Lincoln Electric Power Wave Svm135 B Users Manual Svm135b

SVM135-B to the manual b7a4e6b5-c0b9-4995-809f-d4fe2b940037

2015-02-09

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SVM135-B

Power Wave 455/Power Feed 10

July,2001

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

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SERVICE MANUAL

World's Leader in Welding and Cutting Products

Premier Manufacturer of Industrial Motors

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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SAFETY

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

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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

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

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

____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________

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

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.

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.

Mar ‘95

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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.

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SAFETY

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.

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.

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

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5.e. Also see item 1.b.

Mar ‘95

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iii

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.

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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.

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iii

SAFETY

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.

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

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

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Mar ‘95

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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 suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

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
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . .
A-2
Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7
Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-5
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-23
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-61
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts
Parts List Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List Power Feed 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER WAVE 455/POWER FEED 10

P-291
P-306

INSTALLATION

SECTION A-1

TABLE OF CONTENTS
-INSTALLATION SECTIONInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - Power Feed 10 Wire Drive and Control Box . . . . . . . . . . . . . . . . . . . . . .
A-2
Technical Specifications - Power Wave 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Feeder and Control Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Input Voltage Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7
Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7
Flexible Connection Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-8
Electrode and Work Leads — Electrode Positive Applications . . . . . . . . . . . . . . . . . . . . . . . . .
A-8
Electrode and Work Leads — Electrode Negative Applications . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
Voltage Sensing at the Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
Wire Feeder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
Wire Drive Gear Ratio (High or Low Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
DIP Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-11
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
GMAW Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
Standard Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-16

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SECTION A-1

POWER WAVE 455/POWER FEED 10

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A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER FEED 10 WIRE DRIVE AND
CONTROL BOX
SPEC #

TYPE

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
LOW SPEED RATIO
HIGH SPEED RATIO
Wire Size

Wire Size

Speed

Solid

Cored

Speed

K1540-1 Power Feed 10
Wire Drive

50-800 IPM
(1.27-20.3 m/m)

.025 - 3/32 in.
(0.6 - 2.4 mm)

.035 - .125 in.
(0.9 - 3.2 mm)

75 - 1200 IPM
(2.03 - 30.5 m/m)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

K1538-1 Power Feed 10
Boom Package#

50-800 IPM
(1.27-20.3 m/m)

.025 - 3/32 in.
(0.6 - 2.4 mm)

.035 - .125 in.
(0.9 - 3.2 mm)

75 - 1200 IPM
(2.03 - 30.5 m/m)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

K1541-1 Power Feed 10
Bench Model
Drive and
Control Box

50-800 IPM
(1.27-20.3 m/m)

.025 - 3/32 in.
(0.6 - 2.4 mm)

.035 - .125 in.
(0.9 - 3.2 mm)

75 - 1200 IPM
(2.03 - 30.5 m/m)

.025 - 1/16 in.
(0.6 - 1.6 mm)

.035 - 5/64 in.
(0.9 - 2.0 mm)

SPEC.#

TYPE

Solid

Cored

CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS
INPUT POWER
PHYSICAL SIZE•
TEMPERATURE RATING
Height
13.0 in.
(330 mm)

Dimensions
Width
8.50 in.
( 215 mm)

Depth
4.0 in.
(105 mm)

Weight
8.5 lbs
(3.8 kg)

Operating

Storage

+40˚C
to
-20˚C

+40˚C
to
-40˚C

K1539-1
(Control
Box
Only)*

Power
Feed 10
Control
Box

40 VDC

K1540-1
(Wire
Drive
Only)*

Power
Feed 10
Wire
Drive

40 VDC

7.6 in.
(195 mm)

12.9 in.
(325 mm)

13.7 in.
(345 mm)

30 lbs
(13.6 kg)

K1541-1
Bench
Model
Feeder∆

Power
Feed 10
Bench Model
Drive and
Control Box

40 VDC

18.5 in.
( 470 mm)

13.5 in.
(345 mm)

30.5 in.
(775 mm)

62 lbs
(28.1 kg.)

* Included with K1538-1 Boom package and K1541-1 Bench Feeder.
∆ Dimensions do not include wire reel.
# For Control Box and Wire Drive dimensions and weights, see individual component listings.

POWER WAVE 455/POWER FEED 10

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A-3

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER WAVE 455
INPUT AT RATED OUTPUT - THREE PHASE ONLY
Input Volts

Rated Output @
100% Duty Cycle

Input
Current

Rated Output @
60% Duty Cycle

Input
Current

208V - 60Hz
230V - 60Hz
400V - 60Hz
460V - 60Hz
200V - 50Hz
220V - 50Hz
400V - 50Hz
440V - 50Hz

450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%
450A@38V 100%

70
65
39
35
72
67
40
36

570A@43V 60%
570A@43V 60%
570A@43V 60%
570A@43V 60%
500A@40V 60%
500A@40V 60%
500A@40V 60%
500A@40V 60%

87
82
50
48
79
74
45
41

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OUTPUT
Open
Circuit
Voltage
75 VDC

Current Range

Pulse
Frequency

Pulse
Voltage
Range

Pulse and
Background
Time Range

Auxiliary
Power

5 - 570

0.15 - 1000 Hz

5 - 55 VDC

100 MICRO SEC. 3.3 SEC.

40 VDC AT
10 AMPS
115 VAC AT
10 AMPS

Process Current Ranges (DC)

Current

MIG/MAG
FCAW
SMAW
Pulse

50-570 Amps
40-570 Amps
30-570 Amps
5-750 Amps

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RECOMMENDED INPUT WIRE AND FUSE SIZES
Input
Voltage /
Frequency

Duty
Cycle

208/60/50
230/60/50
400/60/50
460/60/50
208/60/50
230/60/50
400/60/50
460/60/50

100%
100%
100%
100%
60%*
60%*
60%*
60%*

Type 75°C
Copper Wire in
Input Ampere Rating Conduit AWG[IEC]
on Nameplate (AMPS)
Sizes (mm2)
70/72
65/67
39/40
35/36
87/79
82/74
50/45
48/41

4 (25)
4 (25)
8 (10)
8 (10)
4 (25)
4 (25)
6 (10)
6 (10)

Type 75°C
Ground Wire in
Conduit AWG[IEC]
Sizes (mm2)

Type 75°C
(Super Lag)
or Breaker
Size (AMPS)

8 (10)
8 (10)
10 (6)
10 (6)
8 (10)
8 (10)
8 (6)
8 (6)

80
70
50
40
90
90
60
50

PHYSICAL DIMENSIONS
Height
26.10 in.
663 mm

Width
19.86 in.
505 mm

Depth
32.88 in.
835 mm

Weight
250 lbs
114 kg

TEMPERATURE RANGES
Operating Temperature Range
0°C to 40°C

Storage Temperature Range
-50°C to 85°C

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*At 60% duty cycle with 50Hz input power, the machine is de-rated to 500 Amps at 40V.

POWER WAVE 455/POWER FEED 10

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A-4

INSTALLATION

SAFETY PRECAUTIONS
WARNING

LIFTING
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not
attempt to lift the Power Wave with accessories
attached to it.

ELECTRIC SHOCK
can kill.
• Only qualified personnel should perform this installation.
• Turn off the input power to the power
source 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
this equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave
grounding lug (located inside the
reconnect input access door) to a
proper safety (Earth) ground.

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

FEEDER AND CONTROL BOX
MOUNTING
SEPARATION FROM BENCH MODEL
The Control Box can be removed from the bench
model feeder and mounted in a different location.
See Figure A-1.
FIGURE A.1 — SEPARATING CONTROL BOX
AND FEEDER.
WIRE
DRIVE

CONTROL
BOX
CENTER
PANEL

CONNECTOR

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LOCATION AND MOUNTING
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through
the case sides and bottom. Dirt, dust, or any foreign
material that can be drawn into the welder should be
kept at a minimum. Using filters on the air intake to
prevent dirt from building up restricts air flow. Do
not use such filters. Failure to observe these precautions can result in excessive operating temperatures
and nuisance shutdowns.

STACKING

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BOTTOM
PANEL
Complete the following steps to remove the Control
Box:
1. Remove the bottom and center option panels
from the front of the Control Box.

Power Wave machines can be stacked to a maximum of three 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.
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MOUNTING
SCREW

2. Disconnect the connector between the Control
Box and the wire drive located in the middle of
the Control Box back near the bottom of the
Control Box.

ENVIRONMENT
The Power Wave power source carries an IP21 environmental rating. If subjected to occasional falling
water, such as rain, the machine should be sheltered.

POWER WAVE 455/POWER FEED 10

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A-5

INSTALLATION

3. Loosen the four screws inside the Control Box
located along the sides of the back of the Control
Box, two near the bottom and two near the middle.

A-5

6. Replace all option panels removed from front of
Control Box.
7. Place plug button saved in step 2 into hole in
back panel of Control Box.

4. Push the Control Box upwards and then pull the
Control Box away from the wire drive.
CONTROL BOX POWER SOURCE MOUNTING
5. Remove plug button taped to inside of Control
Box and insert it into hole on front panel of wire
drive.

The Power Feed Control Box can be directly mounted on the front of the power source. If this control
location is preferred, complete the following steps to
mount Control Box on the power source:

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BOOM MOUNTING
If you wish to convert to a boom mount, the following components are required to complete the conversion process:
Item 1 K1549-1 Receptacle
Item 2 K1550-1 Receptacle
Assemble the components above as follows:
1. Remove plug button and mount item 1 to the left
hole in the bottom of the Control Box.

1. Remove the bottom and center option panels
from the front of the Control Box.
2. Mount Control Box to the power source, following the instructions supplied with that specific
power source.
3. If the Control Box has an input Amphenol connector mounted on right side of bottom, then disconnect it’s 6-pin electrical connector from the
input connector inside the Control Box.
NOTE: This input connector no longer functions.

2. Remove and save plug button and mount item 2
to the right hole in the bottom of the Control Box.

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3. Insert connector from item 1 into either 4-pin
connector on Control Box motherboard.

4. Connect 6-pin connector that comes out of the
back of the Control Box to the 6 pin connector.
(See specific power source instructions.)

4. Insert 6-pin connector that went to wire drive unit
into item 2.

5. 67 sense lead from left bottom connector (if present) should be connected to 67 sense lead connection from 6-pin connector from motherboard.

5. Connect sense lead from item 1 to sense lead
from 6-pin connector that went to wire drive unit.

6. Replace all option panels removed from front of
Control Box.

POWER WAVE 455/POWER FEED 10

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A-6

ELECTRICAL CONNECTIONS

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INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

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

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A-6

INSTALLATION

Use a three-phase supply line. An 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.2.

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

INPUT VOLTAGE RECONNECT
PROCEDURE

WARNING
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. Refer to the
Technical Specifications at the beginning of this
chapter for proper cable sizes.

HIGH FREQUENCY INTERFERENCE
PROTECTION
If possible, locate the Power Wave away from radio
controlled machinery. The normal operation of the
Power Wave may adversely affect the operation of
RF controlled equipment, which may result in bodily
injury or damage to the equipment.

Turn main input power to the machine OFF
before performing reconnect procedure. Failure
to do so will result in damage to the machine.
DO NOT switch the reconnect bar with machine
power ON.

----------------------------------------------------------Welders are shipped connected for the highest input
voltage listed on the rating plate. To connect to a different input voltage, refer to reconnect instructions
located on the inside of the input access door or in
Figure A.2. If the main reconnect switch is placed in
the wrong position, the welder will not produce output
power. If the Auxiliary (“A”) lead is placed in the
wrong position, there are two possible results. If the
lead is placed in a position higher than the applied
line voltage, the welder may not come on at all. If the
Auxiliary (“A”) lead is placed in a position lower than
the applied line voltage, the welder will not come on,
and the two circuit breakers in the reconnect area will
open. If this occurs, turn off the input voltage, properly connect the “A” lead, reset the breakers, and try
again.

POWER WAVE 455/POWER FEED 10

inspecting or servicing machine.

U / L1

380-415V

Only qualified persons should install,
use or service this equipment.

VOLTAGE=380-415V

VOLTAGE=440-460V

200-208V

220-230V

'A'

380-415V

'A'

440-460V

380-415V

'A'

440-460V

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'A'

440-460V

. Do not touch electrically live parts.

CABLE CONNECTIONS

TYPICAL BENCH FEEDER CONNECTION

CONTROL CABLE CONNECTIONS

Control cable is connected from Power Source (PS)
to Feed Head (FH). If the Control Box is separated
from the FH, a control cable will connect from the PS
to the control box, which will have two control cable
connectors. This could be the control box or the FH
control box depending on how the units were separated. A second control cable would be connected
from the second connector on the control box to the
other FH control box.

• All system control cables are the same but can
vary in length.
• All control cables can be connected end to end to
extend their length.
• All system equipment must be connected to a
control cable.

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220-230V

Do not operate with covers
removed.

440-460V

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200-208V

CR1

S23847

V / L2

. Disconnect input power before

380-415V

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VOLTAGE=200-208V

W / L3

CLEVELAND, OHIO U.S.A.

INPUT SUPPLY CONNECTION DIAGRAM

THE LINCOLN ELECTRIC CO.

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FIGURE A.2 — CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR.

VOLTAGE=220-230V

Welding systems using the Power Feed 10 offer previously unprecedented flexibility in the connection of
system components. This system uses the same
type of control cable between each of the system
components. Connections can be “daisy chained”
from one system component to another. Since communication over the control cables is done by a
robust communications network, the order of connection of the components makes no difference. The
cables can be connected anywhere that there is a
mating connector. See the flexible connections part
of this section for more details.

TYPICAL BOOM FEEDER CONNECTION
Control cable is connected from PS to the control
box. A second control cable would be connected
from the second connector on the control box to the
FH control box.

FLEXIBLE CONNECTION POSSIBILITIES
By using connector kits, a second connector can be
added to the Control box or the FH. This allows the
user to connect equipment types together in any
order.

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NOTE: Maximum cable length between any two
nodes is 250 feet.
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A-7

INSTALLATION

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A-7

POWER WAVE 455/POWER FEED 10

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A-8
CONTROL CABLE SPECIFICATIONS

The cable is a five copper conductor cable in a SOtype rubber jacket. There is one 20 gauge twisted
pair for network communications. This pair has an
impedance of approximately 120 ohms and a propagation delay per foot of < 2.1 ns. There are two 12
gauge conductors that are used to supply the 40
VDC to the network. The fifth wire is 18 gauge and is
used as an electrode sense lead. It is typically connected to the feed plate on the feed head when that
feed head is active.

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AVAILABLE CABLE ASSEMBLIES
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A-8

INSTALLATION

K1543 Control cable only. Available in lengths of
8, 16, 25, 50 and 100 feet.
K1544 Control cable and a 3/0 (85 mm2 ) electrode
cable with stud terminal. It is rated at 600
amps, 60% duty cycle and is available in
lengths of 8, 16, 25, and 50 feet.
K1545 Control cable and a 3/0 (85 mm2) electrode
cable with Twist-Mate™ connector on one
end and a stud terminal on the other. It is
rated at 500 amps, 60% duty cycle and is
available in lengths of 8, 16, 25, and 50 feet.

When using an inverter type power source, use the
largest welding (electrode and ground) cables that
are practical. At least 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.

ELECTRODE AND WORK LEADS —
ELECTRODE POSITIVE APPLICATIONS
Most welding applications run with the electrode
being positive (+). For those applications, connect
the electrode cable between the wire feeder and the
positive (+) output stud on the power source (located
beneath the spring loaded output cover near the bottom of the case front). See Figure A.3.
FIGURE A.3 — ELECTRODE POSITIVE
APPLICATION.
POWER WAVE

TO
WORK

WIRE
FEEDER

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CABLE CONNECTIONS
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work or wire feeder. Avoid
excessive lengths, bundle the electrode and ground
cables together where practical, and do not coil
excess cable. Be sure the connection to the work
makes tight metal-to-metal electrical contact.

A work lead must be run from the negative (-) power
source output stud to the work piece. The work
piece connection must be firm and secure, especially
if pulse welding is planned. Excessive voltage drops
at the work piece connection often result in unsatisfactory pulse welding performance.

Minimum work and electrode cables sizes are as follows:

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Current Minimum Copper Work Cable Size, AWG
60% Duty
Up to 100 ft Length (30m)
Cycle
400 Amps

2/0 (67 mm2)

500 Amps

3/0 (85 mm2)

600 Amps

3/0 (85 mm2)

POWER WAVE 455/POWER FEED 10

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A-9

ELECTRODE AND WORK LEADS —
ELECTRODE NEGATIVE APPLICATIONS
When negative electrode polarity is required, such as
in some Innershield™ applications, install as above,
except reverse the output connections at the power
source (electrode cable to the negative (-) stud, and
work cable to the positive (+) stud). See Figure A.4.

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VOLTAGE SENSING AT THE WORKPIECE
A four-pin voltage sense lead connector is located
beneath the output stud cover. In certain installations, where the work connection is poor, arc performance may be improved by the use of an external
voltage sensing lead. Contact the factory for information on connecting and using this feature.
FIGURE A.4 — ELECTRODE NEGATIVE
APPLICATION.
POWER WAVE

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TO WORK

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A-9

INSTALLATION

WIRE
FEEDER

SELECTING THE PROPER GEAR RATIO
See the Technical Specifications at the front of this
section for feed speed and wire size capabilities with
high and low speed gear ratios. To determine
whether you should be using the high or low speed
ratio, use the following guidelines:
- If you need to operate at wire feed speeds greater
than 800 IPM (20 m/m), you will need to install the
high speed gear (large, 30 tooth, 1.6 inch diameter
gear).
- If you need to operate at wire feed speeds less than
800 IPM (20 m/m), you should use the low speed
gear (small, 20 tooth, 1.1 inch diameter gear).
Using the low speed ratio will provide the maximum
available wire driving force. Note: If you are feeding
only small diameter wires you may, at your option,
install the high speed ratio.

CHANGING THE WIRE DRIVE RATIO
Changing the ratio requires a gear change and a
switch position change located on the feed head PC
Board. The Power Feed 10 is shipped with both a
high speed and a low speed gear. As shipped from
the factory, the low speed (high torque) gear is
installed on the feeder. For identification purposes,
the low speed (high torque) gear has 20 teeth and is
1.1 inches in diameter. The high speed gear has 30
teeth and is 1.6 inches in diameter. See Figure A.5.
FIGURE A.5 — CHANGING WIRE DRIVE RATIO.
WIRE
FEEDER

WIRE FEEDER SETUP
WIRE DRIVE GEAR RATIO (HIGH OR
LOW SPEED)
The speed range capability and drive torque of the
Power Feed 10 wire drive can be easily and quickly
changed by changing the external drive gear. The
Power Feed 10 is shipped with both a high speed
and a low speed gear. As shipped from the factory,
the low speed (high torque) gear is installed on the
feeder. If this is the desired gear ratio, no changes
need to be made.

PHILLIPS
HEAD SCREW

POWER WAVE 455/POWER FEED 10

DRIVE
GEAR

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A-10

INSTALLATION

6. Tighten the screw on lower right face of feed
plate.

RATIO CHANGE PROCEDURE
1. Pull open the pressure door.
2. Remove the Phillips head screw retaining the
pinion gear to be changed and remove the gear.
If the gear is not easily accessible or difficult to
remove, remove the feed plate from the gearbox.
To remove feed plate:

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a. Loosen the clamping collar screw using a
3/16 in. Allen wrench. The clamping collar
screw is accessed from the bottom of the
feed plate. It is the screw which is perpendicular to the feeding direction.

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A-10

b. Loosen the retaining screw, which is also
accessed from bottom of feeder, using a
3/16 in. Allen wrench. Continue to loosen the
screw until the feed plate can be easily
pulled off of the wire feeder.
3. Loosen, but do not remove, the screw on the
lower right face of the feed plate with a 3/16 in.
Allen wrench.
4. Remove the screw on the left face of the feed
plate. If changing from high speed (larger gear)
to low speed (smaller gear), line the upper hole
on the left face of the feed plate with the threads
on the clamping collar. Line the lower hole with
the threads to install larger gear for high speed
feeder. If feed plate does not rotate to allow
holes to line up, further loosen the screw on right
face of feed plate.

7. Re-attach feed plate to wire feeder if removed in
Step 2.
8. Feed plate will be rotated out-of-position due to
the gear change. Adjust the angle of the feed
plate by loosening the clamping collar screw
(Step 2a) and pivoting feed head.
9. Set the High/Low switch code on Feed Head PC
board as follows:
a. Power down the Power Feed by turning off its
campanion Power Wave power source. For
maximum safety, disconnect the control cable
from the Power Feed.
b. Remove the cover from the back of the feed
head (2 screws).
c. Locate the 8-position DIP switch near the top
edge of the PC board, centered left to right.
The setting will be made on the right most
switch, S8.
d. Using a pencil or other small object, slide the
switch down, to the “0” position, when the low
speed gear is installed. Conversely, slide the
switch up, to the “1” position, when the high
speed gear is installed. Refer to Figure A.6.
e. Replace the cover and screws. The PC board
will “read” the switch at power up, automatically adjusting all control parameters for the
speed range selected.

5. Remove the small gear from the output shaft.
Lightly cover the output shaft with engine oil or
equivalent. Install gear onto output shaft and
secure with flat washer, lock washer, and Phillips
head screw which were previously removed.

POWER WAVE 455/POWER FEED 10

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A-11

INSTALLATION
S1

DIP SWITCH SETUP
SETTING DIP SWITCHES IN THE
CONTROL BOX

There are two DIP switch banks on the mother board
of the Control Box. They are labeled S1 and S2 and
are located and oriented as shown in Figure A.3.

FIGURE A.3

S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)

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Switch

Off

US 4-Step Trigger Logic

Euro 4-Step Trigger Logic

WFS Display = inches/minute

WFS Display = meters/minute

Left Display is always preset WFS

Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing

CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing
4

Run-in = Minimum Speed Available

Run-in = weld WFS

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If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5

Spare

Acceleration, MSB (Sets acceleration rate for wire drive) see below

Acceleration

(Sets acceleration rate for wire drive) see below

Acceleration, LSB

(Sets acceleration rate for wire drive) see below

S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only)
Switch

Off

Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)

Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)

Spare

Reserved

Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.
POWER WAVE 455/POWER FEED 10

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A-12

INSTALLATION

A-12

S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)
Switch

Off

Standard speed gearbox limits adjustable

High speed gearbox limits adjustable

WFS Display = inches/minute

WFS Display = meters/minute

Left Display is always preset WFS

Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing

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CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing
4

Run-in = Minimum Speed Available

Run-in = weld WFS

If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5

Memory change with trigger disabled

Memory change with trigger enabled

Acceleration, MSB (Sets acceleration rate for wire drive) see below

Acceleration

(Sets acceleration rate for wire drive) see below

Acceleration, LSB

(Sets acceleration rate for wire drive) see below

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S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up)
Switch

Off

Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)

Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)

Spare

Must be off for normal operation

Adjust lower limits

Must be off for normal operation

Adjust upper limits

Must be on for European units only

Note: the factory shipped settings for all of the S1 and S2 switches is “OFF”.
MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left.
LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right.

