed on the user 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" .

Included in this section is information about the power

source Status LED, and some basic troubleshooting

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.

LIGHT CONDITION

Status LED is solid green (no blinking).

Status LED is blinking green.

Status LED is blinking red and green.

Status LED is solid red (no blinking).

Status LED is blinking red.

MEANING

1. System OK. Power source communicating normally

with wire feeder and its components.

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 sec-

onds after power is turned on, or if the system con-

figuration is changed during operation.

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 sep-

arated by a green light.

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

to reset.

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.

E-3

TROUBLESHOOTING

E-3

POWER WAVE 455M/STT (CE)

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

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 PF-

10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.

Error Code # Description

11 CAN communication bus off.

12 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage

(Left side facing machine)

33 Capacitor "B" under voltage

(Right side facing machine)

34 Capacitor "A" over voltage

(Left side facing machine)

35 Capacitor "B" over voltage

(Right side facing machine)

36 Thermal error

37 Soft start error

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

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 con-

trol cable.

Contact the Service Department for instructions on reloading the

Welding Software.

Contact the Service Department for instructions on reloading the

Welding Software.

Contact the Service Department for instructions on reloading the

Welding Software.

Excessive Primary current present. May be related to a short in the

main transformer or output rectifier.

Low voltage on the main capacitors. May be caused by improper

input configuration.

When accompanied by an overvoltage error on the same side, it

indicates no capacitor voltage present on that side, and is usually

the result of an open or short in the primary side of the machine.

Excess voltage on the main capacitors. May be caused by improp-

er input configuration.

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.

Indicates over temperature. Usually accompanied by Thermal LED.

Check fan operation. Be sure process does not exceed duty cycle

limit of the machine.

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.

The maximum voltage difference between the main capacitors has

been exceeded. May be accompanied by errors 32-35.

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.

E-4

TROUBLESHOOTING

E-4

POWER WAVE 455M/STT (CE)

Observe all Safety Guidelines detailed throughout this manual

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

PROBLEMS

(SYMPTOMS) POSSIBLE AREAS OF

MISADJUSTMENT(S) RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical dam-

age is evident when the sheet

metal covers are removed.

Input fuses keep blowing, or input

breaker keeps tripping.

Machine will not power up (no

lights, no fan, etc.)

1. Contact your local authorized

Lincoln Electric Field Service

facility for technical assis-

tance.

1. Make certain that fuses or

breakers are properly sized.

See Installation section of this

manual for recommended fuse

and breaker sizes.

2. Welding procedure is drawing

too much output current, or

duty cycle is too high. Reduce

output current, duty cycle, or

both.

3. There is internal damage to

the power source. Contact an

authorized Lincoln Electric

Service facility.

1. Make certain that the Power

Switch (SW1) is in the “ON”

position.

2. Circuit breaker CB4 (in recon-

nect area) may have opened.

Reset. Also, check input volt-

age selection, below.

3. Input voltage selection made

improperly. Power down,

check input voltage reconnect

according to diagram on

reconnect cover.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

Authorized Field Service Facility.

E-5

TROUBLESHOOTING

E-5

POWER WAVE 455M/STT (CE)

Observe all Safety Guidelines detailed throughout this manual

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

PROBLEMS

(SYMPTOMS) POSSIBLE AREAS OF

MISADJUSTMENT(S) RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Thermal LED is lit.

Machine won’t weld, can’t get any

output. (CR1 will not pull in.)

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 lou-

vers, or for excessive dirt clog-

ging 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.

1. Input voltage is too low or too

high. Make certain that input volt-

age 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” sec-

tion.

3. Primary current limit has been

exceeded. Possible short in out-

put 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.

.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.

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

E-6

POWER WAVE 455M/STT (CE)

Observe all Safety Guidelines detailed throughout this manual

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

PROBLEMS

(SYMPTOMS) POSSIBLE AREAS OF

MISADJUSTMENT(S) RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Machine often “noodle welds” (out-

put is limited to approximately 100

amps) when running a particular

procedure, especially a procedure

with high WFS.

Machine won’t produce full output.

Auxiliary receptacle is “dead” no

auxiliary voltage .

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.

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.

1. Circuit breaker CB2 (on case

front) may have opened. Reset.

2. Circuit breaker CB4 (in recon-

nect area) may have opened.

Reset.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

Authorized Field Service Facility.