POWER WAVE 455/POWER FEED 10

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A-13

INSTALLATION

A-13

S1 DIP Switch Bank on Control Box Motherboard (For software version S24456)
Switch

Off

Standard speed gearbox limits adjustable

High speed gearbox limits adjustable

WFS Display = inches/minute

WFS Display = meters/minute

Left Display is always preset WFS

Left Display is preset WFS when weld current is not flowing
Left Display is actual weld current when weld current is flowing

CC modes override this switch regardless of position. Left Display is always preset weld current when weld current is not flowing and actual weld current when weld current is flowing

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Run-in = Minimum Speed Available

Run-in = weld WFS

If any option containing a Run-in setting is connected to the motherboard, it automatically
overrides this switch regardless of position.
5

Memory change with trigger disabled

Memory change with trigger enabled

Acceleration, MSB (Sets acceleration rate for wire drive) see below

Acceleration

(Sets acceleration rate for wire drive) see below

Acceleration, LSB

(Sets acceleration rate for wire drive) see below

Note: the factory shipped settings for the S1 switches are as follows:
PF-10 (and Dual) Domestic - All switches “OFF”
PF-10 (and Dual) European - switches 1 & 3-8 “OFF”, 2 “ON”
PF-11 Domestic - switches 2-8 “OFF”, 1 “ON”
PF-11 European - switches 3-8 “OFF”, 1,2 “ON”

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S2 DIP Switch Bank on Control Box Motherboard (For software version S24456)
Switch

Off

Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting)

Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting)

4-Step Domestic Configuration

4-Step European Configuration

Power Feed 10 / Dual

Power Feed 11

Procedure Change with Trigger “OFF”

Procedure Change with Trigger “ON”

Set lower limits

Set upper limits

Must be on for all units (Permits selection of extended modes)

Note: the factory shipped settings for the S2 switches are as follows:
PF-10 (and Dual) Domestic - switches 1-7 “OFF”, 8 “ON”
PF-10 (and Dual) European - switches 1,2,4-7 “OFF”, 3,8 “ON”
PF-11 Domestic - switches 1-3,5-7 “OFF”, 4,8 “ON”
PF-11 European - switches 1,2,5-7 “OFF”, 3,4,8 “ON”

MSB - Most Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the left.
LSB - Least Significant Bit or Byte. This is the bit in a binary number or DIP switch bank that is furthest to the right.
POWER WAVE 455/POWER FEED 10

A-14

INSTALLATION

Setting Wire Drive Acceleration Rate Using
DIP Switch S1 on the Control Box Motherboard

(All software versions)

DIP SWITCH 6

DIP SWITCH 7

DIP SWITCH 8

Acceleration 1 (slow)

Off

Acceleration 2

Off

Acceleration 3

Off

Acceleration 4

Off

Acceleration 5 (fast ) (factory setting)

Off

SETTING DIP SWITCHES IN THE WIRE
DRIVE

ON
1

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There is one DIP switch bank on the control board of
the wire drive. It’s labeled S1 and is located and oriented as shown in Figure A.4.

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A-14

FIGURE A.4

S1 DIP Switch on Wire Drive Control Board (For software version S24029-All & S24467)
Switch

Off

Network Group ID, MSB (Assigns Wire Drive to a specific group)

Network Group ID, LSB (Assigns Wire Drive to a specific group )

Network Feed Head ID, MSB (Assigns feed head number to wire drive)

Network Feed Head ID

(Assigns feed head number to wire drive)

Network Feed Head ID, LSB

(Assigns feed head number to wire drive)

Spare

Electrode Sense Polarity = Positive

Electrode Sense Polarity = Negative

Switch position must match polarity of weld cable attached to feed plate.
8

Gear Box Ratio = Low

Gear Box Ratio = High

Switch position must match actual gear box ratio of wire drive.
Note: the factory shipped settings for all of the S1 switches is “OFF”.
POWER WAVE 455/POWER FEED 10

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A-15
GUN AND CABLE ASSEMBLIES

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GMAW SHIELDING GAS

GUN AND CABLE ASSEMBLIES WITH
STANDARD CONNECTION
The Power Feed 10 wire feeder is equipped with a
factory installed K1500-2 gun connection kit. This kit
is for guns having a Tweco™ #2-#4 connector. The
Power Feed 10 has been designed to make connecting a variety of guns easily and inexpensively with the
K1500 series of gun connection kits. Gun trigger and
dual procedure lead connections connect to the single
five pin receptacle on the front of the feed head box.
See Gun Adapters in Accessories section.

GENERAL GUN CONNECTION GUIDELINES

WARNING
CYLINDER may explode if damaged.
• Keep cylinder upright and chained to
support.
• Keep cylinder away from areas where it
may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch
cylinder.

The instructions supplied with the gun and K1500
series gun adapter should be followed when
installing and configuring a gun. What follows are
some general guidelines that are not intended to
cover all guns.

• Keep cylinder away from welding or
other live electrical circuits.

a. Check that the drive rolls and guide tubes
are proper for the electrode size and type
being used. If not, change them per drive
roll installation instructions in the Operation
section.

• Shut off shielding gas supply when not
in use.

b. Lay the cable out straight. Insert the connector on the welding conductor cable into the
brass conductor block on the front of the wire
drive head. Make sure it is all the way in and
tighten the hand clamp. Keep this connection clean and bright. Connect the trigger
control cable polarized plug into the mating
five cavity receptacle on the front of the wire
drive unit.
NOTE: For Fast-Mate and European connector style
guns, connect gun to gun connector making sure all
pins and gas tube line up with appropriate holes in
connector. Tighten gun by turning large nut on gun
clockwise.
c.

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A-15

INSTALLATION

BUILDUP OF SHIELDING GAS may
harm health or kill.

SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING
SOCIETY.

----------------------------------------------------------Customer must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve, and a hose
from the flow valve to the gas inlet fitting of the wire
drive unit.
Connect a supply hose from the gas
valve outlet to the 5/8-18 female inert
the back panel of the wire drive or, if
inlet of the Gas Guard Regulator. See
section.

For GMA gun cables with separate gas fittings, connect the 3/16 in. I.D. gas hose
from the wire drive unit to the gun cable
barbed fitting.

d. For water cooled guns, refer to the instructions supplied with the kit.

POWER WAVE 455/POWER FEED 10

cylinder flow
gas fitting on
used, on the
Accessories

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A-16

INSTALLATION

STANDARD PANEL INSTALLATION

CV/GOUGE PANEL

CONTROL/DISPLAY PANEL

NOTE: Installation Instructions for the standard
equipment panels will be required only if you have
removed a standard panel and wish to reinstall it.

NOTE: Installation Instructions for the standard
equipment panels will be required only if you have
removed a standard panel and wish to reinstall it.
The Control/Display Panel fits into the upper or middle slots of the Control Box, and is used to adjust
WFS, Amps, Voltage, and Trim. It is also the location
of the Status indicator, a diagnostic tool provided for
system troubleshooting.

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Installation is as follows:
1. Turn off power.

1. Turn off power.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new panel, (top or middle), of the
Control Box cabinet. Discard the blank panel or
save for future use and save the screws.
3. Tilt the new panel away from the front opening of
the Control Box cabinet. Plug the electrical connector into the proper connector on the right side
of the main printed circuit board (14 pin). Make
sure the connector latches in place.
4. Position the new panel, taking care not to damage the printed circuit boards on the back and
align the screw holes.

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The CV/Gouge Panel fits into the lower position of
the Control Box.

2. Remove the two screws from the front of the
Control Box panel. Save the screws, discard the
old panel or save for future use.

Installation is as follows:

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A-16

5. Replace the two screws and tighten.

3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(12 pin). Make sure the connector latches in
place.
4. Position the panel to the opening, taking care not
to damage the switch connections on the back.
5. Align the screw holes, replace the two screws
and tighten.

OPTIONAL PANELS FOR CONTROL BOX
All optional panels for the control box are described
in the Accessories section of this manual.

POWER WAVE 455/POWER FEED 10

OPERATION

SECTION B-1

TABLE OF CONTENTS
-OPERATION SECTIONOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Duty Cycle and Welding Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Power Wave Controls and Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Power Feed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-4
Display Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-5
Board Level Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Weld Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Constant Voltage (CV/MIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Electrode Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Wire Spindle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Wire Reel Loading - Readi-Reels, Spools or Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
To Mount a 30 lb (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel Adapter) (Figure B.4): . . . . . . . . . . . . . . . . .
B-7
To Mount 10 to 44 lb (4.5 to 20 kg) Spools [12 in. (300 mm) Diameter]
or 14 lb (6 kg) Innershield Coils (Figure B.4): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-8
To Mount a 50 to 60 lb (22.7 to 27.2 kg) Coil (Using K1504-1 Coil Reel) (Figure B.5): . . . . . . .
B-8
Feeding Electrode and Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Drive Roll Kit Installation (KP1505-[]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Drive Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Procedure For Setting Angle of Feedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-10

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SECTION B-1

POWER WAVE 455/POWER FEED 10

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B-2

OPERATION

OPERATING INSTRUCTIONS

SYSTEM DESCRIPTION

Read and understand this entire section of operating
instructions before operating the machine.

The Power Wave 455 is a high performance, digitally
controlled inverter welding power source capable of
complex, high-speed waveform control. The Power
Feed 10 is a high performance, digitally controlled,
modular wire feeder. Properly equipped, they can
support the GMAW, GMAW-P, and FCAW processes.

SAFETY INSTRUCTIONS
WARNING

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ELECTRIC SHOCK
can kill.

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B-2

• 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.

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

Operating as a system, each component in the system has special circuitry to “talk with” the other system components, so each component (power source,
wire feeder, electrical accessories) knows what the
other is doing at all times. This shared information
lays the groundwork for a system with superior welding performance.
The Power Feed 10 is a four driven roll feeder that
operates on 40 VDC input power, and is available
configured in both boom and bench models. In addition, the Control Box and wire feed unit can also be
purchased separately. The bench model is designed
so that it can easily be converted to a boom feeder.

FUMES AND GASES
can be dangerous.

RECOMMENDED EQUIPMENT
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.

The Power Feed 10 must be used with the Power
Wave 455.

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----------------------------------------------------------WELDING SPARKS
can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.

----------------------------------------------------------ARC RAYS
can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.

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

POWER WAVE 455/POWER FEED 10

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B-3
DUTY CYCLE AND WELDING
CAPABILITIES

The Power Feed 10 wire feeder is capable of welding
at a 100% duty cycle (continuous welding). The
power source will be the limiting factor in determining
system duty cycle capability.
The Power Wave 455 is rated 450 amps at 38 volts,
100% duty cycle, and 570 amps at 43 volts, 60%
duty cycle. On 50 Hz, the 60% rating is 500 amps at
40 volts, 60% duty cycle. The duty cycle is based
upon a ten minute period. A 60% duty cycle represents six minutes of welding and four minutes of
idling in a ten minute period.

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CONTROLS AND SETTINGS
POWER WAVE CONTROLS AND
STATUS LIGHTS
All operator controls and adjustments are located on
the case front of the Power Wave. See Figure B.1.
FIGURE B.1 — POWER WAVE CONTROLS
AND STATUS LIGHTS.
SPRING LOADED
OUTPUT COVER
(CUTAWAY)

HIGH
TEMPERATURE
LIGHT
STATUS
LIGHT

If the duty cycle is exceeded, a thermostat will shut
off the output until the machine cools to a reasonable
operating temperature.

ON/OFF
SWITCH
115 VAC
AUXILIARY
RECEPTACLE

NEGATIVE
TERMINAL

LIMITATIONS
• The Power Wave is not recommended for processes other than those listed.
• The Power Wave can only be used with Power
Feed wire feeders. Other models of Lincoln feeders, or any models of non-Lincoln wire feeders,
cannot be used.

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B-3

OPERATION

CONTROL
CABLE
CONNECTOR

CIRCUIT
BREAKERS

POSITIVE
TERMINAL

1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady
green light. Error conditions are indicated as follows:

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NOTE: The Power Wave 455 status light will flash
green, and sometimes red and green, for up to one
minute when the Power Wave 455 is first turned on.
This is a normal situation as the machine goes
through a self test at power up.

POWER WAVE 455/POWER FEED 10

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B-4

OPERATION

Light
Meaning
Condition
Steady Green System OK. Power source communicating
normally with wire feeder and its
components.
Blinking
Green

Nothing connected to Wire Feeder
Receptacle.

Alternating
Green and
Red

Recoverable system fault. See
Troubleshooting Section.

Steady Red

Non-recoverable system fault. Must turn
power source off, find source of error, and
turn power back on to reset. See
Troubleshooting Section.

Blinking Red

See Troubleshooting Section.

3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temperature situation occurs. Output is disabled 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.
5. 10 AMP AUXILIARY POWER CIRCUIT BREAKER: Protects 115 volt AC receptacle.

FIGURE B.2 — WIRE FEEDER CONTROLS.
CONTROL BOX
(SHOWN ATTACHED
TO WIRE FEEDER)

2. COLD FEED/
GAS PURGE
SWITCH

COLDFEED
STATUS

4-STEP

2-STEP

3. STATUS
LIGHT 1. 2-STEP/
4-STEP
SWITCH
When the switch is in the 4-step position, the gun
trigger functions as follows:

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4-Step Operation (Current interlock):
1. Closing trigger initiates gas preflow time followed
by run in speed and strike voltage until welding
current is established.

POWER FEED CONTROLS

2. Once current is established, the trigger may be
released and welding will continue.

1. 2-STEP/4-STEP SWITCH OPERATION
The Power Feed head unit has a 2-Step/4-Step
switch shown in Figure B.2. This switch has no
effect in CC modes of operation such as stick welding. When in the 2-step position, the gun trigger functions as follows:

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4. Releasing the trigger stops the wire feed and initiates burnback followed by gas postflow.
2. COLD FEED/GAS PURGE SWITCH

2-Step Operation:
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3. When the trigger is closed again, welding will
continue but the current interlock function will be
disabled.

1. Closing the gun trigger initiates gas preflow time
followed by run in speed and strike voltage until
welding current is established.

The Power Feed head unit has a Cold Feed/Gas
Purge switch. When left untouched, this switch
returns to a center position where no action results.

2. Opening the gun trigger during a weld stops wire
feed and initiates burnback time, followed by gas
postflow time.
POWER WAVE 455/POWER FEED 10

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B-5

OPERATION

B-5

Cold feed function:

1. Indicator Lights:

When this switch is held in the up position, the unit
automatically feeds wire, but does not activate output
to the power source or gas solenoid. The speed of
this cold feed is factory preset to 200 IPM. It can be
adjusted while the switch is held up, by rotating the
WFS encoder knob on the Control Box. Note that
this cold feed speed is independent of WFS or run in
speeds. When the cold feed switch is released, the
cold feed value is memorized for the next time cold
feed is activated.

Indicates either WFS or AMPS for the left display,
and VOLTS or TRIM for the right display.

2. Displays:
Two extra bright, 3 1/2 digit, red LED displays. The
values of the active parameters are displayed, as
defined by their associated indicators. The left display is for WFS or Amps, while the right display is for
voltage or trim.

Gas purge function:
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3. Left Encoder-Wire Feed Speed or Output Amps:
When this switch is held in the down position only the
gas solenoid valve is energized.

3. STATUS LIGHT
A two color light that indicates system errors. Normal
operation is a steady green light.

The left encoder is used to adjust the parameters for
either wire feed speed or output amps, dependent
upon the process and weld mode being used.
Rotating the encoder knob CCW decreases the number value, while rotating the knob CW increases the
number value. The ranges and limits are as follows:
WFS - Low Range: 50 to 800 IPM (1.25 to 19.99 MPM)
High Range: 75 to 1200 IPM (2.0 to 30.5 MPM)

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DISPLAY CONTROL PANEL
The Display Control panel is the main input to the
system. From it, the operator can control WFS,
amps, voltage, and trim depending on the active weld
mode. It is also the location of the Status
indicator, a multicolored diagnostic LED (see
Troubleshooting section). Refer to Figure B.3.
FIGURE B.3 — CONTROL BOX.
1. INDICATOR
1. INDICATOR
LIGHTS
LIGHTS
DISPLAY
2. DISPLAYS
CONTROL
PANEL
3. WFS/
AMPS
ENCODER
A
V
T
WFS

AMPS

VOLTS

TRIM

STATUS

4. VOLTS/
TRIM
ENCODER

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BLANK PANEL
5. STATUS
LIGHT

m WELD MODE
CV/MIG

AMPS - Limited by the power source based on mode
and process.

4. Right Encoder - Trim or Output Volts:
The right encoder operates in the same manner as
the left except that either output Volts or Trim is
adjusted. The ranges and limits are as follows:
VOLTS - 00.0 to 99.9 volts, limited by power source
based on mode and process.
TRIM - 0.50 to 1.50, nominal value is 1.00
When not welding (no output current flow) the displays
reflect the preset values. During welding (output current flowing) the displays depict actual values. These
actual values are held for a period of five seconds after
welding (output current) ceases. This hold feature is
canceled if a trigger pull or encoder adjustment occurs
during the hold time. The actual value displayed is
dependent upon the weld mode and process being
used.
5. Status light:

GOUGE

6. CV/GOUGE PANEL

A two color light that indicates system errors. Normal
operation is a steady green light.

POWER WAVE 455/POWER FEED 10

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B-6
6. CV/GOUGE PANEL

The CV/Gouge Panel provides a fixed toggle switch
selection of two power source modes. The upper
position selects the generic CV/MIG mode from the
power source while the lower position selects the
GOUGE mode.

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OPTIONAL PANELS

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B-6

OPERATION

A number of Optional Features are available for use
with the Power Feed 10. Some Installation information is provided in the ACCESSORIES section,
REFER TO THE INSTRUCTIONS THAT COME
WITH EACH KIT FOR DETAILED INFORMATION
REGARDING INSTALLATION.

BOARD LEVEL ADJUSTMENTS
The control box motherboard provides the capability
to adjust some basic parameters as follows.

BURNBACK
The BURNBACK trimmer (R5) is provided as a basic
adjustment for burnback time. The range is 0.0 to
0.25 seconds, CCW limit is minimum, CW limit is
maximum. This value is overridden by any option
with the ability to independently adjust burnback.

preprogrammed voltages; for example, to compensate for cable and fixture voltage drops. The preset
voltages can be adjusted on the wire feeder’s voltage
display. When a change is made to the voltage at
one wire feed speed, this change is applied to all
other wire feed speed settings. For example, if the
operator turns up the voltage by 10 percent, the
machine automatically increases the preset voltages
at all the other wire feed speeds by 10 percent. The
preset voltage, programmed at the factory, may be
changed with the wire feeder VOLTS adjustment.

ARC GOUGING
Arc gouging can be performed by choosing the arc
gouging weld mode. Doing so automatically energizes the output terminals on the Power Wave, making the power source immediately ready to gouge.
The output current is set by the AMPS control on the
Power Weld wire feeder. The VOLTS/TRIM adjustment has no effect in this mode.
The ARC CONTROL adjusts the arc force.
Increasing the ARC CONTROL setting increases the
arc force, making the arc more harsh but less likely
to stick. Decreasing the ARC CONTROL setting
decreases the arc force, making the arc softer and
smoother.

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ELECTRODE ROUTING
ACCELERATION
See DIP Switch setup in the Installation section.

RUN IN
See DIP Switch setup in the Installation section.

WELD MODE DESCRIPTIONS

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CONSTANT VOLTAGE (CV/MIG)
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special
softwares at the factory. This preprogrammed voltage is the best average voltage for the procedure at
the given wire feed speed. If the wire feed speed is
changed on the wire feeder, the voltage automatically changes with it.

The electrode supply may be either from reels,
Readi-Reels, spools, or bulk packaged drums or
reels. Observe the following precautions:
a. The electrode must be routed to the wire
drive unit so that the bends in the wire are at
a minimum, and also that the force required
to pull the wire from the reel into the wire
drive unit is kept at a minimum.
b. The electrode is “hot” when the gun trigger is
pressed and must be insulated from the
boom and structure.
c.

If more than one wire feed unit shares the
same boom and are not sharing the some
power source output stud, their wire and
reels must be insulated from each other as
well as insulated from their mounting structure.

In some cases, the operator may want to change the
POWER WAVE 455/POWER FEED 10

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B-7

WIRE SPINDLE PLACEMENT
The reel stand provides two mounting locations for
the 2 inch diameter wire reel spindle to accommodate various reel sizes. Each mounting location consists of a tube in the center of the reel stand, and a
locating pin on the right side (viewed from the front)
of the reel stand. The bolt, used with a plain washer
and lock washer, slides through the tube from the left
side of the reel stand. The large plain washer is
placed between the wire spindle hub and the reel
stand. The bolt should be threaded into the wire
spindle such that the locating pin aligns with the
largest of the three holes (the hole that is not
recessed) in the back side of the wire spindle base.
The upper location must be used for 50 to 60 lb
Readi-Reels, spools and coils.
For smaller coils (44 lb, 30 lb, 10 lb, etc.), the spindle
can be placed in either the upper or lower location.
The goal is to make the wire path from the coil to the
incoming wire guide as straight as possible. This will
optimize wire feeding performance.

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WIRE REEL LOADING READI-REELS, SPOOLS
OR COILS
TO MOUNT A 30 LB (14 KG) READIREEL PACKAGE (USING THE MOLDED
PLASTIC K363-P READI-REEL
ADAPTER) (FIGURE B.4):
The spindle should be located in the LOWER mounting hole.
1. Depress the release bar on the retaining collar
and remove it from the spindle.
2. Place the adapter on the spindle.

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3. Re-install the retaining collar. Make sure that the
release bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.
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B-7

OPERATION
FIGURE B.4 — READI-REEL MOUNTING.
2 IN. O.D.
SPINDLE

ADAPTER
RETAINING
SPRING

RETAINING
COLLAR
BRAKE
HOLDING
PIN
GROOVES

READI-REEL
INSIDE
CAGE
WIRES

RELEASE
BAR

6. Set one of the Readi-Reel inside cage wires on
the slot in the retaining spring tab.
7. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
8. Slide cage all the way onto the adapter until the
retaining spring “pops up” fully.

CAUTION
Check to be sure the retaining spring has fully
returned to the locking position and has SECURELY
locked the Readi-Reel cage in place. Retaining
spring must rest on the cage, not the welding electrode.

----------------------------------------------------------9. To remove Readi-Reel from adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.

4. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
5. Position the Readi-Reel so that it will rotate in a
direction when feeding so as to be de-reeled from
the bottom of the coil.

POWER WAVE 455/POWER FEED 10

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B-8

OPERATION

TO MOUNT 10 TO 44 LB (4.5 TO 20
KG) SPOOLS [12 IN. (300 MM)
DIAMETER] OR 14 LB (6 KG)
INNERSHIELD COILS (FIGURE B.4):

4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim
of the reel cover and secure it by wrapping it
around. Cut and remove the remaining tie wires.
FIGURE B.5 — K1504-1 COIL REEL.

The spindle should be located in the LOWER
mounting hole.

SPINNER NUT

(For 8 in. (200 mm) spools, a K468 spindle adapter
must first be slipped onto spindle.)

COVER
PLATE

1. Depress the release bar on the retaining collar
and remove it from the spindle.
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(For 13 to 14 lb (6 kg) Innershield coils, a K435 coil
adapter must be used).

SLOTS

2. Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a direction so as to de-reel from the
bottom of the coil.

CARDBOARD
COIL LINER

COIL

3. Re-install the retaining collar. Make sure that the
release bar “pops up” and that the collar retainers
fully engage the retaining groove on the spindle.

TIE WIRE

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TO MOUNT A 50 TO 60 LB (22.7 TO
27.2 KG) COIL (USING K1504-1 COIL
REEL) (FIGURE B.5):
NOTE: (For 50 to 60 lb Readi-Reels a K438
Readi-Reel adapter must be used).

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REEL

The spindle must be located in the UPPER mounting
hole.
1. With the K1504-1 coil reel mounted on to the 2 in.
(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. See Figure B.5.
2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom as
the reel rotates. The slots in the cardboard liner
should align over the spring loaded arms.

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SPRING
LOADED ARM

3. Tighten the spinner nut against the reel cover as
much as possible by hand using the reel cover
spokes for leverage. DO NOT hammer on the
spinner nut arms.

CAUTION
Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the
wire is feeding through the drive rolls. Failure to do
this will result in “backlashing” of the coil, which may
tangle the wire. A tangled coil will not feed so it must
either be untangled or discarded.

----------------------------------------------------------5. Be sure the coil reel is engaged with the spindle
brake pin and the release bar on the retaining collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.

POWER WAVE 455/POWER FEED 10

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B-9

OPERATION

FEEDING ELECTRODE AND
BRAKE ADJUSTMENT
1. Turn the reel or spool until the free end of the
electrode is accessible.
2. While tightly holding the electrode, cut off the bent
end and straighten the first 6 in. (150 mm). Cut
off the first 1 in. (25 mm). (If the electrode is not
properly straightened, it may not feed or may jam
causing a “birdnest”.)

B-9

7. Install the outer wire guide by sliding over the
locating pins and tightening in place.
8. Engage the upper drive rolls if they are in the
“open” position and close pressure door.
To set drive roll pressure, see Drive Roll Pressure
Setting.

DRIVE ROLL PRESSURE
SETTING

4. Press the Cold Feed Switch while pushing the
electrode into the incoming wire guide.
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3. Insert the free end through the incoming guide.

WARNING
If feeding with the Gun Trigger, the electrode and
wire drive may be electrically “HOT”.

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

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DRIVE ROLL KIT INSTALLATION
(KP1505-[])
1. Turn off welding power source.
2. Pull open pressure door to expose rolls and wire
guides.
3. Remove outer wire guide by turning knurled
thumb screws counterclockwise to unscrew them
from Feedplate.
4. Remove the drive rolls, if any are installed, by
pulling straight off the shaft. Remove the inner
guide.

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The optimum drive roll pressure varies with type of
wire, surface condition, lubrication, and hardness.
Too much pressure could cause “birdnesting”, but
too little pressure could cause wire feed slippage with
load and/or acceleration. The optimum drive roll setting can be determined as follows:

5. Feed the electrode through the gun.
6. Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not overtighten.

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The Power Feed 10 pressure is factory pre-set to
about position “2” as shown on the pressure indicator
on the front of the feedplate door. This is an approximate setting.

5. Insert the inner wire guide, groove side out, over
the two locating pins in the feedplate.
6. Install each drive roll by pushing over the shaft
until it butts up against the locating shoulder on
the drive roll shaft. (Do not exceed maximum wire
size rating of the wire drive).

1. Press end of gun against a solid object that is
electrically isolated from the welder output and
press the gun trigger for several seconds.
2. If the wire “birdnests”, jams, or breaks at the drive
roll, the drive roll pressure is too great. Back the
pressure setting out one turn, run new wire
through the gun, and repeat above steps.
3. If the only result is drive roll slippage, disengage
the gun, pull the gun cable forward about 6 in.
(150 mm). There should be a slight waviness in
the exposed wire. If there is no waviness, the
pressure is too low. Increase the pressure setting
one turn, reconnect the gun, tighten locking clamp
and repeat the above steps.

PROCEDURE FOR SETTING
ANGLE OF FEEDPLATE
1. Loosen the clamping collar screw using a 3/16 in.
Allen wrench. The clamping collar screw is
accessed from the bottom of the feedplate. It is
the screw which is perpendicular to the feeding
direction.
2. Rotate feedplate to the desired angle and tighten
clamping collar screw.

POWER WAVE 455/POWER FEED 10

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OPERATION

WIRE FEED OVERLOAD
PROTECTION
The wire drive has solid-state overload protection of
the wire drive motor. If the wire drive motor becomes
overloaded for an extended period of time the wire
drive will issue a shutdown command to the Control
Box and force its STATUS light to blink between
green and red. The Control Box turns off the power
source, wire feed and gas solenoid. The status light
on the wire drive will continue to blink between green

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B-10

and red for about 30 seconds before the wire drive
will automatically reset. At that time, the wire drive
will issue a shutdown over command to the Control
Box that will return the system to normal operation.
The wire drive will force its STATUS light to solid
green.
Overloads can result from improper tip size, liner,
drive rolls, or guide tubes, obstructions or bends in
the gun cable, feeding wire that is larger than the
rated capacity of the feeder or any other factors that
would impede normal wire feeding.

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B-10

POWER WAVE 455/POWER FEED 10

ACCESSORIES

SECTION C-1

TABLE OF CONTENTS
-ACCESSORIES SECTIONAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
Power Wave Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Wire Feeder Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Drive Roll and Guide Tube Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3
Input Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-4
Cable Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-4
Reel Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-6
Guns and Gun Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-6
Conduit Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-7
Dual Procedure Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-8
Gas and Water Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-8
Chassis Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-8
Description and Installation of Optional Control Box Panels . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-9

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SECTION C-1

POWER WAVE 455/POWER FEED 10

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C-2

ACCESSORIES

GENERAL
The following is a list of the accessories that can be
used with the Power Feed 10 wire feeder and the
Power Wave 455. A description of each item is given
later in the section.
TABLE C.1 — POWER FEED 10 AND POWER WAVE 455 ACCESSORIES.
K1570-1
KP1505 Series
K1543
K1544
K1548-1
K162h
K1504-1
K435
K363P
K438
K489-7
K489-2
K466-10
K471-21,-22, -23
K497-20, -21
K613-7
K556 (250XA)
K556 (400XA)
K206
K289
K309
K489-2
K1500-1
K1500-2
K1500-3
K1500-4
K1546-1
K1546-2
K683-1
K683-3
K590-5
K1536-1
K659-1
K1557-1
K1556-1
K1574-1
K1555-1
K1542-5
K1542-6
K1546-7
K1542-8
K1542-9
K1542-11
K1542-12

DUAL CYLINDER UNDERCARRIAGE
DRIVE ROLL AND GUIDE TUBE KITS
INPUT CABLE ASSEMBLY (CONTROL CABLE ONLY)
INPUT CABLE ASSEMBLY
RECEPTACLE KIT (INPUT AND OUTPUT)
WIRE SPINDLE ADAPTER
COIL ADAPTER
COIL ADAPTER
READI-REEL ADAPTER
READI-REAL ADAPTER
FAST-MATE™ GUN ADAPTERS
CONNECTOR KIT
MAGNUM 400 WELDING GUNS
MAGNUM 200 WELDING GUNS
MAGNUM 550 WELDING GUN CONNECTOR KIT
LINCOLN FUME EXTRACTION GUNS

FAST-MATE™ ADAPTER KIT
LINCOLN INNERSHEILD GUN STANDARD CONNECTION
TWECO™ #2-#4 CONNECTION
TWECO™ #5 CONNECTION
MILLER CONNECTION
CONDUIT ADAPTER
CONDUIT ADAPTER
DUAL PROCEDURE SWITCH
DUAL PROCEDURE SWITCH
WATER CONNECTION KIT (FOR DRIVE ONLY)
WATER FLOW SENSOR KIT
GAS GUARD REGULATOR
SWIVEL MOUNT
LIGHT DUTY CASTER KIT
SECURITY DOOR (LARGE)
INSULATED LIFT HOOK
DUAL PROCEDURE PANEL
“M” PANEL
MX PANEL (LARGE)
MSP PANEL (LARGE)
DUAL PROCEDURE / MEMORY PANEL (SMALL)
MX2 PANEL (LARGE)
MSP2 PANEL (LARGE)

POWER WAVE 455/POWER FEED 10

C-2

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C-3

POWER WAVE OPTIONS AND
ACCESSORIES
The following is a list of available Power Wave
options.

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This is a platform undercarriage for mounting up to
two gas cylinders at the rear of the welder.

The following is a list of available Wire Feeder
options.

DRIVE ROLL AND GUIDE TUBE KITS

FIELD INSTALLED

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K1570-1 DUAL CYLINDER UNDERCARRIAGE

WIRE FEEDER OPTIONS AND
ACCESSORIES

FACTORY INSTALLED
There are no factory installed options available for
the Power Wave machines.

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C-3

ACCESSORIES

The following options/accessories are available for
your Power Wave from your local Lincoln Distributor.
TABLE C.2 — DRIVE ROLL AND GUIDE TUBE KITS.
Wire Size

4-Roll
Drive
(4-Driven)

Solid Steel Electrode
in.
0.023 - 0.025
0.030
0.035
0.040
0.045
0.052
1/16
5/64
3/32

mm
0.6
0.8
0.9
1.0
1.2
1.4
1.6
2.0
2.4

KP1505 - 030S
KP1505 - 030S
KP1505 - 035S
KP1505 - 045S
KP1505 - 045S
KP1505 - 052S
KP1505 - 1/16S
KP1505 - 5/64
KP1505 - 3/32

mm
0.8
0.9
1.0
1.2
1.4
1.6
1.7
2.0
2.4
2.8
2.8
3.0

KP1505 - 035C
KP1505 - 035C
KP1505 - 045C
KP1505 - 045C
KP1505 - 052C
KP1505 - 1/16C
KP1505 - 068
KP1505 - 5/64
KP1505 - 3/32
KP1505 - 7/64H
KP1505 - 7/64
KP1505 - 120

Cored Electrode
in.
0.030
0.035
0.040
0.045
0.052
1/16
0.068
5/64
3/32
7/64 Hard Facing,smooth U groove
7/64
0.120

Aluminum Wire
.035" (0.9 mm) Aluminum
.040" (1.0 mm) Aluminum
3/64" (1.2 mm) Aluminum
1/16" (1.6 mm) Aluminum
3/32” (2.2 mm) Aluminum

KP1507-035A
KP1507-040A
KP1507-3/64A
KP1507-1/16A
KP1507-3/32A
POWER WAVE 455/POWER FEED 10

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C-4

ACCESSORIES

INPUT CABLE ASSEMBLIES
K1543 (Control Cable Only) - Consists of a 5-conductor control cable with a 5-pin control cable plug,
without electrode cable, and is available in lengths of
10 ft, 15 ft, 20 ft, 50 ft, and 100 ft.
K1544 - Consists of a 5-conductor control cable with
a 5-pin control cable plug and a 3/0 electrode cable.
It is rated at 600 amps, 60% duty cycle and is available in lengths of 10 ft,15 ft, 20 ft, and 50 ft.

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With input power disconnected from the power
source, install the input cable by performing the
following:

CABLE RECEPTACLES
K1548-1 RECEPTACLE KIT (INPUT AND
OUTPUT)
This kit contains the contents of both the K1549-1
and K1550-1 kits. Refer to the instructions for each,
below.

RECEPTACLE (OUTPUT)

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Optional Output Connector installation into the
Control Box cabinet and/or into the feed head
enclosure.

Control Box Cabinet Procedure

C-4

in the bottom of the Control Box cabinet and
store it in the bottom of the Control Box cabinet
for future use, should the Optional Output
Connector be removed.
5. Place the Optional Output Connector
(Amphenol) through the hole opened by the previous step (place from the inside, out). Rotate
the Optional Output Connector so its aligning
key is positioned to the front of the Control Box
cabinet. Fasten the Optional Output Connector
to the bottom wall of the Control Box cabinet with
the four screws provided.
6. Secure the choke (large circular component of
the Optional Output Connector) by inserting its
leads into the white nylon clip located near the
Optional Output Connector on the back wall of
the Control Box cabinet. Insert the choke leads
only.
7. The Optional Output Connector has two internal
connectors, a four pin, and a single lead connector. Connect the four pin connector to the
unused four pin connector on the main printed
circuit board. Connect the single lead connector
to a similar connector found on a lead nearby
that branches out of the Control Box wiring harness.
8. Re-install the lower and middle option panels by
reversing the removal process. While reinstalling the option panels, ensure clearance
between Optional Output Connector components, Control Box wiring harness, and option
panel harness (if any).

1. Turn off power.
2. Remove the screws from the front of the lower
and middle option panels of the Control Box.
3. Tilt the option panels away from the front opening of the Control Box cabinet. If the option panel
has an electrical connector, disconnect it from
the main printed circuit board (note connection
point for re-connection later). Remove the option
panel and set aside.
4. Remove the plastic plug (black) from the left hole

POWER WAVE 455/POWER FEED 10

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C-5

ACCESSORIES

Feed Head Enclosure Procedure

RECEPTACLE (INPUT)

1. Turn power off.
2. Remove the Feed Head rear access door. The
Feed Head cover can be removed to aid installation, but is not required.
3. Remove the plastic plug (black) from the hole at
the right rear of the Feed Head and store it in the
left side of the Feed Head rear compartment for
future use, should the Optional Output
Connector be removed.
4. Disconnect a printed circuit board connector,
located at the bottom right corner of the printed
circuit board, and position it to the left so as to
provide clear access to the lower right corner of
the Feed Head enclosure.
5. Place the Optional Output Connector
(Amphenol) through the hole opened by the two
previous steps (place from the inside, out).
Rotate the Optional Output Connector so its
aligning key is positioned to the top of the Feed
Head enclosure. Fasten the Optional Output
Connector to the back wall of the Control Box
cabinet with the four screws provided.
6. Secure the choke (large circular component of
the Optional Output Connector) by inserting its
leads into the white nylon clip located near the
Optional Output Connector on the floor of the
Feed Head. Insert the long choke leads rather
than the short leads that run between the choke
and the Output Connector. Insert the choke
leads only.
7. The Optional Output Connector has two internal
connectors, a four pin, and a single lead connector. Connect the four pin connector to the
unused four pin connector on the printed circuit
board. Connect the single lead connector to a
similar connector found on a lead nearby that
branches out of the Feed Head wiring harness.

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8. Reconnect the printed circuit board connector
that was disconnected earlier.
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C-5

Power Feed Wire Feeder Optional Input
Connector Installation into the Control Box
Cabinet and Conversion to Fixture Wire Feeder
1. Turn off power.
2. Remove the screws from the front of the lower
and middle option panels of the Control Box cabinet.
3. Tilt the option panels away from the front opening of the Control Box cabinet. If the option panel
has an electrical connector, disconnect it from
the main printed circuit board (note connection
point for re-connection later). Remove the option
panel and set aside.
4. Disconnect the connector located at the back
wall of the Control Box cabinet.
5. Loosen (do not remove) the four screws located
on the back wall of the Control Box cabinet.
6. Lift Control Box cabinet off of the four screws
loosened above and set on a work surface. Retighten the four screws to secure for future use.
7. Remove the plastic plug (black) from the right
hole in the bottom wall of the Control Box cabinet and insert it into the hole in the front of the
Feed Head.
8. Place the Optional Input Connector (Amphenol)
through the hole opened by the previous step
(place from the inside, out). Rotate the Optional
Input Connector so it’s aligning key is positioned
to the front of the Control Box cabinet. Fasten the
Optional Input Connector to the bottom wall of
the Control Box cabinet with the four screws provided and connect the option’s opposite end to
the connector previously disconnected in step 4.
9. Secure the choke (large circular component of
the Optional Input Connector) by inserting it’s
leads into the white nylon clip located near the
Optional Input Connector on the back wall of the
Control Box cabinet. Insert the choke leads only.

9. Replace the rear access door and Feed Head
cover if removed.

POWER WAVE 455/POWER FEED 10

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C-6

ACCESSORIES

10. Install an Optional Output Connector into the
Control Box cabinet, if not already present.
11. Mount the Control Box cabinet to the work station fixture at this time, if desired. The four holes
in the back wall of the Control Box cabinet can
be used for this purpose.
12. Re-install the lower and middle option panels by
reversing the removal process. While reinstalling the option panels, ensure clearance
between Optional Input Connector components,
Control Box wiring harness, and option panel
wiring harness (if any).

C-6

K363P - READI-REEL ADAPTER
Adapts Lincoln Readi-Reel coils of electrode 30 lb
(14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spindle.
Durable molded plastic one piece construction.
Designed for easy loading; adapter remains on spindle for quick changeover.

K438 - READI-REEL ADAPTER
Adapts Lincoln Readi-Reel coils of electrode 50 to
60 lb (22.7 to 27.2 kg) to a 2 in. (51 mm) spindle.

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GUNS AND GUN ADAPTERS
REEL ADAPTERS

Spindle for boom mounting Readi-Reels and 2 in. (51
mm) I.D. spools with up to 60 lb (27.2 kg) capacity.
User mounted to appropriately prepared boom
framework. Includes an easily adjustable friction
brake for control of overrun (a 2 in. spindle is standard on Power Feed 10 bench model).

The Power Feed 10 wire feeder is equipped with a
factory installed K1500-2 gun connection kit. This kit
is for guns having a Tweco™ #2-#4 connector. The
Power Feed 10 has been designed to make connecting a variety of guns easy and inexpensive with the
K1500 series of gun connection kits. Gun trigger and
dual procedure lead connections connect to the single 5 pin receptacle on the front of the Feed Head
box.

When a 2 in. (51 mm) spindle is used with ReadiReels, or coils not on 12 in. (305 mm) O.D. spools,
an adapter is required:

FAST-MATE™ GUNS (INCLUDING THE
MAGNUM 450 WATER COOLED GUN)

K162H - WIRE SPINDLE ADAPTER

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K1504-1 - COIL ADAPTER
Permits 50 lb to 60 lb (22.7 to 27.2 kg) coils to be
mounted on 2 in. (51 mm) O.D. spindles.

K435 - COIL ADAPTER
Permits 14 lb (6 kg) Innershield coils to be mounted
on 2 in. (51 mm) O.D. spindles.

A K489-7 adapter will install directly into the wire
drive feedplate, to provide for use of guns with FastMate™ or European style gun connections. This
K489-7 will handle both standard Fast-Mate™and
Dual Schedule Fast-Mate™ guns.
Another way to connect a gun with a Fast-Mate™ or
European style gun connector to the Power Feed 10,
is to use the K489-2 Fast-Mate™ adapter kit.
Installation of this adapter also requires a K1500-1
gun connector.

POWER WAVE 455/POWER FEED 10

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C-7

ACCESSORIES

C-7

MAGNUM 200/300/400 GUNS

K1500-2 (TWECO™ #2-#4 CONNECTION)

The easiest and least expensive way to use Magnum
200/300/400 guns with the Power Feed 10 wire feeder is to order them with the K466-10 connector kit, or
to buy a completely assembled Magnum gun having
the K466-10 connector (such as the K471-21, -22,
and -23 dedicated Magnum 400 guns and the K49720 and -21 Magnum 200 guns).

The K1500-2 gun adapter comes factory installed on
the Power Feed 10 wire feeder. Use this adapter for
guns that have a Tweco™ #2-#4 connector. Such
guns include Magnum 200/300/400 guns with K46610 connector kit, and completely factory assembled
Magnum guns that are factory equipped with the
K466-10 connector (such as the K497-21 dedicated
Magnum 400).

MAGNUM 550 GUNS

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K1500-3 (TWECO™ #5 CONNECTION)
The easiest and least expensive way to use the
Magnum 550 guns with Power Feed 10 wire feeders
is to order the gun with the K613-7 connector kit, and
install a K1500-3 gun connection kit to the wire
feeder.

LINCOLN INNERSHIELD AND SUB ARC GUNS

K1500-4 (MILLER CONNECTION) for any gun having a Miller connector.

All of these guns can be connected to the Power
Feed by using the K1500-1 Adapter Kit.

Install gun adapters per the instructions shipped with
them.

LINCOLN FUME EXTRACTION GUNS

CONDUIT ADAPTERS

The K556 (250XA) and K566 (400XA) guns require
that a K489-2 Fast-Mate™ adapter kit be installed.
Installation of this adapter also requires a K1500-1
gun connector kit.

K1546-1 ADAPTER

The K206, K289, and K309 require only the installation of a K1500-1 connector in the Power Feed wire
feeder.

Install the K1546-1 gun adapter at the incoming end
of the feed plate, secure with the set screw located at
the back of the feed plate. If a brass fitting is supplied
with the conduit, remove it from the feeder end of the
conduit by unscrewing it. Insert the conduit into the
K1546-1, secure the conduit by fastening it to the
adapter with the supplied knob screw.

NON-LINCOLN GUNS
Most competitive guns can be connected to the
Power Feed by using one of the K1500 series
adapter kits.

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K1500-1 (LINCOLN INNERSHIELD GUN
STANDARD CONNECTION)

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The K1500-3 gun adapter is for Magnum 550 guns
with a K613-7 connection kit, and any other gun having a Tweco™ #5 connector.

Use this kit to connect the following guns: Guns having a Lincoln standard innershield gun connector,
Fast-Mate™ guns with K489-2 Fast-Mate™ Adapter
Kit, Magnum 200/300/400 with K466-1 connector kit,
and Magnum 550 guns with the K613-1 gun connection kit.

For use with Lincoln Magnum conduit (wire sizes
0.023 to 0.052)

K1546-2 ADAPTER
For use with Lincoln Magnum conduit (wire sizes
1/16 to 0.120)
Install the K1546-2 gun adapter at the incoming end
of the feed plate; secure with the set screw located at
the back of the feed plate. If a brass fitting is supplied
with the conduit, remove it from the feeder end of the
conduit by unscrewing it. Insert the conduit into the
K1546-2, secure the conduit by fastening it to the
adapter with the supplied knob screw.

POWER WAVE 455/POWER FEED 10

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C-8

ACCESSORIES

DUAL PROCEDURE SWITCH OPTIONS

K659-1 GAS GUARD REGULATOR

K683-3 DUAL PROCEDURE SWITCH

Adjustable flow regulator with removable adjuster key
for CO2 and Argon blend gases. Mounts onto feeder
inlet, and reduces gas waste and arc start “blow” by
reducing surge caused by excess pressure in supply
hose.

Kit includes gun switch and mountings for Lincoln
Innershield and Magnum guns, with 15 ft (4.5 m)
control cable and 5-pin plug with two leads to connect to gun trigger.

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Connect the 5-pin plug of the K683-3 Dual Procedure
Switch to the Power Feed 10 wire feeder trigger/dual
procedure 5-socket receptacle.
The two lead plug cord extending out of the 5-pin
plug of the Dual Procedure Switch is to be connected
to the two trigger leads of the welding gun per
instructions shipped with the kit.

K683-1 DUAL PROCEDURE SWITCH
The K683-3 Dual Procedure Switch is the recommended method of obtaining dual procedure; but if it
is desired to use an existing K683-1 with the Power
Feed 10, it can be done. A K683-1 Dual Procedure
Switch can be used on the Power Feed 10 if a K6862 adapter is used. The K682-1 kit includes gun
switch and mountings for Lincoln Innershield and
Magnum guns, with 15 ft (4.5 m) control cable and 3pin plug. K686-2 adapter permits 3-pin plug and 5pin gun trigger plug to be connected to Power Feed
10 5-pin trigger/dual procedure receptacle.

Install the 5/8-18 male outlet of the regulator to the
5/8-18 female gas inlet on the back panel of the wire
drive. Secure fitting with flow adjuster key at top.
Attach gas supply to 5/8-18 female inlet of regulator.

CHASSIS OPTIONS
K1557-1 SWIVEL PLATFORM
The K1557-1 Swivel platform attaches to the power
source. This kit includes a feeder adapter plate that
allows the feeder to rotate on top of the power
source. The feeder can be easily separated from the
swivel mount at any time. This option is compatible
with the K1556-1 Light Duty Caster Kit.
K1556-1 LIGHT DUTY CASTER KIT
This option provides four casters and all required
hardware to mount it to the Power Feed 10. This
option is compatible with the K1557-1 Swivel
Platform.
K1574-1 SECURITY DOOR (LARGE)

GAS AND WATER KITS
K590-5 WATER CONNECTION KIT
(FOR DRIVE ONLY)
Install per the instructions shipped with the kit.

K1536-1 WATER FLOW SENSOR KIT

K1574-1 Security Door Installation into the Control
Box cabinet.
1. Turn off power.
2. Unlatch and swing open the small door. Remove
the two screws from the horizontal hinge rod.
Save the screws.
3. While holding the door so it doesn’t fall, slide the
rod out sideways releasing the door.

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Install per the instructions shipped with the kit.

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C-8

POWER WAVE 455/POWER FEED 10

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C-9

ACCESSORIES

4. Position the new door between the panel holes
and re-install the rod so the screw holes can be
accessed.
5. Replace the two screws and tighten.
6. Swing the door into the up position. A lock may
be installed through the side holes for security
purposes.

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For applications where an insulated lift bail is
required. This kit provides an easily installed, heavy
duty insulated lift eye that mounts to the wire reel
stand mast. See the instructions provided with the kit
for installation.