E-7

TROUBLESHOOTING

E-7

POWER WAVE 455M/STT (CE)

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS) POSSIBLE AREAS OF

MISADJUSTMENT(S) RECOMMENDED

COURSE OF ACTION

General degradation of the weld

performance

Excessively long and erratic arc.

In the STT mode, the arc is exces-

sively long and erratic.

In the STT mode, the spatter is

higher than normal and the arc is

inconsistent.

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 cal-

ibration.

4. Check the actual current displayed

on the Power Feed 10 vs. actual

current measured via external

meter.

5. Check the actual voltage dis-

played on the Power Feed 10 vs.

actual voltage measured via exter-

nal meter.

6. Check the actual WFS displayed

on the Power Feed 10 vs. actual

WFS measured via external

meter.

1. Check for proper configuration and

implementation of voltage sensing

circuits.

1. Check that the (21) work sense

lead is connected, and configured

properly.

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.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

Authorized Field Service Facility.

F-1

DIAGRAMS

F-1

POWER WAVE 455M/STT (CE)

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..

TO J9

202

WORK

202A TO R1

TO TP6

ARCLINK

RECEPTACLE

ELECTRODE

223

221

206A R3

TO D5

289D

288C

288D

289E288E

J1 4

3R3R

238

J10

STATUS

LED

RECT

THERM

223

222

CHOPPER BOARD

SEC

(BOTTOM

LEFT)

POWER BD

RECTIFIER

EMITTER

212

213

813

811

216

CONTROL BOARD

TO J61

CR1

TO AUX #1

503

504

505

506

INPUT

20D

1718

15 16

CB1

J41

251

J47

P90

P91

RECT

292

SEC

(TOP

LEFT)

L1B

CR1

SW1

CB4 T2

H1D T3

612

NEG

346

AUX. #1

CHOKE

THERM

CURRENT

TRANSDUCER

TO C8

19D

SWITCH BOARD

289A

288B

TO C10

SW1

POWER

C10

289F

202

225

206

TP6

289E

289D

289C

289B

288E

288D

288C

288B

289C

289A

TO C10

289B

NEG

STT

601

TO J60

NEG

19C

HARMONI C

FILTER

REAR OF MACHINE

TO J6,J10B

TO SOLID STATE RELAY

444

FAN

THIS AREA VIEWED FROM

288F

RECONNECT

PANEL

CR1

231

AUX #1

J61 5

POS

CB1

10A CIRCUIT

BREAKER

TP3

TO R1

CB2

10A CIRCUIT

BREAKER

TP2

206 TO J9

202A

TP5

206A

NEG

PRI

(BOTTOM

RIGHT)

SWITCH

BD #2

SWITCH

BD #1

SWITCH

BD #2

MAIN

TRANSFORMER

LEFT SIDE

NEG

POS

.05/600V

403

288A

511

604

H1A TO AUX #2

CB3

3.5A

BREAKER

TO SW1

200-208V

220-230V

440-460V

550-575V

POS

TO SUPPLY LINES

VOLTAGE

SENSE

RECEPTACLE

TO A SYSTEM GROUND PER

NATIONAL ELECTRICAL CODE.

RS232

CONNECTOR

FRONT OF MACHINE

115V

RECEPTACLE

TO RECONNECT PANEL

2J74

J76

PRI

(BOTTOM

LEFT)

20C

TO AUX #1

404

405

406

21A

67A

TO C3

J46 3

POS

DC BUS BOARD

J41

50Y

N.D.

.05/600V

STATUS LED (R/G)

TO J7

N.A.

THERMAL LED (Y)

TO J7

J11

SWITCH BOARD

X3A

TO FAN

224A

291

CB3

TO J61

TO INPUT SWITCH

612B

612

H1 TO AUX #1

AUXILIARY TRANSFORMER #1

SEC

(BOTTOM

RIGHT)

SWITCH BD #2

POS

SWITCH BD #1

11 12

20D

SWITCH BD #2

CAPACITORS=MFD/VOLTS

RESISTORS=OHMS/WATTS

(200-208)

(220-230)

PRI

(TOP

LEFT)

(115V)

(24V)

COLLECTOR

TO J61

H1D

(TOP)

LOAD LINE

TO CB4

612B

L3A

L1A

TO CONTACTOR

TO TP3

232

604

238

601

INPUT BOARD

NEG

TO AUX #1

812

813

287

811

816

19C

SWITCH

BD #1

514

AUXILIARY TRANSFORMER #2

NOTES:

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

ALIGNS WITH BLACK LEAD OF LED SOCKET.