DESCRIPTION AND INSTALLATION OF
OPTIONAL CONTROL BOX PANELS
K1542-5 DUAL PROCEDURE PANEL
The Dual Procedure Panel provides a fixed large toggle switch or the use of a gun switch for the selection
of either of two procedures. The upper position of the
switch selects PROCEDURE A, while the lower
selects PROCEDURE B. The middle position selects
the GUN switch, in which case the procedure is
determined by the position of the switch located at
the gun.
NOTE: Due to the nature of fixed position switches,
this option does not allow the indication of a remotely
selected procedure. When in the gun mode there is
no provision to indicate, at the Control Box, which
procedure has been remotely selected (at the gun).
Installation is as follows:
1. Turn off power.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option, (middle or top), of the
Control Box cabinet. Save the screws, discard
the old panel or save for future use.

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3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(10 pin). Make sure the connector latches in
place.
4. Position the new panel, taking care not to damage the switch connections on the back.
5. Align the screw holes, replace the two screws
and tighten.

K1555-1 INSULATED LIFT BAIL

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C-9

K1542-6 M PANEL
The M Panel provides a large toggle switch selection
of three power source modes. The upper position
selects the generic CV/MIG mode from the power
source, the middle position selects the CV/FLUX
CORED mode, and the lower position selects the
CC/STICK/GOUGE mode. Arc control is accomplished through the use of the ARC CONTROL
potentiometer. The arc control value is actually a trim
with zero being the nominal and the scale ranging
from (-10) to (+10). Preflow, postflow, and spot time
default to zero or off. Run in defaults to the minimum
value, or weld speed depending on the position of its
associated DIP switch. See Installation section for
DIP switch settings. Burnback defaults to the on
board trimmer adjustment.
NOTE: Due to the nature of fixed position switches,
potentiometers, and default values, this option does
not allow the mode, arc control, timers, or burnback
values to be included in dual procedure or memory
information. They are overridden by the fixed values.

CC/STICK/GOUGE Mode
Selecting the CC/STICK/GOUGE mode on this panel
automatically energizes the output terminals on the
power source, making the power source immediately
ready to weld. In the CC modes, the output current is
set by the AMPS control, and the VOLTS/TRIM
adjustment has no effect in this mode. In this mode,
the ARC CONTROL adjusts the arc force. Increasing
the ARC CONTROL setting increases the arc force,
making the arc more harsh but less likely to stick.
Decreasing the ARC CONTROL setting decreases
the arc force, making the arc softer and smoother.

POWER WAVE 455/POWER FEED 10

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C-10

ACCESSORIES

Constant Voltage (CV/MIG and CV/Flux Cored)
Procedures

Display - Displays the value or status of the active
parameter.

When in this mode, the ARC CONTROL adjusts the
inductance. (This adjustment is often referred to as
“pinch”. Inductance is inversely proportional to
pinch.) Increasing the ARC CONTROL setting
decreases the inductance, which results in the arc
getting colder and pinched tighter. Decreasing the
ARC CONTROL setting increases the inductance,
which results in the arc getting wider (reduced pinch).

Available Modes - CV/MIG
CV/ FLUX CORED
CC/STICK CRISP
CC/STICK SOFT

Installation is as follows:

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1. Turn off power.
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C-10

2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.
3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board (12
pin). Make sure the connector latches in place.
4. Position the new panel, taking care not to damage the connections on the back.

Due to the nature of the system, the following feature
is required for safety reasons. Upon entering any
constant current (CC) mode, the right encoder,
labeled VOLTS, TRIM, on the Display/Control Panel
acts as a “soft” contactor switch. The encoder knob
must be turned CW at least 45° to activate the output
(turning CCW 45° deactivates the output). This prevents the output from inadvertently becoming “hot”
when scrolling through the weld modes. The exception to this rule is when the weld mode is entered by
a change in procedure (using a memory panel such
as the K1542-9 Memory/Dual Procedure panel). In
this case, the state of the contactor is recalled as it
was left when the procedure was exited.
In the CC modes, the output current is set by the
AMPS control, and the VOLTS/TRIM adjustment has
no effect in this mode. In this mode, the ARC
CONTROL adjusts the arc force. Increasing the ARC
CONTROL setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the ARC CONTROL setting decreases the arc force,
making the arc softer and smoother.

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5. Align the screw holes, replace the two screws
and tighten.
Parameter Ranges
K1542-7 MX PANEL (LARGE PANEL)
The MX Panel provides a selection of four power
source modes. In addition, it provides for the adjustment of the following parameters: PREFLOW, RUN
IN, ARC CONTROL, BURNBACK, POSTFLOW, and
SPOT time.

Descriptions

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Indicator Lights - Extra bright red LED’s indicate the
mode and active parameter being displayed.

PREFLOW 0.0 to 2.5 seconds (0.1 sec. increments).
RUN IN Low Range: 50 to 150 IPM (1.25 to 3.80 MPM).
High Range: 75 to 150 IPM (2.00 to 3.80 MPM).
ARC CONTROL Trim (-10.0) to (+10.0) , (0) is nominal.
BURNBACK 0.0 to 0.25 sec. (0.01 sec. increments).
POSTFLOW 0.0 to 2.5 sec. (0.1 sec. increments).
SPOT 0 to 25 sec. (0.1 sec. increments).

POWER WAVE 455/POWER FEED 10

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C-11

ACCESSORIES

Mode Selection
The MODE SELECT switch is a momentary large
three position toggle switch that defaults to the center
(off) position. Moving the switch up advances the
mode indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.

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4. Position the new panel, taking care not to damage the connections on the back.
5. Align the screw holes, replace the two screws
and tighten.

K1542-8 MSP PANEL (LARGE PANEL)

The PARAMETER SELECT switch is a momentary
large three position toggle switch that defaults to the
center (off) position. Moving the switch up advances
the parameter indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.

The MSP Panel provides a selection of numerous
process specific and generic power source modes. In
addition, it provides for the adjustment of the following parameters: PREFLOW, RUN IN, ARC CONTROL, BURNBACK, POSTFLOW, and SPOT time.
Only one parameter, as defined by the parameter
indicator, may be displayed and adjusted at a time.

Description
Indicator Lights - Red LED’s indicate the active parameter being displayed.

The value of the active parameter, as defined by the
parameter indicator, is displayed on the parameter
display. The PARAMETER SET switch is a momentary large three position toggle switch that defaults to
the center (off) position. Moving the switch bat up
advances the displayed value in the positive direction, down advances it in the negative direction.
Holding the switch in either direction will result in the
displayed value advancing at a high rate of speed in
that direction, until the switch is released. When the
indicator reaches its upper or lower limit, advancing
ceases until the direction of the switch is changed.
Installation is as follows:
1. Turn off power.

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Parameter Selection

Parameter Adjustment

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C-11

Display - 3 1/2 digit, red LED display. Displays the
value or status of the active parameter.

Parameter Ranges
WELD MODE Adjustable per mode schedule.
PREFLOW 0.0 to 2.5 seconds (0.1 sec. increments).
RUN IN Low Range: 50 to 150 IPM (1.25 to 3.80 MPM).
High Range: 75 to 150 IPM (2.00 to 3.80 MPM).
ARC CONTROL Trim (-10.0) to (+10.0) , (0) is nominal.
BURNBACK 0.0 to 0.25 sec. (0.01 sec. increments).
POSTFLOW 0.0 to 2.5 sec. (0.1 sec. increments).
SPOT 0 to 25 sec. (0.1 sec. increments).

POWER WAVE 455/POWER FEED 10

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C-12

ACCESSORIES

Mode Schedule - Table on the front of the option
used by the operator to correlate the displayed mode
number to an actual power source mode.
Due to the nature of the system, the following feature
is required for safety reasons. Upon entering any
constant current (CC) mode, the right encoder,
labeled VOLTS, TRIM, on the Display/Control Panel
acts as a “soft” contactor switch. The encoder knob
must be turned CW at least 45° to activate the output
(turning CCW 45° deactivates the output). This prevents the output from inadvertently becoming “hot”
when scrolling through the weld modes. The exception to this rule is when the weld mode is entered by
a change in procedure (using a memory panel such
as the K1542-9 Memory/Dual Procedure panel). In
this case, the state of the contactor is recalled as it
was left when the procedure was exited.
In the CC modes, the output current is set by the
AMPS control, and the VOLTS/TRIM adjustment has
no effect in this mode. In this mode, the ARC
CONTROL adjusts the arc force. Increasing the ARC
CONTROL setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the ARC CONTROL setting decreases the arc force,
making the arc softer and smoother.

C-12

that direction, until the switch is released. When the
indicator reaches its upper or lower limit, advancing
ceases until the direction of the switch is changed.

GMAW Pulse Procedures
In these procedures, the actual voltage greatly
depends on the waveform used. The peak currents,
background currents, rise times, fall times, and pulse
times all affect the actual voltage. The actual voltage
for a given wire feed speed is not directly predictable
unless the waveform is known. In this case, it is not
practical to preset an actual voltage for the procedure. Instead, an arc length adjustment is provided.
The machine “knows” what the best arc length is at
the given wire feed speed but allows the operator to
change it.
The arc length trim (usually referred to simply as
“trim”) can be adjusted between 0.500 and 1.500 on
the Control Box’s VOLTS/TRIM display. A trim of
1.000 means that no adjustments will be made to the
preset arc lengths. A trim setting less than 1.000
decreases the preset arc lengths. The arc length trim
adjustment is factored in at all wire feed speed settings. Increasing the trim by 10 percent at a given
wire feed speed also increases all the other arc
length trim settings of the procedure by 10 percent.

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Parameter Selection
The PARAMETER SELECT switch is a momentary
large three position toggle switch that defaults to the
center (off) position. Moving the switch up advances
the parameter indicator in the upward direction, down
advances it in the downward direction. Holding the
switch in either direction will result in the indicator
advancing at a high rate of speed in that direction,
until the switch is released. When the indicator
reaches its upper or lower limit, advancing ceases
until the direction of the switch is changed.

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Parameter Adjustment
The value of the active parameter, as defined by the
parameter indicator, is displayed on the parameter
display. The PARAMETER SET switch is a momentary large three position toggle switch that defaults to
the center (off) position. Moving the switch up
advances the displayed value in the positive direction, down advances it in the negative direction.
Holding the switch in either direction will result in the
displayed value advancing at a high rate of speed in

Lincoln Power Wave power sources utilizes a control
scheme known as adaptive control in all pulse
modes. Because the Power Wave utilizes adaptive
control, it can adjust the pulsing parameters based
on changes in the arc due to changes in the electrical
sitckout of the electrode. (Electrical stickout is the
distance from the contact to the workpiece.) The
Power Wave is optimized for use with a 0.75 in. stickout. The adaptive behavior is programmed to support
a stickout range from 0.5 in. to 1.25 in. In the low and
high end of the wire feed speed ranges of most
processes, the adaptive behavior may be restricted.
This is a physical restriction due to reaching the edge
of the operating range for the process.
The ARC CONTROL adjustment allows the pulse frequency to be varied. Increasing the ARC CONTROL
causes the frequency setting to increase, while
decreasing the ARC CONTROL causes the frequency to decrease. Varying the ARC CONTROL, and
hence, the pulse frequency, affects the droplet transfer and allows fine-tuning for different welding
positions.

POWER WAVE 455/POWER FEED 10

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C-13

ACCESSORIES

Installation is as follows:
Dual Procedure Selection
1. Turn off power.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.

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3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(12 pin). Make sure the connector latches in
place.
4. Position the new panel, taking care not to damage the connections and the printed circuit board
on the back.
5. Align the screw holes, replace the two screws
and tighten.

K1542-9 DUAL PROCEDURE/MEMORY PANEL
(SMALL PANEL)
The Dual Procedure/Memory panel provides for the
selection of either of two procedures, or a gun switch
for remote selection of the procedure. In addition,
there are six permanent memory storage locations
for saving commonly used procedures. Procedures A
and B are “soft” type memories that record any
changes made to them. The six memory locations
are “hard” or more permanent type memories. Any
changes made must be consciously saved back to
them. Furthermore, each memory contains only one
procedure, therefore any combination of memories
may be recalled to procedure A and B.

Descriptions

The procedure switch is used to scroll the indicator to
select PROCEDURE A, PROCEDURE B, or the
GUN switch. When the GUN switch is selected, the
procedure is determined by the position of the switch
located at the gun. Under this condition, indicators
will show that the gun switch has been selected and
also which procedure the gun switch is requesting.

Memory Selection
RECALL - When a memory key is depressed, its indicator comes on and its contents are copied to the
active procedure. As long as no changes are made
to the contents of that procedure, the memory indicator will be on any time that procedure is active. This
indicates that their contents are the same. Any
change to that procedure will cause the memory indicator to go off, indicating that they are no longer
equal.
SAVE - The save mode allows “hard” memories to be
changed. Pressing the SAVE key will light the save
indicator, and enter the save mode. In the save
mode, the indicator for the memory that was the
source of the active procedure’s contents will blink,
whether their contents are still equal or not. This feature allows the user to choose to save an active procedure back to its source, or some other location.
To complete the save transaction requires the selection of one of the memory keys. When the memory
key is pressed in the save mode, it’s contents are
overwritten with the contents of the active procedure.
This means that the contents of the memory location
and the active procedure are now equal, and thereore, by definition, each of their indicators will be lit,
and the save mode will be exited. To exit the save
mode without saving, depress the save key a second
time. This feature allows the operator to determine
the source of the active procedure’s contents without
actually overwriting it.

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Indicator Lights - Red LED’s indicate the procedure
and active memory and save mode if applicable.

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C-13

POWER WAVE 455/POWER FEED 10

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C-14

ACCESSORIES

Installation is as follows:
1. Turn off power.
2. Remove the two screws from the front of the
blank option panel at the location you choose to
install your new option (bottom) of the Control
Box cabinet. Save the screws, discard the old
panel or save for future use.

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3. Tilt the new option panel away from the front
opening of the Control Box cabinet. Plug the
electrical connector into the proper connector on
the right side of the main printed circuit board
(10 pin). Make sure the connector latches in
place.
4. Position the new panel, taking care not to damage the connections and the printed circuit board
on the back.
5. Align the screw holes, replace the two screws
and tighten.

C-14

The value of the active Set Up parameter, as defined
by the Set Up LED, is displayed on the MX2 panel
Set Up display. The value can be modified with the
Set switch. The Set switch is an up/down center-off
momentary toggle switch. Moving the switch bat up
or down adjusts the displayed value in the corresponding direction. Holding the switch in either direction will cause the display to move quickly in the corresponding direction until the switch is released, or
the upper or lower parameter limit is reached.
To energize the output studs in either CC/Stick
mode, the right Control/Display panel knob, labeled
Volts/Trim, must be used. The Volts/Trim knob must
be turned clockwise roughly a quarter revolution to
energize the output studs. (The Volts/trim display will
indicate ‘On’ when the studs are energized.)
Similarly, turning the knob a quarter turn counterclockwise de-energizes the output studs. If a
CC/Stick weld mode is entered through use of the
Dual Procedure, the studs will be in the same state
as when they were last used. If a CC/Stick weld
mode is entered through a Memory recall, the studs
will be de-energized.

K1542-11 MX2 Panel:

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K1542-12 MSP2 Panel:
This panel provides a selection of four weld modes:
CV/MIG, CV/Flux Cored, CC/Stick/soft and
CC/Stick/Crisp through a toggle switch and indicator
lights (LEDs). It allows for adjustment of all set up
parameters, Preflow, Run In, Arc Control, Burnback,
Postflow, and Crater, through an up/down toggle
switch, indicator lights and a 3 digit display.
Weld modes are selected with the Mode Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves the
Weld Mode LED in the corresponding direction.
Holding the switch in either direction will cause the
indicator to move quickly in the corresponding direction until the switch is released, or the upper or lower
limit is reached.

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To adjust Set Up parameters, first select the Set Up
parameter for adjustment, and then adjust the displayed value up or down.
Set Up parameters are selected with the Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves the
Weld Mode LED in the corresponding direction.
Holding the switch in either direction will cause the
indicator to move quickly in the corresponding direction until the switch is released, or the upper or lower
limit is reached.

This panel provides a selection of over 25 weld
modes, including CV, pulse, FCAW and CC, through
a toggle switch and indicator lights (LEDs). It allows
for adjustment of all set up parameters, Preflow, Run
In, Arc Control, Burnback, Postflow, and Crater,
through an up/down toggle switch, indicator lights
and a 3 digit display.
To adjust a set up parameter (Weld Mode being one
of those parameters), first select one of the set up
parameters for adjustment, and then adjust the displayed value up or down.
Set up parameters are selected with the Select
switch, an up/down center-off momentary toggle
switch. Moving the switch bat up or down moves an
LED in the corresponding direction. Holding the
switch in either direction will cause the indicator to
move quickly in the corresponding direction until the
switch is released, or the upper or lower limit is
reached.

POWER WAVE 455/POWER FEED 10

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C-15

ACCESSORIES

The value of the active set up parameter is shown on
the MSP2 panel digital display. The value can be modified with the Set switch. The Set switch is an up/down
center-off momentary toggle switch. Moving the switch
bat up or down adjusts the displayed value in the corresponding direction. Holding the switch in either direction will cause the display to move quickly in the corresponding direction until the switch is released, or the
upper or lower parameter limit is reached.
To energize the output studs in either CC/Stick mode,
the right Control/Display panel knob, labeled
Volts/Trim, must be used. The Volts/Trim knob must
be turned clockwise roughly a quarter revolution to
energize the output studs. (The Volts/trim display will
indicate ‘On’ when the studs are energized.)
Similarly, turning the knob a quarter turn counterclockwise de-energizes the output studs. If a CC/Stick
weld mode is entered through use of the Dual
Procedure, the studs will be in the same state as
when they were last used. If a CC/Stick weld mode is
entered through a Memory recall, the studs will be deenergized.

C-15

Arc Control - Unitless characteristic, also known as
Inductance or Wave Control. Allows operator to vary
the arc characteristics from “soft” to “harsh” in all weld
modes. Adjustable from -10.0 to 10.0 in increments of
0.1. Off (0.0) is nominal.
Burnback - Time delay after the trigger is releasedduring which the power source remains energized but
the Wire Drive stops feeding wire. Adjustable from
0.00 (Off) to 0.25 seconds in 0.01 second increments.
Postflow - Time delay after burnback is complete,
during which shielding gas flows. Adjustable from 0.0
(Off) to 10.0 seconds in 0.1 second increments.
Crater - Used only when welding with the 4-Step trigger mode. Can be set to Off or On. When On,
Adjustments can be made to WFS and Volts/Trim on
the Control/Display panel. These settings are then
used for ‘cratering’ when in the 4-Step trigger mode
(see explanation of 2 Step and 4 Step operation
below). When Off, ‘cratering’ is not possible.

CONTROL BOX -- PC BOARD ADJUSTMENTS
CONTROL BOX PANELS -- SET UP
CONTROLS DESCRIPTION

The Control Box Mother board provides the capability
to adjust some wire feeding parameters as follows:

Certain large option panels can modify the set up
parameters Preflow, Run In, Arc Control, Burnback,
Postflow, and Crater. The meaning of those parameters, and their maximum and minimum values, follows.

Acceleration: The motor acceleration can be varied
in five steps, from slow to fast. See “Setting DIP
Switches in the Control Box” section.

Preflow - Time delay after the trigger is pulled, but
before weld starts, during which shielding gas flows.
Weld start is defined as the time when both the power
source is energized and the Wire Drive begins feeding
wire. Adjustable from 0.0 (Off) to 2.5 seconds in 0.1s
increments.

Burnback: For the options which cannot adjust the
Burnback set up parameter (CV/G and M panels) a
PC board adjustment (trimmer R5) is provided. The
range is 0.0 to 0.25 seconds, increasing in the clockwise direction. This is ignored by options which have
the ability to adjust Burnback (MX2 and MSP2 panels).

Run In - Wire feed speed during arc starting. Wire
Drive will feed wire at the Run In speed for one second, or until weld current flows. Low speed gear
range: Off (Run In speed equals weld wire feed
speed) or adjustable from 50 to 150 IPM (1.25 to 3.80
MPM). High speed gear range: Off (Run In speed
equals weld wire feed speed) or adjustable from 75 to
150 IPM (2.00 to 3.80 MPM). NOTE: Run In settings
over 150 IPM produce strange display values used for
troubleshooting and service. If encountered, reset Run
In to 150 IPM or less.

Run In: For the options which cannot adjust the Run
In set up parameter (CV/G and M panels) a PC board
DIP switch setting is provided. In one position, the run
in speed will be the minimum Wire Drive WFS. At the
other setting, run in will occur at the same speed as
set on the WFS knob. This DIP switch setting is
ignored by options which have the ability to adjust
Run In (MX2 and MSP2 panels). See “Setting DIP
Switches in the Control Box” section.

POWER WAVE 455/POWER FEED 10

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C-16

ACCESSORIES

CONTROL BOX -- SETTING OPERATING LIMITS
Upper and lower operating limits can be set for the
WFS/Amps setting and the Volts/Trim setting. Doing
so requires knowledge of how to set the limits, and
access to the PC board in the Control Box.
There are two independent sets of limits, Procedure
A limits and Procedure B limits. If a DP/M door
option is installed, the A and B limits must be set
independently. If there is no DP/M door option, the
Control Box defaults to Procedure A, and only
Procedure A limits can be set.
With system power on, select the weld mode for
which you want to set limits. If a Dual Procedure
option is installed, select the procedure A. Turn the
system power off. Remove the two screws holding
the Control/Display panel to the Control Box, but do
not unplug it. Tilt the panel down to allow access to
DIP switches S1-1, S2-6 and S2-7. (See “Setting DIP
Switches in the Control Box” section.) Do not allow
the panel to hang by the wiring harness.
Determine if the Wire Drive is set up for low or high
speed. If low speed, S1-1 should be off. If high
speed, set S1-1 to on.
To adjust the lower limit, set S2-6 to on. Turn the
power on and adjust the WFS/Amps and Volts/Trim
knobs to the desired lower limits. Note: You will not
be able to adjust the lower limit outside of the minimum and maximum wire feed speed of the Wire
Drive, nor above the upper limit. Turn the system
power off. Return S2-6 to off.

operator to adjust his Volts in synergic and non-synergic CV modes. Procedure B could be set up with
different limits. Limits are absolute -- they will override values stored in the memories. Note that limits
do not apply to set up parameters, such a Preflow
and Arc Control.

OPERATION WITH PREVIOUS
SOFTWARE VERSION
The operation of the previous Control Box software
version (S24004-2) is different than described earlier
in this section. The differences are as follows:
• The Memory/Dual Procedure panel is not a valid
option.
• The MX (K1542-1) and MSP (K1542-8) are are
used in place of the MX2 and MSP2 options.
• Limits cannot be set.
The key difference in the MX/MSP panels, compared
to the MX2/MSP2 panels, is the Spot function. In the
old software, a 0.1 to 2.5 second Spot function was
available on these two panels. No Crater function
was available (Crater replaced Spot in the graphics
on these two panels).
An upgrade kit is available to change the software
from S24004-2 to the latest version of Control Box
software. Once the upgrade is done, the Dual
Procedure/ Memory panel becomes a valid option,
limits can be set, and Spot is replaced by Crater.

To adjust the upper limit, set S2-7 to on. Turn the
power on and adjust the WFS/Amps and Volts/Trim
knobs to the desired upper limits. Note: You will not
be able to adjust the upper limit outside of the minimum and maximum wire feed speed of the Wire
Drive, nor below the lower limit. Turn the system
power off. Return S2-7 to off.