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT

OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR

OPERATION.

RIGHT SIDE OF MACHINE

228

226

224

220

504

503

406

505

506

211

816

21A

418

514

273

274

TO J6, J10B

RIGHT SIDE

512

VOLTAGE SENSE

SELECT

BOARD

SWITCH B D #1

J40

403

THERM

J72

J75

WIRE DRIVE INTERFACE

MODULE

BOARD

J42

TO J5

225

SEC

(TOP

RIGHT)

J50

J60

273

228

274

226

TO J8

J43

251

253

254

NEG

DIGITAL POWER

SUPPLY BOARD

3R TO 3W

MAIN CHOKE

221

231

232

291

X3A

.05/600V

TP1

TO C8

288A

345 287

TP7

RECTIFIER

SWITCH

RECONNECT

414

’A

’

LEFT SIDE OF MACHINE

RECONNECT SWITCH

TP4

444

TO FAN

J47

475

477

476

216

478

211

213

212

W=WHITE

U=BLUE

R=RED

COMPONENT VALUES:

N=BROWN

REAR OF MACHINE

G=GREEN

B=BLACK

LEAD COLOR CODING

CB3

ELECTRICAL SYMBOLS PER E1537

H1A

AUX #1

L3B

TO AUX#1

OUTPUT

RECT

253

254

TO J46

POWER BD RECT

J10A

J11

812

886

880

TO J8

X2 U

J42

J43

TO POWER BD.

RECTIFIER

(51V)

(380-415)

X3 WH3

AUX #2

RECONNECT PANEL

MAIN TRANSFORMER

TO D5

34-

SOLID

STATE

RELAY

(440-460)

2.7 10W

.022

800V

PRI

(TOP

RIGHT)

POS

NEG

DIODE

.022

800V

2.7

10W

2.7

10W

.022

800V

N.C.

N.J.

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V

CONNECTOR

DEVICENET

I/O

RECEPTACLE

ROBOTIC/WIREDRIVE

INTERFACE RECEPTACLE

CIRCUIT

10A

FUSE

J83

P90

P91

J82

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

67C

67B

892

851

852

853

854

855

856

222

891

857

858

859

860

3 CONDUC TOR

TWISTED/SHIELDED

SHIELD GROUND TO CASE

2B 2W

+40VDC

267

266

268

THERM

GND-B

267

266

268A

893

894

227

WATER

COOLER

RECEPTACLE

350

352

539

541

521

522

BLACK

847

861

862

J82 154B

153B

51B

52B

WHITE

J84

847

880

886

522

521

541

539

J83

856

855

854

853

852

851

J85

857

511

512

862

861

860

859 9

858

(550-575) H6A

CR1

J60

CHOKE

THERMTO RECT

THERM

RECONNECT

SWITCH

H6 5

(550-575) H6A

P50

VOLTAGE. CONNECTION SHOWN IS FOR 440-575V

20 F

400V

20 F

400V

+24V

+24V GND

CAN_H

CAN_L

418

518

800

840

518 2

414

J10B

SSR

405

404

893

891

894

J73

743

741

800

840

AC AC

346

345

830

262

268

268A

220A

292

262

(115V)

CB2

350

352

P52

33A

2(230V)

33A

224A

224

220

220A

J43

TO RECT

THERM

AUX #2

100V

2400oF

500V

3500oF

500V

3500oF

HARMONIC

FILTER

20C 19D

N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)

ALIGNS WITH WHITE LEAD OF LED SOCKET.

53A

54A

52A

51A

J16

MODULE

INTERFACE

CONNECTOR

J81 741

743

GND-A

67C

153B

154B

51B

52B

STT SNUBBER

RESISTOR BANK

STT SNUBBER

CAPACITOR BANK

STT CURRENT

TRANSDUCER

STT SNUBBER

DIODE

HARMONIC

FILTER

RED

BLACK

GREEN

WHITE

BLACK

RED

BLACK

GREEN

H1B

.0047/3KV

C11

ETHERNET

CB2

5A CIRCUIT

BREAKER

351

352A

220V RECEPTACLE

CE Model

ETHERNET / DEVICENET OR DEVICENET MODULE

MODULE

TO CONTACTOR

CBA

INPUT

LINE

FILTER

L3A

.0047oF

440

L1A

SWITCH LEAD

FILTER

FRONT

HORIZONTAL

BAFFLE

REAR

HORIZONTAL

BAFFLE

FAN

SHROUD

RECONNECT

SHELL

RECONNECT

BRACKET

CASE

FRONT

UPPER

BASE

REAR

UPPER

BASE

AUX.