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If a Dual Procedure panel is installed, repeat the
above procedure with the Procedure B selected.
When done, attach the Control/Display panel to the
Control Box. The machine is now ready for normal
operation with the new limits.
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C-16

CONTROL BOX -- USING OPERATING LIMITS
Once set, limits apply to all weld modes. Limiting
Procedure A to 200 to 300 inches per minute, for
example, limits the ability of the operator to adjust his
WFS in pulse, CV and FCAW weld modes. Limiting
the Volts to 23.0 to 24.5 would limit the ability of the
POWER WAVE 455/POWER FEED 10

MAINTENANCE

SECTION D-1

TABLE OF CONTENTS
-MAINTENANCE SECTIONMaintenance ............................................................................................................................................. Section D
Safety Precautions.............................................................................................................................
D-2
Routine Maintenance .........................................................................................................................
D-2
Power Wave ................................................................................................................................
D-2
Wire Feeder.................................................................................................................................
D-2
Periodic Maintenance ........................................................................................................................
D-2
Wire Drive Motor and Gearbox....................................................................................................
D-2
Gun and Cable Maintenance.......................................................................................................
D-2

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SECTION D-1

POWER WAVE 455/POWER FEED 10

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D-2

MAINTENANCE

SAFETY PRECAUTIONS

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AVOIDING WIRE FEEDING PROBLEMS
Wire feeding problems can be avoided by observing
the following gun handling and feeder set up procedures:

WARNING
ELECTRIC SHOCK
can kill.

a. Do not kink or pull cable around sharp corners.

• Do not touch electrically live parts
such as output terminals or internal
wiring.
• Only qualified personnel should
perform maintenance work.

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D-2

Observe all additional Safety Guidelines detailed
throughout this manual.

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

b. Keep the electrode cable as straight as possible when welding or loading electrode
through cable.
c.

Do not allow dolly wheels or trucks to run
over cables.

d. Keep cable clean by following maintenance
instructions.

ROUTINE MAINTENANCE

e. Use only clean, rust-free electrode. The
Lincoln electrodes have proper surface lubrication.

POWER WAVE

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.

g. Do not use excessive wire spindle brake settings.

Replace contact tip when the arc starts to
become unstable or the contact tip end is
fused or deformed.

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h. Use proper drive rolls, wire guides and drive
roll pressure settings.

WIRE FEEDER
DRIVE ROLLS AND GUIDE TUBES

PERIODIC MAINTENANCE

After feeding every coil of wire, inspect the drive roll
section. Clean as necessary. Do not use a solvent
for cleaning the drive rolls because it may wash the
lubricant out of the bearing. The drive rolls and Inner
Wire Guides are stamped with the wire sizes they will
feed. If a wire size other than that stamped on the
roll(s) is to be used, the roll(s) and Inner Wire Guides
must be changed.

WIRE DRIVE MOTOR AND GEARBOX

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All drive rolls have two identical grooves. The rolls
may be flipped over to use the other groove.

Every year inspect the gearbox and coat the gear
teeth with grease. Do not use graphite grease.
Refer to the Troubleshooting section for disassembly of Drive Motor and Wire Feed Assembly.

GUN AND CABLE MAINTENANCE
See appropriate Operator’s Manual.

See Procedure to Install Drive Rolls and Wire
Guides in the Operation section for roll changing
instructions.
WIRE REEL MOUNTING - READI-REELS AND
10 THROUGH 30 LB (4.5-14 KG) SPOOLS
No routine maintenance required. Do not lubricate
2 in. (51 mm) spindle.
POWER WAVE 455/POWER FEED 10

THEORY OF OPERATION

SECTION E-1

TABLE OF CONTENTS
-THEORY OF OPERATION SECTIONTheory of Operation ................................................................................................................................. Section E
Modular Inverter Based Welding System...........................................................................................
E-2
System Diagram A .............................................................................................................................
E-2
System Diagram B .............................................................................................................................
E-3
System Diagram C.............................................................................................................................
E-4
Power Source General Description....................................................................................................
E-5
Input Voltage and Precharge .............................................................................................................
E-5
Switch Boards and Main Transformer................................................................................................
E-6
Control Board.....................................................................................................................................
E-7
Output Rectifier and Choke................................................................................................................
E-8
Thermal Protection.............................................................................................................................
E-9
Protective Circuits ..............................................................................................................................
E-9
Over Current Protection .....................................................................................................................
E-9
Under/Over Voltage Protection ..........................................................................................................
E-9
Insulated Gate Bipolar Transistor (IGBT) Operation..........................................................................
E-10
Pulse Width Modulation .....................................................................................................................
E-11
Minimum Output ..........................................................................................................................
E-11
Maximum Output .........................................................................................................................
E-11
Control Box (User Interface) ..............................................................................................................
E-12
Power Feed 10 Feed Head................................................................................................................
E-13

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SECTION E-1

POWER WAVE 455/POWER FEED 10

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E-2

THEORY OF OPERATION
FIGURE E.1 — SYSTEM DIAGRAM A.

POWER
SOURCE

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CONTROL BOX
(USER INTERFACE)

INTERNAL
CONNECTION
WIRE DRIVE

MODULAR INVERTER
BASED WELDING SYSTEM
The Welding Network is an assembly of
welding equipment joined together by a
common network communication cable.
These individual welding components consist of a power source (Power Wave 455), a
user interface (Power Feed 10 Control Box)
and a modular wire drive (Power Feed 10
Wire Drive). Each discrete element in the
system is designed to “talk” with the other
system components so that all information
is shared and the entire system is in sync.
This communication and shared information
network lays the groundwork for a system
with superior welding performance and
capabilities.

SYSTEM DIAGRAM A
This basic system utilizes two physical
pieces of equipment. Refer to Figure E.1.
The power source (Power Wave 455) and
the combination Control Box and wire drive
(Power Feed 10) are the two circuit elements. Note the Control Box (user interface) is attached to, and internally connected to, the wire drive unit.
The communication cable is depicted by the
heavy black connector line. PC board
power, communications and intelligence
between the power source and the combination wire drive/control box unit are conveyed through this cable.

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The equipment can be connected together
in a daisy-chain fashion. Lincoln customers
can configure a system to meet their

specific requirements and also locate and
identify each piece of equipment for maximum efficiency and ease of operation.

POWER WAVE 455/POWER FEED 10

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E-3

THEORY OF OPERATION
FIGURE E.2 — SYSTEM DIAGRAM B.

CONTROL
BOX
(USER
INTERFACE)
INTERNAL
CONNECTION

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POWER
SOURCE

WIRE DRIVE

SYSTEM DIAGRAM B
This system utilizes two physical pieces of
equipment. Refer to Figure E.2. The combination Control Box (user interface) and
power source (Power Wave 455) make up
one of the circuit elements. This combination unit is coupled to the wire drive module
(Power Feed 10). Note the Control Box is
attached to and internally connected to the
power source.

The communication cable is depicted by the
heavy black connector line. PC board
power, communications and intelligence
between the wire drive and combination
power source/Control Box unit are conveyed through this cable.

POWER WAVE 455/POWER FEED 10

E-4

THEORY OF OPERATION
FIGURE E.3 — SYSTEM DIAGRAM C.

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E-4

CONTROL BOX
(USER
INTERFACE)

WIRE DRIVE

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SYSTEM DIAGRAM C

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The power source (Power Wave 455), the
Control Box (user interface) and the wire
drive (Power Feed 10) are the three discrete and physically separate circuit components employed in this configuration. Refer
to Figure E.3. The three elements are daisychained together via the communication

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POWER
SOURCE

cables. All PC board power, communications and intelligence are transmitted via the
two cables.
This component configuration might be
used if the wire drive unit was mounted on a
boom and the Control Box located remotely
from the power source.

POWER WAVE 455/POWER FEED 10

FIGURE E.4 — INPUT VOLTAGE AND RECHARGE.
MAIN
TRANSFORMER

INPUT
CONTACTOR

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INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T

I
N
P
U
T

B
O
A
R
D

#1 AUX.
TRANS.

S
W

PRIMARY
CURRENT
SENSOR

I
T

CAPACITOR
VOLTAGE
FEEDBACK

C
H

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CHOKE

RIGHT
SWITCH
BOARD

CONTROL SIGNALS

CAPACITOR
VOLTAGE
FEEDBACK

PWM
DRIVE

OUTPUT
TERMINAL
THERMOSTATS

RECTIFIER
CURRENT FEEDBACK

65VDC
CONTROL BOARD
AUX.
RECONNECT

VOLTAGE FEEDBACK

#2AUX.
TRANS.
FAN
MOTOR

POWER
BOARD
40VDC

115VAC
RECEPTACLE

WIRE FEEDER
RECEPTACLE

RS232
CONN.

The Power Wave 455 is an inverter based
welding power source that is designed to be
part of a modular, multi-process welding
system. It is a high performance, digitally
controlled inverter capable of complex,
high-speed waveform control. With the
appropriate modular components it can support constant current, constant voltage and
pulse welding processes. The output rating
is 450 amps at 38 volts with a 100% duty
cycle.

INPUT VOLTAGE AND
PRECHARGE

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OUTPUT
TERMINAL

PWM
DRIVE

POWER SOURCE
GENERAL DESCRIPTION

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CURRENT
SENSOR

LEFT
SWITCH
BOARD

PS
OW
WTI
EC
RH

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E-5

THEORY OF OPERATION

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E-5

The Power Wave 455 can be connected for
a variety of three phase voltages. Refer to
Figure E.4. The initial input power is
applied to the Power Wave 455 through a
line switch located on the front of the
machine. Two phases of the three-phase
input power is applied to the input board
and both auxiliary transformers. The various secondary voltages developed by the
#1 auxiliary transformer are applied to the
input board, the power board rectifier and
the fan motor. The 115 VAC secondary

VOLTAGE THERMAL
LIGHT
SENSE
RECEPTACLE

STATUS
LIGHT

voltage developed by the No. 2 auxiliary
transformer is applied to the 115 VAC
receptacle.
The 65 VDC produced from the power
board rectifier is utilized by the power board
to provide various DC voltages for the control board and wire feeder.
The two phases which are connected to the
input board, through the power switch, are
connected to the input rectifier. During
precharge or “soft start” these two phases
are current limited by the input board. This
AC input voltage is rectified, and the resultant DC voltage is applied through the
reconnect switches to the input capacitors
located on the switch boards. The control
board monitors the voltage across the
capacitors. When the capacitors have
charged to an acceptable level, the control
board signals the input board to energize
the main input contactor making all three
phases of input power, without current limiting, available to the input capacitors. At
this point, the Power Wave 455 is in the
“Run Mode” of operation. If the capacitors
become under or overvoltage, the control
board will signal the input board to deenergize the main input contactor, and the
Power Wave 455 will be disabled.

POWER WAVE 455/POWER FEED 10

FIGURE E.5 — SWITCH BOARDS AND MAIN TRANSFORMER.
MAIN
TRANSFORMER

INPUT
CONTACTOR

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INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T

I
N
P
U
T

B
O
A
R
D

#1 AUX.
TRANS.

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OUTPUT
TERMINAL

PWM
DRIVE
S
W

PRIMARY
CURRENT
SENSOR

I
T

CAPACITOR
VOLTAGE
FEEDBACK

C
H

CHOKE

RIGHT
SWITCH
BOARD

CONTROL SIGNALS

CAPACITOR
VOLTAGE
FEEDBACK

PWM
DRIVE

OUTPUT
TERMINAL
THERMOSTATS

RECTIFIER
CURRENT FEEDBACK

65VDC
CONTROL BOARD
AUX.
RECONNECT

VOLTAGE FEEDBACK

#2AUX.
TRANS.
FAN
MOTOR

POWER
BOARD
40VDC

115VAC
RECEPTACLE

WIRE FEEDER
RECEPTACLE

RS232
CONN.

SWITCH BOARDS AND
MAIN TRANSFORMER

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CURRENT
SENSOR

LEFT
SWITCH
BOARD

PS
OW
WTI
EC
RH

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E-6

THEORY OF OPERATION

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E-6

There are two switch boards in the Power
Wave 455, each containing an input capacitor and insulated gate bipolar transistor
(IGBT) switching circuitry. Refer to Figure
E.5. When the machine reconnect switches
are configured for a lower input voltage
(below 300 VAC) the input capacitors are
connected in parallel. When the machine is
configured for higher input voltages (300
VAC and above) the input capacitors are
connected in series.
When the input capacitors are fully charged
they act as power supplies for the IGBT
switching circuit. The Insulated Gate
Bipolar Transistors switch the DC power,
from the input capacitors, “on and off” thus
supplying pulsed DC current to the main
transformer primary windings. See IGBT
Operation Discussion and Diagrams in
this section.

VOLTAGE THERMAL
LIGHT
SENSE
RECEPTACLE

STATUS
LIGHT

Each switch board feeds current to a separate, oppositely wound primary winding of
the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the
IGBT switch boards induce an AC square
wave output signal at the secondary of the
main transformer. These primary currents
are monitored by the current transformer
(CT). If the primary currents become abnormally high, the control board will shut off the
IGBTs, thus disabling machine output. The
DC current flow through each primary winding is clamped back to each respective
input capacitor when the IGBTs are turned
off. This is needed due to the inductance of
the transformer primary winding. The firing
of the two switch boards occurs during
halves of a 50 microsecond interval, creating a constant 20 kHz output.

POWER WAVE 455/POWER FEED 10

FIGURE E.6 — CONTROL BOARD.
MAIN
TRANSFORMER

INPUT
CONTACTOR

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INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T

I
N
P
U
T

B
O
A
R
D

#1 AUX.
TRANS.

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OUTPUT
TERMINAL

PWM
DRIVE
S
W

PRIMARY
CURRENT
SENSOR

I
T

CAPACITOR
VOLTAGE
FEEDBACK

C
H

CHOKE

RIGHT
SWITCH
BOARD

CONTROL SIGNALS

CAPACITOR
VOLTAGE
FEEDBACK

PWM
DRIVE

OUTPUT
TERMINAL
THERMOSTATS

RECTIFIER
CURRENT FEEDBACK

65VDC
CONTROL BOARD
AUX.
RECONNECT

VOLTAGE FEEDBACK

#2AUX.
TRANS.
FAN
MOTOR

POWER
BOARD
40VDC

115VAC
RECEPTACLE

WIRE FEEDER
RECEPTACLE

RS232
CONN.

CONTROL BOARD

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CURRENT
SENSOR

LEFT
SWITCH
BOARD

PS
OW
WTI
EC
RH

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E-7

THEORY OF OPERATION

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E-7

The control board performs the primary
interfacing functions to establish and maintain output control of the Power Wave 455.
Refer to Figure E.6. The control board
sends and receives digital command information through the wire feeder receptacle
and or the RS232 connector. The software
that is contained within the control board
processes and compares these commands
with the voltage and current feedback information it receives from the current sensor
and voltage sensing leads. The appropriate

VOLTAGE THERMAL
LIGHT
SENSE
RECEPTACLE

STATUS
LIGHT

pulse width modulation (PWM) signal (See
Pulse Width Modulation in this section) is
sent to the switch board IGBTs. In this
manner, the digitally controlled high-speed
welding waveform is created.
The control board also monitors the thermostats, main transformer primary current,
and capacitor voltage, and activates either
the thermal light and/or the status light.
Dependent upon the fault situation, the control board will either disable or reduce
machine output, or de-energize the main
input contactor.

POWER WAVE 455/POWER FEED 10

FIGURE E.7 — OUTPUT RECTIFIER AND CHOKE.
MAIN
TRANSFORMER

INPUT
CONTACTOR

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INPUT
RECTIFIER
R
E
C
O
N
N
E
C
T

I
N
P
U
T

B
O
A
R
D

#1 AUX.
TRANS.

S
W

PRIMARY
CURRENT
SENSOR

I
T

CAPACITOR
VOLTAGE
FEEDBACK

C
H

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CHOKE

RIGHT
SWITCH
BOARD

CONTROL SIGNALS

CAPACITOR
VOLTAGE
FEEDBACK

PWM
DRIVE

OUTPUT
TERMINAL
THERMOSTATS

RECTIFIER
CURRENT FEEDBACK

65VDC
CONTROL BOARD
AUX.
RECONNECT

VOLTAGE FEEDBACK

#2AUX.
TRANS.
FAN
MOTOR

POWER
BOARD
40VDC

115VAC
RECEPTACLE

WIRE FEEDER
RECEPTACLE

RS232
CONN.

The output rectifier receives the AC output
from the main transformer secondary and

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OUTPUT
TERMINAL

PWM
DRIVE

OUTPUT RECTIFIER
AND CHOKE

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CURRENT
SENSOR

LEFT
SWITCH
BOARD

PS
OW
WTI
EC
RH

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E-8

THEORY OF OPERATION

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E-8

VOLTAGE THERMAL
LIGHT
SENSE
RECEPTACLE

STATUS
LIGHT

rectifies it to a DC voltage level. Since the
output choke is in series with the negative
leg of the output rectifier and also in series
with the welding load, a filtered DC output is
applied to the machine output terminals.
Refer to Figure E.7.

POWER WAVE 455/POWER FEED 10

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E-9

THEORY OF OPERATION
THERMAL PROTECTION
Two normally closed (NC) thermostats protect the machine from excessive operating
temperatures. These thermostats are wired
in series and are connected to the control
board. One of the thermostats is located on
the heat sink of the output rectifier and the
other is located near the fan. (On later production machines this thermostat is located
on the output choke) Excessive temperatures may be caused by a lack of cooling air
or operating the machine beyond its duty
cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the
machine. The yellow thermal light, located
on the front of the machine, will be illuminated. The thermostats are self-resetting once
the machine cools sufficiently. If the thermostat shutdown was caused by excessive
output or duty cycle and the fan is operating
normally, the power switch may be left on
and the reset should occur within a 15minute period. If the fan is not turning or
the air intake louvers are obstructed, then
the power must be removed from the
machine, and the fan problem or air
obstruction corrected. On later production
machines (above code 10500) the cooling
fan runs only when necessary. The F.A.N.
(fan as needed) system is controlled by the
control board via a solid state relay.

E-9

OVER CURRENT
PROTECTION
If the average current exceeds 590 amps,
then the peak current will be limited to 100
amps until the average current decreases to
under 50 amps.

UNDER/OVER VOLTAGE
PROTECTION
A protective circuit is included on the
control board to monitor the voltage across
the input capacitors. In the event that a
capacitor voltage is too high, or too low, the
protection circuit will de-energize the input
contactor. Machine output will be disabled
and the “soft start” mode will be repeated.
The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required.
(May be required if machine has been
off for a long period of time and is connected for high input voltage operation.)
2. Voltage across a capacitor exceeds
390 volts. (High line surges or improper input voltage connections.)
3. Voltage across a capacitor is under 70
volts. (Due to improper input voltage
connections.)

PROTECTIVE CIRCUITS
4. Internal component damage.
Protective circuits are designed into the
Power Wave 455 to sense trouble and shut
down the machine before damage occurs to
the machine's internal components.

POWER WAVE 455/POWER FEED 10

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E-10

FIGURE E.8 — IGBT OPERATION.
POSITIVE
VOLTAGE
APPLIED

SOURCE
n+

GATE

BODY REGION

DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER

n+
P+

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DRAIN

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E-10

THEORY OF OPERATION

SOURCE
n+

nn+
P+

GATE

BODY REGION
DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER

DRAIN

A. PASSIVE

B. ACTIVE

INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
An IGBT is a type of transistor. IGBT are
semiconductors well suited for high frequency switching and high current applications.
Example A in Figure E.8 shows an IGBT in
passive mode. There is no gate signal, zero
volts relative to the source, and therefore,
no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components

connected to the source. The circuit is
turned OFF like a light switch.
Example B shows the IGBT in an active
mode. When the gate signal , a positive DC
voltage relative to the source, is applied to
the gate terminal of the IGBT, it is capable
of conducting current. A voltage supply connected to the drain terminal will allow the
IGBT to conduct and supply current to the
circuit components coupled to the source.
Current will flow through the conducting
IGBT to downstream components as long
as the positive gate signal is present. This is
similar to turning ON a light switch.

POWER WAVE 455/POWER FEED 10

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E-11

THEORY OF OPERATION
FIGURE E.9 — TYPICAL IGBT OUTPUTS.
(+)

(-)
1 µsec

48 µsec

1 µsec

50 µsec

MINIMUM OUTPUT

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(+)

(-)

24 µsec
2 µsec

24 µsec
50 µsec

MAXIMUM OUTPUT

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The term Pulse Width Modulation is used to
describe how much time is devoted to conduction in the positive and negative portions
of the cycle. Changing the pulse width is
known as modulation. Pulse Width
Modulation (PWM) is the varying of the
pulse width over the allowed range of a
cycle to affect the output of the machine.

MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the cycle. The top
drawing in Figure E.9 shows the minimum
output signal possible over a 50-microsecond time period.

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PULSE WIDTH
MODULATION

microsecond. The negative portion is the
other IGBT group1. The dwell time (off time)
is 48 microseconds (both IGBT groups off).
Since only two microseconds of the 50microsecond time period is devoted to conducting, the output power is minimized.

MAXIMUM OUTPUT
By holding the gate signal on for 24
microseconds each, and allowing only two
microseconds of dwell time (off time) during
the 50-microsecond cycle, the output is
maximized. The darkened area under the
top curve can be compared to the area
under the bottom curve. The more dark
area that is under the curve indicates that
more power is present.
1An IGBT group consists of two IGBT
modules feeding one transformer primary
winding.

The positive portion of the signal represents
one IGBT group 1 conducting for one

POWER WAVE 455/POWER FEED 10

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E-12

FIGURE E.10 — CONTROL BOX (USER INTERFACE).
DISPLAY AND
ENCODER PANEL
(STANDARD)
STATUS
LED

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DIP
SWITCHES

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E-12

THEORY OF OPERATION

NETWORK
CONNECTOR
(INTERNAL)

USER
INTERFACE
MOTHERBOARD

AMPHENOL-INPUT
NETWORK RECEPTACLE
(OPTIONAL)

CONTROL BOX
(USER INTERFACE)
The system Control Box is the main entry
point for all system parameters, and from it
the user can control both power source and
wire feeder functions. Refer to Figure E.10.
The user interface motherboard is the heart
of the Control Box. Dependent upon the
option panels and the information received
through the network cable, it directs the
entire system as to the options, wire feed
speed, and weld cycle requirements and
parameters.
The options are divided into two physical
size categories. The smaller option, typically installed in the middle section of the control box, is dedicated to dual procedure,
head selection, and memory related functions. The larger, or bottom section, is
reserved for control of the setup functions
for the power source (Power Wave 455)
and wire drive (Power Feeder 10) such as
mode, arc control, run in and timer set up.

SMALL
PANEL
OPTIONS

LARGE
PANEL
OPTIONS

AMPHENOL-OUTPUT
NETWORK RECEPTACLE
(OPTIONAL)
In addition to the large and smaller size
options, there is a Display Panel which is
standard on the Control Box unit. The
Display Panel, typically installed in the
upper position of the Control Box assembly,
houses the encoder controls and the STATUS LED. The controls are used to adjust
the wire feed speed, current, voltage and
trim parameters. The STATUS LED is
designed to blink a red and green code if a
fault should occur.
The internal Network Connector is used
when the Control Box is mounted on either
the power source or the wire drive units.
See System Diagram A and System
Diagram B in this section.
The optional Network Input and Output
receptacles are utilized when the Control
Box assembly is mounted independently
from both the wire drive and power source.
See System Diagram C in this section.
There are two DIP switch banks located on
the motherboard. They are labeled S1 and
S2 and are used to set display, trigger,
acceleration and run in functions.

POWER WAVE 455/POWER FEED 10

FIGURE E.11 — POWER FEED 10 FEED HEAD.
VOLTAGE
SENSE
LEAD #67A

LEAD #67
DRIVE
MOTOR

TO POWER
SOURCE OR
CONTROL
BOX

CONTROL BOARD
FEEDBACK

STATUS LED

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GUN TRIGGER AND
DUAL PROCEDURE
RECEPTACLE

INPUT
NETWORK
RECEPTACLE
NETWORK
CONNECTOR
(INTERNAL)

2-STEP/
4-STEP
GAS
COLD
SOLENOID
INCH/
GAS
PURGE

NETWORK
OUTPUT
RECEPTACLE
(OPTIONAL)

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POWER FEED 10
FEED HEAD

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TACH

GEAR BOX
AND
CONDUCTOR
BLOCK

SHUTDOWN

DIP SWITCH

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E-13

THEORY OF OPERATION

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E-13

The Power Feed 10 is a four roll, high performance, digitally controlled, modular wire
feeder that operates on 40 VDC input
power. It is designed to be part of a modular, multi-process welding system. Refer to
Figure E.11.
Network communications, intelligence, PC
board input power, and arc voltage feedback is received and transmitted through
the input network receptacle. The internal
network connector plug is utilized when the
Control Box is mounted directly to the wire
drive unit. See System Diagram A in this
section. The optional network output receptacle is used when the system components
are connected in a daisy-chain fashion.
The feed drive control board processes the
information it receives from the various user
operated switches such as the gun trigger,
2-step/4-step, and cold inch switches and
sends this information to other system components. This information is evaluated and

the correct commands are transmitted to
the feed drive. The feed drive control board
then sends the signals to energize the
active components such as the solenoid
and wire drive motor. The tach feedback
signal is processed on the control board
which regulates the motor armature voltage
so as to maintain the required wire feed
speed.
When the gun trigger is pulled, the voltage
sense board relays the electrode sense signal to the input network receptacle for processing by the Control Box.
The optional shutdown feature can be
implemented as a means of stopping the
wire feeding in the event that the water
cooler (if used) is not turned on.
The STATUS LED is designed to blink a red
and green code if a fault should occur.
There is one DIP switch bank located on the
wire drive control board. It is labeled S1
and is used to set gear ratios, arc polarity,
and for network identification purposes.

POWER WAVE 455/POWER FEED 10

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E-14

NOTES

POWER WAVE 455/POWER FEED 10

E-14

TROUBLESHOOTING AND REPAIR

SECTION F-1

TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTIONTroubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-5
Power Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-5
Power Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-13
Power Wave 455 Control Board LED Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-22
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-23
Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-23
Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-25
Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-29
Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-31
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-35
Auxiliary Transformer No. 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-37
Auxiliary Transformer No. 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-39
Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-43
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-47
Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-51
Tach Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-53
Voltage Sense PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-55
Dual Encoder PC Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-57
Control Cable Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-59
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-61
Gas Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-61
Wire Feeder Control Board Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-63
Tach (Hall Effect) Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-65
Gear Box and Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-67
Switch Board and Filter Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
F-71
Meter Accuracy Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-74
Control or Power Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-75
Auxiliary Transformer No. 1 Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . .
F-79
Main Input Contactor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-83
Input Rectifier Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-87
Output Rectifier and Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-89
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-93
Power Source Error Interpretation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-93
Performance Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-94
Functional Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-95

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SECTION F-1

POWER WAVE 455/POWER FEED 10

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F-2

TROUBLESHOOTING AND REPAIR

F-2

HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual.

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

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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
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: function problems, feeding problems, and welding problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION.
The last column labeled “RECOMMENDED
COURSE OF ACTION” lists the most likely
components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either good or bad. If there
are a number of possible components,
check the components in the order listed to
eliminate one possibility at a time until you
locate the cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical
troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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

POWER WAVE 455/POWER FEED 10

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F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

ELECTRIC SHOCK
can kill.
Have an electrician install
and service this equipment.
Turn the input power OFF
at the fuse box before
working on equipment. Do
not touch electrically hot
parts.

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CAUTION
Sometimes machine failures appear to be
due to PC board failures. These problems
can sometimes be traced to poor electrical
connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:

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

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1. Determine to the best of your technical
ability that the PC board is the most
likely component causing the failure
symptom.
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PC board can be
damaged by static
electricity.

WARNING

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

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F-3

2. Check for loose connections at the PC
board to assure that the PC board is
properly connected.
3. If the problem persists, replace the suspect PC board using standard practices
to avoid static electrical damage and
electrical shock. Read the warning
inside the static resistant bag and perform the following procedures:

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy

- Remove your body’s
static charge before
opening the staticshielding bag. Wear an
anti-static wrist strap.
For safety, use a 1 Meg
ohm resistive cord connected to a grounded
part of the equipment
frame.

- If you don’t have a
wrist strap, touch an unpainted, grounded,
part of the equipment frame. Keep touching
the frame to prevent static build-up. Be sure
not to touch any electrically live parts at the
same time.
- Tools which come in contact with the PC
board must be either conductive, anti-static
or static-dissipative.
- Remove the PC board from the staticshielding bag and place it directly into the
equipment. Don’t set the PC board on or
near paper, plastic or cloth which could
have a static charge. If the PC board cannot
be installed immediately, put it back in the
static-shielding bag.
- If the PC board uses protective shorting
jumpers, don’t remove them until installation
is complete.
- If you return a PC board to the Lincoln
Electric Company for credit, it must be in
the static-shielding bag. This will prevent
further damage and allow proper failure
analysis.

POWER WAVE 455/POWER FEED 10

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F-4

TROUBLESHOOTING AND REPAIR
4. Test the machine to determine if the
failure symptom has been corrected by
the replacement PC board.
NOTE: It is desirable to have a spare
(known good) PC board available for PC
board troubleshooting.
NOTE: Allow the machine to heat up so
that all electrical components can reach
their operating temperature.

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5. Remove the replacement PC board and
substitute it with the original PC board
to recreate the original problem.
NOTE: Do not substitute boards that show
physical damage.

F-4

harness, junction blocks, and terminal strips.
b. If the original problem is recreated
by the substitution of the original
board, then the PC board was the
problem. Reinstall the replacement
PC board and test the machine.
6. Always indicate that this procedure was
followed when warranty reports are to
be submitted.
NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY
PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

a. If the original problem does not reappear by substituting the original
board, then the PC board was not
the problem. Continue to look for
bad connections in the control wiring

POWER WAVE 455/POWER FEED 10

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F-5

TROUBLESHOOTING AND REPAIR

TROUBLESHOOTING GUIDE
POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS

RECOMMENDED
COURSE OF ACTION

Major physical or electrical damage is evident when the sheet
metal cover(s) are removed.

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

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

The machine is dead -- no output -no fan -- no LEDs.

1. Make certain the input power
switch SW1 is in the ON position.

1. Check the input power switch
(SW1) for proper operation.
Also check the associated leads
for loose or faulty connections.
See wiring diagram.

2. Check the main input fuses. If
open, replace.

2. Check CB4 for proper operation.
3. Check the 6 amp circuit breaker
(CB4). Reset if tripped.
4. Make certain the reconnect
panel is configured correctly for
the applied input voltage.

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The main input fuses (or breaker)
repeatedly fail.

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F-5

1. Make certain the fuses or breakers are properly sized.
2. Make certain the reconnect
panel is configured properly for
the applied input voltage.
3. The welding procedure may be
drawing too much input current
or the duty cycle may be too
high. Reduce the welding current and/or reduce the duty
cycle.

3. Perform the T1 Auxiliary
Transformer Test.
4. Perform the Power Board Test.

1. Check the reconnect switches
and associated wiring. See
wiring diagram.
2. Perform the Input Rectifier
Test.
3. Perform the Switch Board
Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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TROUBLESHOOTING AND REPAIR

F-6

POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)

The Power Wave has no output -the fan is running -- a “clicking”
sound may be heard coming from
the machine. The main contactor
CR1 is not “pulling in”. If the
STATUS LED is not steady green,
see LED Code Table.

1. Turn the input power OFF
immediately.

1. Perform the T1 Auxiliary
Transformer Test.

2. Make certain the reconnect
panel is configured correctly for
the applied input voltage.

2. Perform the Main Contactor
Test.

3. If the machine is connected for
380 VAC or higher and has not
been used for a long period of
time, the capacitors may require
“conditioning”. Let the Power
Wave 455 run at an idle state
for 30 minutes.

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F-6

3. Perform the Input Rectifier
Test.
4. Perform the Switch Board
Test.
5. The power board rectifier may
be faulty. Check or replace.
Also check associated wiring.
See wiring diagram.
6. Perform the Power Board Test.
7. The input voltage board may be
faulty.

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8. The control board may be faulty.
The fan runs slow or intermittently
-- low or no weld output.

1. Make certain the reconnect
panel is configured correctly.

1. Perform the T1 Auxiliary
Transformer Test.
2. The power board rectifier may
be faulty. Check or replace.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-7

TROUBLESHOOTING AND REPAIR

F-7

POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)

The thermal LED is lit. The
machine regularly overheats.

1. Welding application may exceed
recommended duty cycle.

1. One of the thermostats may be
faulty. Check or replace. See
wiring diagram.

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2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the Maintenance Section of this manual.
3. Air intake and exhaust louvers
may be blocked due to inadequate
clearance
around
machine.
4. Make sure the fan is functioning
correctly.
The Auxiliary Receptacle is “dead”.
The 115 VAC is missing.

1. Check the 10 amp circuit breaker (CB2) located on the case
front. Reset if necessary.

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2. Check the 10 amp circuit breaker (CB3) located in the reconnect area. Reset if necessary.
The Power Wave 455 won’t produce full output.

1. The input voltage may be too
low, limiting the output capability
of the Power Wave 455. Make
certain the input voltage is proper for the machine and reconnect panel configuration.
2. Make sure all three phases of
input power are being applied to
the machine.

1. Check the receptacle and associated wiring for loose or faulty
connections. See wiring diagram. (Plugs P80 and P81)
2. Perform the Auxiliary Transformer T2 Test.
1. Perform the Output Rectifier
Test.
2. Perform the Power Board Test.
3. Compare the display voltage
reading with an actual voltage
reading at the output terminals.
If the discrepancy is greater
than two volts the control board
may be faulty.

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4. Perform the Current Transducer Test.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-8

TROUBLESHOOTING AND REPAIR

F-8

POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELDING PROBLEMS

RECOMMENDED
COURSE OF ACTION

For no apparent reason, the welding characteristics have changed.

1. Check for proper wire feed
speed setting. In the MIG/MAG
and FCAW modes, check for
proper voltage settings. In the
MIG/MAG pulse modes, check
the arc length trim setting.
These controls are on the
Control Box (user interface).

1. If zero arc voltage is displayed
on the Control Box while welding, the voltage sense leads
may be broken. Check lead #67
at the wire drive. See wiring
diagram. Also check leads
#202 (Neg. output terminal) and
#206 (Pos. output terminal).
See Power Wave 455 wiring
diagram. If external voltage
sensing is utilized, check the
#21 lead between the 4-pin
receptacle on the Power Wave
455 and the workpeice.

2. Check for proper shielding gas
and gas flow.
3. Check for loose or faulty welding cables and connections.

2. Perform the Output Rectifier
Test.
3. The control board may be faulty.

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4. Perform the Current Transducer Test.
The machine often “noodle welds”
with a particular procedure.

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1. Perform the Current Transducer Test.
2. The control board may be faulty.

Power Wave 455 - When the
average output current exceeds
570 amps, the output current is
phased back to 100 amps.
The arc burns back to the tip.

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1. The machine may be trying to
deliver too much power. When
the average output current
exceeds a maximum limit, the
machine will “phase back” to
protect itself. Adjust the procedure or reduce the load to lower
the current draw from the Power
Wave 455 machine.

1. The voltage settings may be too
high for the procedure.

1. Perform the Voltage Sense PC
Board Test.

2. The voltage sensing lead or connection may be faulty. See the
Power Feed 10 Wiring Diagram

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-9

TROUBLESHOOTING AND REPAIR

POWER WAVE
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS

RECOMMENDED
COURSE OF ACTION

The wire feeder won’t work. No
lights. Apparently the wire feeder
is not being powered-up.

1. Make certain the Power Wave
455 is turned on.

1. Check for 40 VDC on pin “D” (+)
and pin “E” (-) at the Power
Wave 455 wire feeder receptacle. See wiring diagram.

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2. Check circuit breaker CB1 located on the case front of the
Power Wave 455. Reset if necessary.

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F-9

3. Check the 6 amp circuit breaker
(CB4) located on the reconnect
panel. Reset if necessary.
4. Check the control cable
between the power source and
the wire feeder.
Check for loose or broken connections. Check continuity on
all five leads from one end to
the other.

If 40 volts DC is not present at
the Power Wave wire feeder
receptacle, perform the Power
Board Test.
2. Check the power board rectifier.
See wiring diagram.
3. Perform the T1 Auxiliary
Transformer Test.
4. If the 40 volts DC is present at
the Power Wave wire feeder
receptacle, the problem is in
the control cable or the
wire drive/control box. See
Wire Drive/Control Box
Troubleshooting.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-10

TROUBLESHOOTING AND REPAIR

F-10

POWER WAVE 455 STATUS LED CHART
STATUS LED
CONDITION

POSSIBLE FAULT(S)

LED is solid green (not blinking)

System operating normally.

LED is solid red

-- Indicates that nothing is connected to the wire feeder receptacle.
Connect a control cable to the Power Wave 455 wire feeder receptacle.
The other end of the control cable must be connected to either a
Control Box or wire drive unit.

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-- The control cable may be faulty. Check continuity on all five leads from
end to end in the control cable.
-- The wire drive and/or Control Box may not be properly configured or
connected together. See Installation section of Power Feed 10
Instruction Manual.
-- If the wire drive unit and Control Box are properly configured, consult
the Status LED Error Code Table.
LED is solid red (not blinking)

-- The Power Wave 455 cannot communicate with the wire drive unit
and/or the Control Box due to a problem within the Power Wave 455.
Consult the three column Troubleshooting Guide.
-- The welding software may be corrupt. Contact the Lincoln Electric
Service Department.

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LED is blinking red and green

-- If the Thermal LED is also lit, consult the Power Wave three column
Troubleshooting Guide “Thermal LED is lit”.
-- The input voltage is too high or too low. Make certain the input voltage
is proper according to the rating plate located on the rear of the Power
Wave 455.
-- The Power Wave 455 is having trouble communicating with the wire
drive or control box. Turn the Power Wave 455 off. Disconnect the
control cable from the wire feeder receptacle on the power source.
Turn the Power Wave 455 on. If the status LED then blinks green, the
problem is external to the power source. If the LED is still blinking red
and green, consult Status LED Error Code Table.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-11

TROUBLESHOOTING AND REPAIR

F-11

STATUS LED ERROR CODE TABLE
NOTE: The error code signal sequence is always preceeded by a 2 second green light. If more than one error
code is present, a 4 second off signal will separate the individual error code signals. Note that the [2 sec.green]
is only displayed at the beginning of the entire code sequence, not between codes if more than one error code is
present.
Example: (Code. #11 “one long red” followed by “one short red”) followed by (Code. #21 “two long reds”
followed by “one short red”).

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[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [4.0 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

DIGITAL COMMUNICATION ERROR CODE LED
ERRORS
SEQUENCE
#11 CAN bus off (Excessive
number of communication errors).

[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

#12 Ul time out (Loss of communication to control box).

[2 sec.green] [1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off]
[0.4 sec.red]

WELDING FILE ERRORS

ERROR CODE LED SEQUENCE

#21 Unprogrammed mode

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
[0.4 sec.red]

#22 Empty weld table

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

#23 Weld table check sum (table is
corrupt)

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [1.6 sec.off]
[0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-12

TROUBLESHOOTING AND REPAIR

F-12

STATUS LED ERROR CODE TABLE (Continued)
POWER SOURCE
ERRORS

ERROR CODE
LED SEQUENCE

#31 Primary over current

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red]

#32 Capacitor “A” under voltage

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

#33 Capacitor “B” under voltage

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red]

#34 Capacitor “A” over voltage

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]

#35 Capacitor “B” over voltage

[2 sec.green] [1.2 sec.red] [0.4 sec.off] [1.2 sec.red] [0.4 sec.off]
[1.2 sec.red] [1.6 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red]
[0.4 sec.off] [0.4 sec.red] [0.4 sec.off] [0.4 sec.red] [0.4 sec.off]
[0.4 sec.red]

#36 Thermal overload

#37 Machine failed soft start

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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TROUBLESHOOTING AND REPAIR

F-13

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS

RECOMMENDED
COURSE OF ACTION

Major physical or electrical damage is evident when the sheet
metal cover(s) are removed.

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

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

No wire feed, solenoid or arc voltage. The STATUS LEDs are
steady green.

1. The gun trigger may be faulty.
Check or replace.

1. Check the continuity of leads
#556 and #557 from the gun
trigger receptacle to plug J5
pins #11 and #12. See wire
drive wiring diagram.

2. Make certain the Control Box is
configured for a wire feeding
mode.

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F-13

3. Check option panel connections and switch(s) for proper
operation.

No control of wire feed speed. All
STATUS LEDs are steady green.
The preset wire feed speed is
adjustable on the Control Box.

1. Check for a mechanical restriction in the wire feed path.

No welding arc voltage when the
gun trigger is activated. The wire
feeds normally and the gas solenoid functions properly. The
STATUS LEDs are steady green
on the wire drive unit and the
Contol Box.

1. The power source may unable
to produce welding output due
to a thermal fault or other malfunction. Check STATUS LED
on Power Wave 455 machine.
See Power Wave 455
Troubleshooting.

2. The wire drive control board
may be faulty.
3. The Control Box control board
may be faulty.
1. Perform the Tach Feedback
Test.
2. The wire drive control board
may be faulty.
1. Make certain the Power Wave
455 power source is functioning correctly.
2. The wire drive control board
may be faulty.
3. The Control Box control board
may be faulty.

The wire feed speed does not
change when welding current is
established. The WFS stays at the
run-in speed. The STATUS LEDs
are steady green.

1. The run in and weld wire feed
speeds may be set to the same
value. Set run in speed to a
value that gives best starting
results.

1. Perform the Current Transducer Test.
2. If the run in wire feed speed
cannot be adjusted, perform the
Tach Feedback Test and also
the Drive Motor Test.
3. The wire drive control board
may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-14

TROUBLESHOOTING AND REPAIR

F-14

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)

The purge switch on the wire drive
unit does not activate the gas solenoid, but gun trigger closure in the
MIG or Pulse modes does acitvate
the solenoid. The LEDs are steady
green on the power source,
Control Box and wire drive unit.

1. Make certain the COLD
INCH/GAS PURGE switch is
operating properly.

The COLD INCH/GAS PURGE
switch does not turn on the wire
drive motor but gun trigger closure
in the MIG or Pulse modes does
activate the wire drive motor. The
LEDs are steady green on the
power source, Control Box and
wire drive unit.

1. Make certain the COLD
INCH/GAS PURGE switch is
operating properly.

The voltmeter on the Control Box
does not function properly even
though the STATUS LEDS are
steady green.

1. Make sure the DIP switches are
configured correctly for the welding polarity being used. See
Setting DIP Switches in the
Wire Drive in the Installation
section of this manual.

2. Check for loose or faulty leads
between COLD INCH/GAS
PURGE switch and the wire
drive control board. See wiring
diagram.

2. Check for loose or faulty leads
between the COLD INCH/GAS
PURGE switch and the wire
drive control board. See wiring
diagram.

2. Check the #67 lead on the wire
drive unit. Make sure it is connected to the motor gear box
and also the voltage sense PC
board.
3. Check the work sensing leads
on the Power Wave 455 power
source. Check leads #202
(Neg. output terminal) and #206
(Pos. output terminal). See
Power Wave 455 wiring diagram. If external voltage sensing is utilized, check the #21
lead between the 4-pin receptacle on the front of the Power
Wave 455 and the workpiece.

1. If the COLD INCH/GAS PURGE
switch is operating correctly and
the associated leads are OK,
the wire drive control board may
be faulty.

1. Check leads #512B and #511
from plug J4 on the wire drive
control board to the voltage
sense PC board.
2. Perform the Voltage Sense
Board Test.
3. The display board may be
faulty.
4. The wire drive control board
may be faulty.
5. The Control Box control board
may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-15

TROUBLESHOOTING AND REPAIR

F-15

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)

The ammeter on the Control Box
does not function properly even
though the STATUS LEDs are
steady green.

1. Make sure the DIP switches are
configured correctly for the
welding process and polarity
being used. See Setting DIP
Switches in the Wire Drive in
the Installation section of this
manual.

1. Perform the Current Transducer Test.
2. The display board, located in
the control box, may be faulty.
3. The control board, located in the
power source, may be faulty.

2. Check the following connections
on the Power Wave 455
machine. Check for loose or
faulty connections between plug
J90 at the current transducer
and plug J21 on the Power
Wave 455 control board.
The display and/or indicator LEDs
do not change when their corresponding switches and or knobs
are activated or turned.

1. Check for loose or faulty connections between the encoder
panel and the Control Box control board.
2. Check for loose or faulty connections between the appropriate switches and the Control
Box control board.

The mode and/or settings change
while welding under normal conditions.

1. Contact the Lincoln Electric service dept. for possible software
updates
1-800-833-9353.
(Please ref. your current software number.)

The feeder resets when the gun
trigger is activated. The LEDs blink
and the displays are intermittent.

1. The auxiliary reconnect (Lead
“A”) may not be configured correctly. See Figure A.2. in the
Installation Section of this manual.

1. Check suspected potentiometer
and/or switches for correct
resistances and operation.
2. Perform the Encoder PC Board
Test.
3. The Control Box control board
may be faulty.

1. Perform the Power Board Test.
2. Perform
the
Auxiliary
Transformer Test #1.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

Return to Master TOC

TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)

The displays are blank (not lit). The
wire feeds when the gun trigger is
activated.

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F-16

POWER FEED

1. Check for loose or faulty connections at plug J1 on the display board, to plug J4 on the
Control Box control board.

1. Check for 12 VDC at plug J1 pin
7 (lead #512+) to plug J1 pin 8
(lead #500-) on the display
board. If the 12 VDC is present,
then the display board may be
faulty.
2. If the 12 VDC is low or not present, check for loose or faulty
connections on leads #512 and
#500.
3. The Control Box control board
may be faulty.

The dual procedure is not functional when using the remote Dual
Prodedure switch. The STATUS
LEDs are steady green on the
power source, Control Box and
wire drive units.

1. Make certain the the bat switch
on the Dual Procedure Panel is
in the middle position. This
enables the gun remote dual
procedure switch.

1. The remote Dual Procedure
switch may be faulty. Check
switch and associated leads.
2. The local dual procedure switch
may be faulty.
Remove power to the machine.
Disconnect plug J5 from the
Control Box control board.
Check for continuity (less than
one ohm) between pins 1 and 7
when the Dual Procedure switch
is in position “A”. Next check for
continuity (less than one ohm)
between pins 1 and 8 when the
Dual Procedure switch is in the
“B” position. If either of these
continuity tests fail, replace the
switch. When the switch is in
the center postion there should
not be any continuity between
pins.

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F-16

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3. The Control Box control board
may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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TROUBLESHOOTING AND REPAIR

F-17

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)

The Dual Procedure is not functioning when using the local Dual
Procedure switch on the Control
Box. The STATUS LEDs are
steady green on the power source,
Control Box and wire drive units.

1. Check the leads and plug J5
between the switch and the
Control Box control board for
loose or faulty connections.
See wiring diagram.

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F-17

1. The local dual procedure switch
may be faulty.
Remove power to the machine.
Disconnect plug J5 from the
Control Box control board.
Check for continuity (less than
one ohm) between pins 1 and 7
when the Dual Procedure switch
is in position “A”. Next check for
continuity (less than one ohm)
between pins 1 and 8 when the
Dual Procedure switch is in the
“B” position. If either of these
continuity tests fail, replace the
switch. When the switch is in
the center position, there should
not be any continuity between
pins.

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2. The Control Box control board
may be faulty.
The wire feed speed is consistent
and adjustable, but runs at the
wrong speed.

1. The DIP switch on the wire drive
unit may not be set for the correct gear ratio. See the Installation section of this manual.