PROTECTIVE BONDING CIRCUIT

352A

P51

N.E.

N.F.

N.G.

H4B

N.J.

N.E. LEAD 33 IS PRESENT IN MODELS W ITH 115V RECEPTACLE

ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN

MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.

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

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

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.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD

LEAD H4B CONNECTS H4 TO SW1.

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

BELOW 11150.

TO SW 1

J1 & J3

ARE NOT USED

153B

154B

67B

52B

51B 51A

53A

54A

67A

52A

CASEFRONT

CONNECTOR

ONLY PRESENT IF F EEDHEAD

MODULE IS NOT PRESENT

ONLY PRESENT IF FEEDHEAD

MODULE IS PRESENT

J70 & J71

ARE NOT USED

GND-A

FEEDHEAD

THERMAL

LED

TO TP3

N.D.

L10

J710

ETHERNET

PORT

RJ 45 TYPE

THE ETHERNET CONNECTION

IS ONLY PRESENT IN THE

ETHERNET / DEVICENET MODULE

CASEFRONT

PANEL

N.D.

J40

J50

J43

TO J47

J20

J40

J50

N.F.

COMPONENT VALUE UNITS:

CAPACITOR: MFD/VOLTS

RESISTOR: OHMS/WATTS

CONNECTOR PIN NUMBERS:

VIEW OF CONNECTOR ON PC BOARD

126

712

LATCH

EX. 12 PIN CONNECTOR

5475

476

477

478

TO WORK

TO ELECTRODE

J16

TO WORK

153B

154B

52B

51B

TO MAIN

TRANSFORMER

TO RECONNECT

SWITCH

LEGEND

DASHED " " = STT MACHINE ONLY

PHANTOM " " = OPTION

N.L.

POWER WAVE 455M/STT (CE) WIRING DIAGRAM

G4420

N.K.

F-2

CONNECTION DIAGRAM

F-2

POWER WAVE 455M/STT (CE)

Connection Diagram Semi-automatic "Simple System"

(Electrode Positive, CV/Pulse Configuration shown)

POWER WAVE / STT

STT STUD

WIRE

FEEDER

CONTROL CABLE K1543

WORK

WORK SENSE

F-3

CONNECTION DIAGRAM

F-3

POWER WAVE 455/STT

Connection Diagram Semi-automatic "Simple System"

(Electrode Positive, STT Configuration shown)

POWER WAVE / STT

STT STUD

WIRE

FEEDER

CONTROL CABLE K1543

WORK

WORK SENSE

F-4

DIAGRAMS

F-4

POWER WAVE 455M/STT (CE)

32.88

26.10

22.63

12.35

19.00

19.90

19.16

9.48 14.62

23.12 23.51

11-14-97

M18241

DIMENSION PRINT - POWER WAVE 455M

NOTES

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO

BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS

CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A

ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

●Do not touch electrically live parts or

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 moja-

da.

●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 molha-

da.

●Isole-se da peça e terra.

●Keep flammable materials away.

●Mantenga el material combustible

fuera del área de trabajo.

●Gardez à l’écart de tout matériel

inflammable.

●Entfernen Sie brennbarres Material!

●Mantenha inflamáveis bem guarda-

dos.

●Wear eye, ear and body protection.

●Protéjase los ojos, los oídos y el

cuerpo.

●Protégez vos yeux, vos oreilles et

votre corps.

●Tragen Sie Augen-, Ohren- und Kör-

perschutz!

●Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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.

●Keep your head out of fumes.

●Use ventilation or exhaust to

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-

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.

●Turn power off before servicing.

●Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

●Débranchez le courant avant l’entre-

tien.

●Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

●Não opere com as tampas removidas.

●Desligue a corrente antes de fazer

serviço.

●Não toque as partes elétricas nuas.

●Do not operate with panel open or

guards off.

●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

oder Innenschutzverkleidung in

Betrieb setzen!

●Mantenha-se afastado das partes

moventes.

●Não opere com os paineis abertos

ou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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Lincoln Electric Power Wave Im808 A Users Manual

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