1. The wire drive control board
may be faulty.

The unit shuts off while welding or
attempting to weld. The STATUS
LED is alternating between red and
green every second. The unit tries
to recover after 30 seconds and
may repeat sequence.

1. The shut down circuit in the
wire drive unit may be electrically “open”. Make sure leads
#570 and #571 are connected
together.

1. Disconnect any shutdown
device from leads #570 and
#571 (0.25 in. insulated tab terminals). Connect leads #570
and #571 together. If the feeder
STATUS LED is now steady
green, the problem is in the
external shutdown circuit.

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2. The drive motor may be over
loaded due to a mechanial
restriction in the wire feeding
path. See Operation section of
this manual.

2. If there are no restrictions in the
wire feeding path, the drive
motor or gear box may be faulty.
3. The wire drive control board
may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-18

TROUBLESHOOTING AND REPAIR

F-18

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
RECOMMENDED
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS (Continued)

When the gun trigger is activated,
the drive rolls do not turn. The arc
voltage is present and the solenoid
is energized. The STATUS LEDs
are steady green.

1. Check plug J3 on the wire drive
control board, and leads #550
and #551 for loose or faulty connections. See wiring diagram.

1. Perform the Drive Motor Test.

The wire is feeding rough or not
feeding, but the drive rolls are
turning.

1. The drive roll pressure may be
incorrect. Set drive roll pressure. See Operation section in
this manual.

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

2. The wire drive control board
may be faulty.

2. Check for dirty or rusty electrode wire.
3. Make sure the drive rolls and
wire guides are positioned and
installed correctly. See Operation section of this manual.

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4. Check for mechanical restrictions in the wire feeding path.
When in CC modes with the
optional “MX” or “MSP” panels, the
output does not energize.

1. Rotate Volts/Trim encoder knob
at least 45° clockwise. This is
normal. See Accessories section for detailed operation.

1. Check option panel installation
for loose or faulty connections.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-19

TROUBLESHOOTING AND REPAIR

F-19

POWER FEED
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELDING PROBLEMS

RECOMMENDED
COURSE OF ACTION

The gun tip seizes in diffuser.

1. The tip may be overheating due
to prolonged or excessive high
current and /or duty cycle. Do
not exceed the current and duty
cycle rating of the gun.

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

2. A light application of high temperature antiseize lubricant
(such as Graphite Grease) may
be applied to tip threads.
Poor arc striking with sticking or
“blast-offs”. The weld bead may
be narrow and ropy with weld
porosity.

1. Make sure the weld procedures
are correct for the process being
used. Check gas, wire feed,
speed and arc voltage.

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

2. Remove the gun liner and check
the rubber seal for any sign of
deterioration or damage. Be
sure the set screw in the connector block is in place and
tightened against the liner
bushing.
3. Check the welding cables for
loose or faulty connections.
The arc is variable and/or hunting.
The power source, Control Box
and drive units seem to be operating properly.

1. Check the contact tip. It may be
worn or the wrong size for the
electrode wire being used.

1. Contact the Lincoln Electric
Service Department, 216-3832531 or 1-800-833-9353
(WELD).

2. Check for loose or faulty welding cables and connections.

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3. Make sure the weld procedures
are correct for the process being
used. Check gas, wire feed
speed and arc voltage.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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TROUBLESHOOTING AND REPAIR

F-20

POWER FEED ERROR CODE CHART
DISPLAYED
CODE

POSSIBLE CAUSE
RECOMMENDED
(FAULT)
COURSE OF ACTION
CONTROL BOX/WIRE DRIVE ERROR CODE CHART

Err 011

More than one control box has the
same group number.

Make sure the group DIP switch
setting is unique for each Control
Box. See Installation section of
this manual.

Err 003

There are too many objects in the
group.

A given group can support a maximun of seven objects. Remove
any objects over seven either by
changing the group DIP switch settings or physically disconnecting
the “extra” objects. See Installation section of this manual.

Err 004

More than one object of the same
equipment type with the same
group number and feed head number.

Adjust the DIP switch setting to
make either the group number or
the feed head number unique for all
objects of the same equipment
type. See Installation section of
this manual.

Err 005

A wire drive unit has its DIP switches set to zero. It is in a group that
has more than one object.

The appropriate wire drive numbers
are 1 through 7. Check the DIP
switch setting chart in the Installation section of this manual.

Err 006

The unit did not receive a recognition command from the power
source.

Check to see if the STATUS LED on
the Power Wave 455 is not steady
green. If it is not steady green, refer
to the Power Wave 455 Status
LED Chart and Code Table. Check
the control cables for loose or faulty
connections. Also check the continuity of all five leads from one end
to the other. The control board in the
PW 455 may be faulty.

Err 020

An attempt was made to reprogram
the Control Box or the wire drive
unit, but the program did not verify.

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F-20

Check for potential electrical high
frequency noise in the surrounding
area. Remove any potential HF
noise and program the unit again.
If the Err 020 still occurs, either
replace the EEPROM chip(s) in the
board being programmed or
replace the entire PC board being
programmed.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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TROUBLESHOOTING AND REPAIR

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F-21

POWER FEED ERROR CODE CHART
Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
CONTROL BOX/WIRE DRIVE ERROR CODE CHART (Continued)
Err 100

For some reason the Power Wave
455 issued a shutdown command.

See Err 006 in this chart.

Err 200

No response from the Power Wave
455.

See Err 006 in this chart.

Err 201

No response from either the
Control Box or wire feed unit.

If this condition occurs while welding, the status LED should be flashing red on the problem unit.
Otherwise, check for any units that
are flashing green. This indicates
that the particular unit has not been
recognized and there is a power
source problem. See Power Wave
455 Troubleshooting. If the STATUS LED is either flashing red or
steady red, there may be a fault in
the control cable(s).

Err 210

EEPROM error

The parameter(s) recalled at power
up was out of range. Rotate
Encoder Knob to reset. Check all
settings before proceeding to weld.
If this condition persists, replace
the Control Box control board.

Err 211

A microprocessor RAM error
occurred in the Control Box.

Remove the input power. Wait five
seconds. Turn power on. If Err
211 is displayed again, the Control
Box control board may be faulty.

- - - (three dashes)

Appears on the control box display.

This is an indication that constant
current such as STICK or GOUGE
mode has been selected. Turning
the right encoder clockwise when in
this state will activate output from
the Power Wave 455. Turning the
right encoder counterclockwise will
deactivate output.

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F-21

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

----------------------------------------------------------------------------------------------------------------------------POWER WAVE 455/POWER FEED 10

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F-22

NOTES
PW 455 CONTROL BOARD LED DEFINITIONS
LED COLOR AND NUMBER

CIRCUIT INDICATORS

Green LED 1

-15 VDC Supply

Green LED 3

+15 VDC Supply

Green LED 4

+5 VDC Supply

Red LED 5

On when jumper removed from J26

Green 6 LED

+5 VDC Communication Supply

Red LED 7

Fault Error Indicator

Green LED 8

+5 VDC RS232 Supply

NOTE: The only LED that changes state when the machine is running is
LED 7 (Fault Indicator). The rest are either on or off depending upon the
power supply or jumper status.

POWER WAVE 455/POWER FEED 10

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F-23

TROUBLESHOOTING AND REPAIR

TEST PROCEDURES
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

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If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).

-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This “safety” procedure should be performed before any internal maintenance or repair
procedures are attempted on the Power Wave 455. Capacitance normally discharges
within 2 minutes of removing input power. This procedure is used to check that the
capacitors have properly discharged.
This procedure takes approximately 9 minutes to perform.

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MATERIALS NEEDED
3/8 in. nutdriver
Volt-Ohmmeter
25-1000 ohms @ 25 watts (minimum) resistor
Electrically insulated gloves and pliers

POWER WAVE 455/POWER FEED 10

F-23

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F-24

TROUBLESHOOTING AND REPAIR

F-24

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.1 — CAPACITOR DISCHARGE PROCEDURE.

SWITCH
BOARD
CAPACITOR
TERMINALS

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TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
left and right case sides.
3. Be careful not to make contact with the
capacitor terminals that are located in
the bottom center of the left and right
side switch boards. See Figure F.1.

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4. Carefully check for a DC voltage at the
capacitor terminals on both boards.
Note the polarity is marked on the PC
board and also lead #19 is positive.
5. If any voltage is present, proceed to
Step #6. If no voltage is present, the
capacitors are discharged.

6. Using the high wattage resistor (251000 ohms @ 25 watts (minimum),
electrically insulated gloves and pliers,
connect the resistor across the two
capacitor terminals. Hold the resistor in
place for 10 seconds. DO NOT
TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS.
NEVER USE A SHORTING STRAP
FOR THIS PROCEDURE.
7. Repeat procedure for the other
capacitor.
8. Recheck the voltage across the capacitor terminals. The voltage should be
zero. If any voltage remains, repeat the
discharge procedure.
NOTE: Voltage present after the discharge
has been performed is an abnormal condition and may indicate a switch board
problem.

POWER WAVE 455/POWER FEED 10

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F-25

TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST

WARNING
Service and repair should only be performed by Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric service department for
technical troubleshooting assistance before you proceed. Call 216-383-2531 or
1-800-833-9353(WELD).

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning
correctly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because these
boards can be damaged easily. In addition, it is dangerous to work on these boards
with the machine energized.
This procedure takes approximately 20 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
3/8 in. wrench
Analog Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-25

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F-26

TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST (continued)
FIGURE F.2 — RECONNECT SWITCHES.
19D
19C

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RECONNECT
SWITCHES

TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.

5. Using the Analog ohmmeter, perform
the resistance tests detailed in Table
F.1. Refer to Figure F.3 for the test
points.

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3. Perform the Capacitor Discharge
Procedure.

4. Locate label and remove leads 19C
and 19D from the reconnect switches
with the 3/8 in. wrench. Note lead
placement for reassembly. Clear leads.
Refer to Figure F.2.

POWER WAVE 455/POWER FEED 10

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F-27

TROUBLESHOOTING AND REPAIR
SWITCH BOARD TEST (continued)
FIGURE F.3 — SWITCH BOARD TEST POINTS.

SWITCH
BOARD

-20 +19

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11/12
OR
15/16

6. If any test fails replace both switch
boards. See Switch Board Removal
and Replacement.
7. If the switch board resistance tests are
OK, check the molex pin connections
and associated wiring from the switch
boards to the control board. See wiring
diagram.

13/14
OR
17/18
8. Reconnect leads 19C and 19D to the
reconnect switches. Ensure that the
leads are installed in the same location
they were removed from.
9. Install the right and left case sides
using the 3/8 in. nutdriver.

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TABLE F.1 — SWITCH BOARD RESISTANCE TEST.
APPLY POSITIVE TEST
PROBE TO TERMINAL

APPLY NEGATIVE TEST
PROBE TO TERMINAL

NORMAL
RESISTANCE READING

+19
+19
11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18

11/12 OR 15/16
13/14 OR 17/18
- 20
- 20
11/12 OR 15/16
13/14 OR 17/18
+19
+19

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

POWER WAVE 455/POWER FEED 10

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F-28

NOTES

POWER WAVE 455/POWER FEED 10

F-28

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F-29

TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
The test will help determine if any of the output rectifiers are shorted.
This procedure takes approximately 10 minutes to perform.

MATERIALS NEEDED

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Analog Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-29

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F-30

TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER TEST (continued)
FIGURE F.4 — OUTPUT RECTIFIER TEST.

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NEGATIVE (-)
OUTPUT
TERMINAL

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F-30

POSITIVE (+)
OUTPUT
TERMINAL

TEST PROCEDURE
1. Remove main input supply power to the
Power Wave 455.
NOTE: Later code machines have a 50
ohm resistor across the welding output terminals. It will be necessary to remove the
case sides and Perform the Input Filter
Capacitor Discharge Procedure. Remove
and insulate one of the resistor leads (#
202A or #206A) from the appropriate welding output terminal. See the wiring diagram.
2. Remove any output load that may be
connected to the Power Wave 455.

3. With the analog ohmmeter, measure
the resistance between the positive and
negative output terminals. Refer to
Figure F.4. IMPORTANT: The positive
(+) meter probe must be attached to the
positive (+) output terminal and the
negative (-) meter probe must be
attached to the negative (-) output terminal.
4. If the reading is more than 200 ohms,
the output rectifier modules are not
shorted. If the reading is less than 200
ohms, one or more of the rectifier modules are shorted. Refer to the Output
Rectifier Module Replacement
Procedure.

POWER WAVE 455/POWER FEED 10

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F-31

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
This procedure takes approximately 15 minutes to perform.

MATERIALS NEEDED

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Analog Volt-Ohmmeter
Phillips head screwdriver
Wiring diagram
3/8 in. nutdriver

POWER WAVE 455/POWER FEED 10

F-31

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F-32

TROUBLESHOOTING AND REPAIR

F-32

INPUT RECTIFIER TEST (continued)
FIGURE F.5 — INPUT RECTIFIER TEST.
INPUT
RECTIFIER

C
B

NEG (-)

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POS (+)

TEST PROCEDURE
1. Remove input power to the Power
Wave 455.

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2. Using the 3/8 in. nutdriver, remove the
case top.
3. Perform the Capacitor Discharge
Procedure.

NOTE: Some RTV sealant may have to be
removed from the input rectifier terminals.
The RTV should be replaced when test is
complete.
5. With the Phillips head screwdriver
remove the positive and negative leads
from the rectifier.
6. Use the analog ohmmeter to perform
the tests detailed in Table F.2.

4. Locate the Input Rectifier and lead
locations. Refer to Figure F.5.

POWER WAVE 455/POWER FEED 10

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F-33

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST (continued)

TABLE F.2 — INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS.
TEST POINT TERMINALS

ANALOG METER X10 RANGE

+ Probe

- Probe

Acceptable Meter Readings

A
B
C

NEG
NEG
NEG

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms

A
B
C

POS
POS
POS

Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

NEG
NEG
NEG

A
B
C

Less than 100 ohms
Less than 100 ohms
Less than 100 ohms

POS
POS
POS

A
B
C

Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms

7. If the input rectifier does not meet the
acceptable readings outlined in the
table, the component may be faulty.
Replace.

9. If the input rectifier is good, be sure to
reconnect the positive and negative
leads to the correct terminals and
torque to 31 in/lbs. See wiring diagram.

NOTE: Before replacing the input rectifier,
perform the Switch Board Test and the
Input Contactor Test.

10. Replace any RTV sealant previously
removed.

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11. Install the case top.

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F-33

8. When installing a new input rectifier,
see Input Rectifier Removal and
Replacement procedure.

POWER WAVE 455/POWER FEED 10

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F-34

NOTES

POWER WAVE 455/POWER FEED 10

F-34

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F-35

TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.
This procedure takes approximately 17 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter
External 24 VAC supply

POWER WAVE 455/POWER FEED 10

F-35

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F-36

TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST (continued)
FIGURE F.6 — INPUT CONTACTOR COIL.

INPUT
CONTACTOR

X4/X4A

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601/601A

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TEST PROCEDURE

FIGURE F.7 — INPUT CONTACTOR
TEST POINTS.

1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
input access panel and case top.
3. Locate, mark, and remove the four
leads (601, 601A, X4 and X4A) that are
connected to the input contactor coil.
Refer to Figure F.6.

4. Using the external 24 VAC supply,
apply 24 VAC to the terminals of the
input contactor coil. If the contactor
does NOT activate, the input contactor
is faulty. Replace.

6. When the contactor is NOT activated,
the resistance should be infinite or very
high across the contacts. If the resistance is low, the input contactor is
faulty.

5. With the input contactor activated,
check the continuity across the three
sets of contacts. (Zero ohms or very
low resistance is normal). Refer to
Figure F.7. If the resistance is high, the
input contactor is faulty. Replace the
input contactor.

7. Reconnect the four leads (601, 601A,
X4, and X4A) to the input contactor coil.
8. Install the input access door and case
top using the 3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-37

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2 and also if the correct voltage is being induced on the secondary
winding of the transformer.
This procedure takes approximately 10 minutes to perform.

MATERIALS NEEDED

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Volt-Ohmmeter (Multimeter)
3/8 in. nutdriver
Wiring diagram

POWER WAVE 455/POWER FEED 10

F-37

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F-38

AUXILIARY TRANSFORMER NO. 2 TEST (continued)
FIGURE F.8 — AUXILIARY TRANSFORMER NO. 2 TEST.

4
P81

TEST PROCEDURE
1. Remove the main input supply power to
the Power Wave 455 machine.

8. If 115 VAC is not present between pins
#1 and #4, check the associated leads
and plugs for loose or faulty connections.

WARNING

2. Remove any load that may be connected to the 115 VAC receptacle.

High voltage is present at plug P80.

4. Perform the Capacitor Discharge
Procedure.

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P80

3. Using the 3/8 in. nutdriver, remove the
left and right case sides.

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F-38

TROUBLESHOOTING AND REPAIR

9. Carefully test for the correct AC input
voltage applied to the primary windings
at plug P80. See wiring diagram.

5. Locate plugs P80 and P81 at the
Auxiliary Transformer No. 2. Refer to
Figure F.8.

10. If the correct AC input voltage is
applied to the primary of the Auxiliary
Transformer No. 2 and the secondary
voltage is NOT correct, the transformer
may be faulty. Replace.

6. Carefully apply the correct input power
and check for 115 VAC at plug P81
pins #1 and #4.

11. Install the left and right case sides
using the 3/8 in. nutdriver.

7. If 115 VAC is present, the Auxiliary
Transformer No. 2 is good.
POWER WAVE 455/POWER FEED 10

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F-39

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1 and also if the correct voltage is being induced on the secondary
windings of the transformer.
This procedure takes approximately 16 minutes to perform.

MATERIALS NEEDED

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Volt-Ohmmeter (Multimeter)
3/8 in. nutdriver
Wiring diagram

POWER WAVE 455/POWER FEED 10

F-39

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F-40

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (continued)
FIGURE F.9 — AUXILIARY TRANSFORMER NO. 1 TEST.
POWER BOARD
RECTIFIER BRIDGE

MAIN
CONTACTOR

X4
X2

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FAN MOTOR
LEADS

TEST PROCEDURE
1. Remove the main input supply power to
the Power Wave 455 machine.
2. Using the 3/8 in. nutdriver, remove the
case sides and top.
3. Perform the Capacitor Discharge
Procedure.

4. Locate secondary leads X1 and X2 (at
power board rectifier bridge). Refer to
Figure F.9.
5. Locate secondary leads X3 and X5 (fan
motor leads).
6. Locate secondary lead X4 (at main
contactor).

POWER WAVE 455/POWER FEED 10

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F-41

TROUBLESHOOTING AND REPAIR

F-41

AUXILIARY TRANSFORMER NO. 1 TEST (continued)
TABLE F.3 — SECONDARY VOLTAGES.

LEAD IDENTIFICATION

NORMAL EXPECTED
VOLTAGE

X1 to X2

52 VAC

X3 to X5

115 VAC

X3 to X4

24 VAC

7. Carefully apply the correct input voltage
to the Power Wave 455 and check for
the correct secondary voltages per
Table F.3.
NOTE: The secondary voltages will vary if
the input line voltage varies.
8. If the correct secondary voltages are
present, the T1 auxiliary transformer is
functioning properly. If any of the secondary voltages are missing or low,
check to make certain the primary is
configured correctly for the input voltage applied. See wiring diagram.

WARNING
High voltage is present at primary of
Auxiliary Transformer.
9. If the correct input voltage is applied to
the primary, and the secondary voltage(s) are not correct, the T1 transformer may be faulty.
10. Install the case sides and top using the
3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-42

NOTES

POWER WAVE 455/POWER FEED 10

F-42

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F-43

TROUBLESHOOTING AND REPAIR
POWER BOARD TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages and
also if the power board is regulating and producing the correct DC voltages.
This procedure takes approximately 20 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter
Wiring diagram

POWER WAVE 455/POWER FEED 10

F-43

TROUBLESHOOTING AND REPAIR

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FIGURE F.10 — POWER BOARD TEST.

2
1

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6
J31

6
5

91011
12

TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case sides and top.
3. Perform the Capacitor Discharge
Procedure.

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12345
3

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50
WT

51
BK

J32

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F-44

POWER BOARD TEST (continued)

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F-44

6. Carefully test for the correct voltages at
the power board as per Table F.4.
NOTE: Capacitor C3 (25000 mfd/100 V)
may hold a charge. Do not come in contact with the capacitor terminals.
7. If the 65 VDC is low or not present at
plug J32, check the rectifier bridge and
C3 filter capacitor. See wiring diagram.
Also perform the T1 Auxiliary
Transformer Test.

4. Locate the power board and plugs J31
and J32. Also locate leads #51 (black)
and #50 (white). Do not remove plugs
or leads from the power board. Refer
to Figure F.10.

8. If any of the DC voltages are low, or not
present, at plug J31, the power board
may be faulty.

5. Carefully apply the correct input voltage
to the Power Wave 455.

9. Install the case sides and top using the
3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-45

TROUBLESHOOTING AND REPAIR

F-45

POWER BOARD TEST (continued)
TABLE F.4 — POWER BOARD VOLTAGE CHECKS.
NORMAL
ACCEPTABLE
VOLTAGE
READING

CHECK POINT
LOCATION

TEST
DESCRIPTION

CONNECTOR
PLUG PIN NO.

LEAD NO.
OR
IDENTITY

POWER PC
BOARD
CONNECTOR
PLUG J32

CHECK 65 VDC
SUPPLY FROM
POWER BOARD
RECTIFIER
BRIDGE

1 & 2(+)
4 & 5(-)

POS(+)
NEG(-)

73 VDC

225(+)
222(-)

15 VDC

221(+)
222(-)

5 VDC

222(+)
223(-)

15 VDC

274(+)
273(-)

5 VDC

226(+)
228(-)

5 VDC

WHITE (+)
BLACK (-)

40 VDC

POS

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POWER PC
BOARD
CONNECTOR
PLUG J31

CHECK +15
VDC SUPPLY
FROM POWER
PC BOARD

POWER PC
BOARD
CONNECTOR
PLUG J31

CHECK +5 VDC
SUPPLY FROM
POWER PC
BOARD

POWER PC
BOARD
CONNECTOR
PLUG J31

CHECK -15 VDC
SUPPLY FROM
POWER PC
BOARD

POWER PC
BOARD
CONNECTOR
PLUG J31

CHECK +5 VDC
“CAN” SUPPLY
FROM POWER
PC BOARD

2(+)
4(-)
225

222

7(+)
4(-)
222
221

4(+)
3(-)
223 222

11(+)
12(-)

274 273

POWER PC
BOARD
CONNECTOR
PLUG J31

CHECK +5 VDC
“RS232”
SUPPLY FROM
POWER PC
BOARD

6(+)
5(-)

POWER PC
BOARD SPADE
TERMINALS

CHECK +40
VDC WIRE
FEEDER SUPPLY
FROM POWER PC
BOARD

#50 TERMINAL
TO
#51 TERMINAL

228 226

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NEG

POWER WAVE 455/POWER FEED 10

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F-46

NOTES

POWER WAVE 455/POWER FEED 10

F-46

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F-47

TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the current transducer and associated wiring is functioning correctly.
This procedure takes approximately 25 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-47

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F-48

TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.11 — CURRENT TRANSDUCER TEST.

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NOTE: On later codes
the transducer is located
on left side of the
machine near the output
choke.

1234
CURRENT
TRANSDUCER

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TEST PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver remove the
right side case cover.
3. Perform the Capacitor Discharge
Procedure.
4. Locate the current transducer at the
lower right front of the machine.

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5. Apply the correct input power to the
Power Wave 455.

P90
7. Check for the correct DC supply voltages to the current transducer at plug
P90.
A. Pin 1 (lead 212+) to pin 4 (lead
216-) should read +15 VDC.
B. Pin 2 (lead 213-) to pin 4 (lead
216+) should read -15 VDC.
8. If either of the supply voltages are low
or missing, check the associated leads
between the current transducer and the
control board. If the leads are OK and
the DC supply voltages are not present,
the control board may be faulty.

6. Locate plug P90 at the current transducer. Do not remove the plug. Refer
to Figure F.11.

POWER WAVE 455/POWER FEED 10

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F-49

TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
TABLE F.5 — CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS.

OUTPUT LOAD CURRENT

EXPECTED TRANSDUCER FEEDBACK
VOLTAGE

500
450
400
350
300
250
200
150
100

4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8

9. Check the feedback voltage from the
current transducer. With the Power
Wave system in a constant current
mode and the machine loaded to 250
amps, the current feedback voltage can
be read at plug P90.
A. Pin 3 (lead 211) to pin 4 (lead
216) should read 2.0 VDC (machine
loaded to 250 amps).

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10. If for any reason the machine cannot be
loaded to 250 amps, Table F.5 shows
what feedback voltage is produced at
various current loads.

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F-49

11. If the correct supply voltages are
applied to the current transducer, and
with the machine loaded, the feedback
voltage is missing or not correct, the
current transducer may be faulty. Also
make certain that lead #211 has continuity (zero ohms) between the current
transducer and the control board. See
wiring diagram.
12. Install the right side case cover using
the 3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-50

NOTES

POWER WAVE 455/POWER FEED 10

F-50

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F-51

TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the wire drive motor is receiving the correct voltage, and
if it is capable of running properly.
This procedure takes approximately 12 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-51

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F-52

TROUBLESHOOTING AND REPAIR

F-52

DRIVE MOTOR TEST (continued)
FIGURE F.12 — DRIVE MOTOR TEST.
#551

#550

J3
#550 (-)
BLACK

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#551 (+)
WHITE

PROCEDURE

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1. Remove input power to wire feed unit.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate the two quick connectors in the
two motor armature leads. Refer to
Figure F.12. Do NOT disconnect the
leads.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder. Activate the gun trigger
and with the motor running check at the
quick connectors [#551 White (+) to
#550 Black (-)] for approximately 1
VDC to 32 VDC dependent upon motor
speed. The motor speed should vary
with changes in motor armature
voltage.

5. If the correct voltages are NOT present
at the motor leads, check the associated leads between the motor and plug
J3 on the control board. If the leads
are OK, the control board may be
faulty.
6. If the correct voltages are present at
the motor armature leads and the motor
does not run and vary speed with
changes in armature voltage, the motor
or gear box may be faulty. See Gear
Box and Drive Motor Removal and
Replacement.
7. Install the wire feeder cover using the
3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-53

TROUBLESHOOTING AND REPAIR
TACH FEEDBACK TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will determine if the tach unit is receiving the correct supply voltage from the
control board, and also if the tach unit is sending feedback information to the control
board.
This procedure takes approximately 7 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-53

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F-54

TROUBLESHOOTING AND REPAIR

F-54

TACH FEEDBACK TEST (continued)
FIGURE F.13 — TACH FEEDBACK TEST.
#1
#3
BLACK RED

#2
(BLUE)

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WIRE FEED
CONTROL BOARD

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TEST PROCEDURE
1. Remove input power from the wire
feeder unit.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate plug J4 on the control board.
Refer to Figure F.13. Do NOT remove
the plug from the control board.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder unit and check for approximately 12 VDC from pin #1 (red wire)
positive to pin #3 (black wire) negative.
This is the supply voltage from the control board to the tach feedback unit. If
the 12 VDC is missing or not correct,
the wire feeder control board may be
faulty. Also check for loose or faulty
wires and connections.

5. With the gun trigger activated and the
motor running, check the feedback voltage at plug J4 pin #2 (blue wire) positive to pin #3 (black wire) negative.
Normal feedback voltage is approximately 5 VDC. If the correct supply voltage is present and the feedback voltage is missing, the tach unit may be
faulty. With the motor NOT running,
the feedback voltage may be either 0 or
10 VDC depending upon where the
motor stopped.
6. Remove input power from the wire
feeder unit.
7. Install the wire feeder cover with the 3/8
in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-55

TROUBLESHOOTING AND REPAIR
VOLTAGE SENSE PC BOARD TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the voltage sensing board is receiving the correct activation signal from the control board and also if the voltage sensing board is processing
arc voltage sensing information.
This procedure takes approximately 13 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-55

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F-56

TROUBLESHOOTING AND REPAIR
VOLTAGE SENSE PC BOARD TEST (continued)
FIGURE F.14 — VOLTAGE SENSING BOARD TEST.
J2

1 2 3
J1
4 5 6

1
2

NOTE: Inspect the molex
plug connector pins on the
Voltage Sense Board. If
any of them are gold plated the P.C. board should
be replaced

TEST PROCEDURE
1. Remove input power from the wire feed
unit.

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2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.

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F-56

3. Locate the voltage sense PC board and
plugs J1 and J2. Do not remove the
plugs from the voltage sense PC board.
Refer to Figure F.14.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
wire feeder. With the gun trigger activated, check for approximately 12 VDC
at plug J1 pin 1 (+) to pin 4 (-). If the 12
VDC is NOT present, the control board
may be faulty. Also check for loose or
faulty wires and connections between
the control board (plug J6) and plug J1
on the voltage sense PC board.

5. With the gun trigger activated and arc
voltage present at the conductor block,
check for arc voltage from plug J1 pin 3
(lead 67) to the workpiece. If actual
arc voltage is NOT present, check the
continuity of lead 67 from the conductor
block to plug J1 pin 3 on the voltage
sense PC board.
6. If the actual arc voltage IS present at
plug J1 pin 3 (lead 67), then check for
arc voltage from plug J2 pin 1 (lead
67A) to the workpiece. See wiring diagram.
7. If the 12 VDC IS present in Step #4 and
the arc voltage IS present in Step #5
but the arc voltage is NOT present in
Step #6 (lead 67A), the voltage sense
PC board may be faulty.
8. Remove all input power from the wire
feeder unit.

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9. Install the wire feeder cover with the 3/8
in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-57

TROUBLESHOOTING AND REPAIR
DUAL ENCODER PC BOARD TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the encoder PC board is functioning properly.
This procedure takes approximately 20 minutes to perform.

MATERIALS NEEDED

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Phillips head screwdriver
Volt-Ohmmeter (Analog Recommended)

POWER WAVE 455/POWER FEED 10

F-57

DUAL ENCODER PC BOARD TEST (continued)
FIGURE F.15 — DUAL ENCODER TEST.
DISPLAY
BOARD

CONTROL
BOARD

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8
9
10
11
12
13
14

1 2 3 4 5 6 78

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1. Remove input power from control box
assembly.

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2. Using the Phillips head screwdriver,
remove the display/encoder assembly
panel from the Control Box. Refer to
Figure F.15.
NOTE: The panel assembly cannot be
removed completely without removing the
lead plug from the control board. DO NOT
remove the lead plug.
3. Locate the dual encoder PC board and
plug J1. Also locate plug J4 on the
control board.
4. Apply the correct input power (from the
Power Wave 455 control cable) to the
Control Box.

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1
2
3
4
5
6
7

TEST PROCEDURE

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F-58

TROUBLESHOOTING AND REPAIR

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F-58

5. Check for approximately 12 VDC from
plug J1 pin 2+ (lead 512C) to plug J1
pin 1 - (lead 500C). This is the supply
voltage from the control board to the
encoder board. If this voltage is missing, check the continuity of the leads
between the control board (J4) and the
encoder board (J1). See wiring diagram. The control board may be faulty.

6. While rotating the wire feed speed
(WFS) control check for a “pulsing” 0
to 5 VDC signal at plug J1 pin 5 + (lead
553) to J1 pin 1 - (lead 500C). Also
check for a “pulsing” 0 to 5 VDC signal
from plug J1 pin 6 + (lead 554) to J1 pin
1 - (lead 500C).
7. While rotating the volts/trim control
check for a “pulsing” 0 to 5 VDC signal
at plug J1 pin 3 + (lead 555) to J1 pin 1(lead 500C). Also check for a “pulsing”
0 to 5 VDC signal at plug J1 pin 4 +
(lead 556) to J1 pin 1 - (lead 500C).
8. If the 12 VDC supply in Step 5 is present and any of the 0 to 5 VDC “pulsing”* signals are missing, the encoder
PC board may be faulty.
*“Pulsing” means that as the control is
rotated the signal will fluctuate from 0
to 5 VDC.
9. Remove input power to the control box
assembly.
10. Install the display/encoder assembly
panel into the Control Box.

POWER WAVE 455/POWER FEED 10

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F-59

TROUBLESHOOTING AND REPAIR
CONTROL CABLE CONTINUITY TEST

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-----------------------------------------------------------------------------------------------TEST DESCRIPTION
This test will help determine if the control cable is functional.
This procedure takes approximately 6 minutes to perform.

MATERIALS NEEDED

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Volt-Ohmmeter

POWER WAVE 455/POWER FEED 10

F-59

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F-60

TROUBLESHOOTING AND REPAIR
CONTROL CABLE CONTINUITY TEST (continued)
FIGURE F.16 — CABLE CONTINUITY TEST.
WIRE FEEDER END

POWER SOURCE END

D
B

A
C

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TABLE F.6 CONTROL CABLE PIN AND LEAD DESIGNATIONS.
FIVE PIN AMPHENOL AT
POWER SOURCE END

FIVE PIN AMPHENOL AT
WIRE FEEDER/CONTROL BOX END

A
B
C
D
E

TEST PROCEDURE
1. Disconnect the input power to the
Power Wave 455 machine.

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2. Disconnect the control cable amphenols from the power source and the
wire feeder.
3. Using the ohmmeter measure the resistance of the individual control cable
leads from the amphenol on the power
source end to the amphenol on the wire

feeder/Control Box end. Refer to Figure
F.16 and Table F-6.
4. If any conductor resistance measures
greater than 1.0 ohm, the cable is
faulty and should be replaced. If the
resistance between any two conductors
or any conductor and the amphenol
body is less than 0.5M ohms, the cable
is faulty and should be replaced.
5. Connect the control cable amphenols to
the wire feeder and power source.

POWER WAVE 455/POWER FEED 10

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F-61

TROUBLESHOOTING AND REPAIR

COMPONENT REPLACEMENT PROCEDURES
GAS SOLENOID REMOVAL AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This will aid the technician in the removal and replacement of the gas solenoid.
This procedure takes approximately 12 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
Needlenose pliers
5/16 in. nutdriver
3/4 in. wrench

POWER WAVE 455/POWER FEED 10

F-61

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F-62

TROUBLESHOOTING AND REPAIR
GAS SOLENOID REMOVAL AND REPLACEMENT (continued)
FIGURE F.17 — GAS SOLENOID REMOVAL AND REPLACEMENT.

MOUNTING
SCREW

BRASS
FITTING

GAS
HOSE

GAS
SOLENOID
HOSE
FITTING

PROCEDURE

INSTALLATION

1. Remove input power to the wire feeder.

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2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Locate the gas solenoid on the rear
panel of the wire feeder. Refer to
Figure F.17.
4. Using the 3/4 in. wrench, remove the
external brass fitting.

7. Using the 5/16 in. nutdriver, remove the
two screws mounting the solenoid to
the rear case panel.
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1. If a new solenoid is to be installed, it
may be necessary to remove the hose
fitting from the “old” solenoid and install
it into the new solenoid using the 1/2 in.
wrench.
2. Place the gas solenoid into the wire
feeder and secure it to the rear case
panel using the two 5/16 in. mounting
screws.
3. Install the gas hose onto the solenoid.

5. Carefully remove the two leads from
the solenoid.
6. Remove the gas hose from the solenoid.

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F-62

4. Connect the two electrical leads to the
gas solenoid.
5. Install the external brass fitting onto the
gas solenoid using the 3/4 in. wrench.
6. Install the wire feeder cover with the 3/8
in. nutdriver.

8. Carefully remove the gas solenoid from
the wire feeder.

POWER WAVE 455/POWER FEED 10

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F-63

TROUBLESHOOTING AND REPAIR
WIRE FEEDER CONTROL BOARD REMOVAL
AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This will aid the technician in the removal and replacement of the control board.
This procedure takes approximately 7 minutes to complete.

MATERIALS NEEDED

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3/8 in. nutdriver
Pliers
Anti-static wrist strap

POWER WAVE 455/POWER FEED 10

F-63

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F-64

TROUBLESHOOTING AND REPAIR

WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.18 — WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT.
LOCKING
TAB
WIRE FEEDER
CONTROL BOARD

PROCEDURE

INSTALLATION

1. Remove input power to the wire feeder.
2. Using the 3/8 in. nutdriver, remove the
cover from the wire feeder.
3. Observe static precautions detailed
in PC Board Troubleshooting
Procedures at the beginning of this
section.

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4. Disconnect the molex type plugs from
the control board. Refer to Figure F.18.
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F-64

5. Disengage the PC board supports by
squeezing each support in turn with a
pair of pliers and gently pulling out on
the board next to the support. When all
five supports have been disconnected,
carefully remove the control PC board
from the wire feeder.

NOTE: Press the PC board onto the support
by pressing near the mounting hole you are
securing. Pressing near the center of the
PC board could damage the circuitry within
the board.
1. Align the holes on the PC board with
the supports attached to the wire feeder
and press the PC board until it is held
securely in place.
2. Connect the molex type plugs to the
control board.
3. Install the wire feeder cover using the
3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-65

TROUBLESHOOTING AND REPAIR
TACH (HALL EFFECT) ASSEMBLY REMOVAL
AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
The procedure will aid the technician in the removal and replacement of the tach
assembly from the gear box.
This procedure takes approximately 10 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
9/16 in. wrench

POWER WAVE 455/POWER FEED 10

F-65

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F-66

TROUBLESHOOTING AND REPAIR

F-66

TACH (HALL EFFECT) ASSEMBLY REMOVAL AND REPLACEMENT (continued)
FIGURE F.19 — TACH REMOVAL AND REPLACEMENT.
LOCK
NUT
HALL
EFFECT
DEVICE

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TACH
ASSEMBLY

REMOVAL PROCEDURE
1. Remove input power to the wire feeder.
2. Using the 3/8 in. nutdriver, remove the
case cover.
3. Locate the tach assembly on the top of
the gear box. Refer to Figure F.19.

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4. Locate and remove plug J4 from the
control board.
5. Thread plug J4 and associated leads
through the vertical baffle. Cut any
necessary cable ties.
6. Using the 9/16 in. wrench, loosen the
locking nut on the Hall Effect device.

REPLACEMENT PROCEDURE
1. Carefully screw the Hall Effect device
into the gear box assembly until it gently “bottoms out” on the rotary magnet
inside.
2. Unscrew the Hall Effect device 1/2 turn
from the rotary magnet. Tighten the
locking nut to 8 in/lbs.
3. Thread the J4 leads through the vertical
baffle and install cable ties where
appropriate.
4. Connect plug J4 into the control board.
5. Install the wire feeder cover using the
3/8 in. nutdriver.

7. Carefully unscrew the Hall Effect device
from the gear box assembly.
POWER WAVE 455/POWER FEED 10

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F-67

TROUBLESHOOTING AND REPAIR
GEAR BOX AND DRIVE MOTOR REMOVAL
AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This test will aid the technican in the removal and replacement of the wire feed drive
motor.
Removal and installation of the gearbox and drive motor assembly
takes approximately 20 minutes to perform. Removal and installation
of the drive motor takes approximately 10 minutes. Removal and
installation of the gearbox takes approximately 4 minutes to complete.

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MATERIALS NEEDED
3/8 in. nutdriver
Slot head screwdriver
Phillips head screwdriver
7/16 in. socket wrench with extension
Needlenose pliers
5/16 in. wrench
3/16 in. Allen wrench

POWER WAVE 455/POWER FEED 10

F-67

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F-68

TROUBLESHOOTING AND REPAIR

GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.20 — GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT.
DRIVE
MOTOR

MOUNTING BOLT

INSPECTION COVER
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GEAR BOX
#551
(BLACK)

WIRE
DRIVE
ASSEMBLY

#550
(WHITE)

INSULATION

GAS
FITTING

PROCEDURE

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1. Remove the input power to the wire
drive unit.
2. Using the 3/8 in. nutdriver, remove the
case cover.
3. Locate and remove plug J4 from the
control board. Refer to Figure F.20.

4. Thread plug J4 and associated leads
through the vertical baffle. Cut any
necessary cable ties.
5. Locate and disconnect the motor leads
(#551 and #550) at the quick connects.
Cut any necessary cable ties.
6. Using the Phillips head screwdriver,
remove the #67 lead from the conductor block.

POWER WAVE 455/POWER FEED 10

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F-69

TROUBLESHOOTING AND REPAIR

GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT (continued)
7. Using the needlenose pliers, disconnect the gas hose from the brass gun
connector block.

2. Tighten the two Allen type screws at
the bottom of the wire drive unit using
the 3/16 in. Allen wrench.

8. Using the 7/16 in. socket wrench,
remove the four mounting bolts, lock
washers, and flat washers from the
glastic base insulator.

3. Attach lead #67 to the conductor block.

9. Carefully slide and remove the entire
gear box, drive motor, and wire drive
assembly from the wire feeder
case. Note insulation placement for
reassembly.

10. Using the slot head screwdriver,
remove the gear box inspection cover
nearest to the drive motor.

7. Install the gear box inspection cover
and secure it with slot head screws.

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13. Carefully remove the motor from the
gear box assembly. Note motor lead
placement for reassembly.
TO REMOVE THE WIRE DRIVE
ASSEMBLY FROM THE GEAR BOX:
14. Using the 3/16 in. Allen wrench, loosen
the two Allen type screws at the bottom
of the wire drive unit.
15. Remove lead #67 from the conductor
block.

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5. Install the slot head screws that mount
the “top” of the drive motor to the gear
box.
6. Install the mounting screw located
inside the gearbox using the 5/16 in.
wrench.

12. Using the slot head screwdriver,
remove the two screws mounting the
“top” of the motor to the gear box.
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4. Carefully slide the drive motor into the
gear box assembly. Be sure to position
the motor leads so that they can be
properly connected.

TO REMOVE THE DRIVE MOTOR
FROM THE GEAR BOX:

11. Using the 5/16 in. wrench, remove the
motor mounting screw located inside
the gear box.

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F-69

16. Carefully slide and remove the wire
drive assembly from the gear box
assembly.

8. Properly place insulation in the bottom
of the wire feeder case.
9. Place the entire gear box, drive motor
and wire drive assembly into the wire
feeder case, aligning the holes in the
glastic base insulator with the mounting
holes in the case.
10. Mount the gear box and drive motor
assembly to the wire feeder case using
the four mounting bolts, lock washers
and flat washers.
11. Connect the gas hose to the brass gun
connector block.
12. Connect drive motor leads #550 and
#551 to their quick disconnects.
13. Thread plug J4 and associated leads
through the vertical baffle and attach it
to the control board. Install cable ties
as necessary.
14. Install the wire feeder cover using the
3/8 in. nutdriver.

REPLACEMENT PROCEDURES
1. Carefully slide the wire drive assembly
and gear box together.
POWER WAVE 455/POWER FEED 10

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F-70

NOTES

POWER WAVE 455/POWER FEED 10

F-70

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F-71

TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).
This procedure takes approximately 25 minutes to perform.

MATERIALS NEEDED

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3/8 in. nutdriver
7/16 in. wrench
3/16 in. Allen wrench
Slot head screwdriver

POWER WAVE 455/POWER FEED 10

F-71

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F-72

SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.21 — SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT.

MOUNTING
SCREW (4X)
MOLEX PLUG
SWITCH
BOARD

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19+

13/14
OR
17/18

REMOVAL PROCEDURE
NOTE: Observe all static electricity precautions.

2. Using the 3/8 in. nutdriver, remove the
case top and sides.
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11/12
OR
15/16

20NYLON
SCREW
(2X)

1. Remove input power to the Power
Wave 455.

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F-72

TROUBLESHOOTING AND REPAIR

3. Perform the Capacitor Discharge
Procedure.

4. Remove the molex plug from the top of
the switch board. Refer to Figure F.21.
5. Using the 7/16 in. wrench, remove
leads 11/12 or 15/16 from the switch
board.
6. Using the 7/16 in. wrench, remove
leads 13/14 or 17/18 from the switch
board.
7. Using the 7/16 in. wrench, remove
leads 19+ and 20- from the switch
board capacitor connection bolts.

POWER WAVE 455/POWER FEED 10

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F-73

TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR REMOVAL
AND REPLACEMENT (continued)
8. With the slot head screwdriver, remove
the two nylon mounting screws at the
bottom of the switch board. Note
placement of the shake-proof washers
and fiber spacers.
9. Using the 3/16 in. Allen wrench, carefully remove the four cap screws that
mount the switch board to the heatsink.

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10. Carefully remove the switch board from
the heatsink.

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F-73

11. If the filter capacitor is to be removed,
carefully slide it out of the mounting
bracket.

5. Mount the new switch board and tighten the four cap head screws in the following manner.
• Tighten all until snug.
• Tighten all from 24 to 28 in/lbs.
• Tighten all from 40 to 48 in/lbs.
6. Make sure the capacitor is positioned
correctly. Connect leads 19+ and 20to the correct terminals. Tighten to
55 in/lbs.
7. Position and mount the two nylon
screws, fiber spacers, and washers.
Torque from 4 to 8 in/lbs.

REPLACEMENT PROCEDURE
1. If the filter capacitor is to be replaced,
carefully slide the new capacitor into
the mounting bracket. Position the
capacitor so the correct polarity terminal is lined up with the correct hole on
the switch board.
2. All heatsink and IGBT mounting surfaces must be clean.

8. Connect leads 11/12 or 15/16 to the
correct terminal.
9. Connect leads 13/14 or 17/18 to the
correct terminal.
10. Connect the molex plug to the top of
the switch board.
11. Install the case top and sides using the
3/8 in. nutdriver.

3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 in. to 0.010 in. to
the mating surfaces. Do not apply
around mounting holes.
4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to
apply compound to screw threads or
threaded area of terminals.

POWER WAVE 455/POWER FEED 10

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F-74

TROUBLESHOOTING AND REPAIR

F-74

POWER WAVE 455 / PF-10 METER ACCURACY CHECK

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-----------------------------------------------------------------------------------------------DESCRIPTION
This procedure will aid the technician in checking and calibrating meter displays.
This procedure takes approximately 30 minutes to perform.

MATERIAL NEEDED

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DC ammeter and meter grade shunt, +/- 1% accuracy
DC voltmeter, +/- 1% accuracy
Resistive load bank
DSP, STT or other PF-10 option panel with mode light and set switch
PW-455 and PF-10 Operator’s manual for reference

METER ACCURACY CHECK
1. With power off, locate DIP switch bank
S2 on the PF-10 Control PC board.
(There are 8 switches, number 1 on the
left, through number 8).
2. Set switch 8 to the up position.
3. Connect a resistive load between the output block of the PF-10 and the work terminal of the PW-455 machine.
4. Turn machine on.
5. Using the Set Control on the PF-10, set
the display to mode 200. Turn the right
knob of the PF-10 to energize the output.
6. Adjust the resistive load and the left knob
of the PF-10 to achieve 300A at 32v. The
left knob will adjust the output current.
Amps and volts will be displayed on the
PF-10 meters.
7. After the load condition is set, accuracy is
measured by comparing the meter of the
PF-10 to the master meter. At 300A,
amperage must agree within +/-10A. At
32V, voltage must agree within +/- 1V.

8. At conclusion of test, turn the power off
and set the DIP switch to its original position.

PROCEDURE TO REPAIR IF
METERS ARE OUT OF RANGE
If the measured voltage is not within the
acceptable range, the Control PC board
must be replaced. The Control PC board
can not be calibrated.
If the measured current is not within the
acceptable current range, adjust trimmer
R126 on the Control PC board. R126 is
located on the upper left corner of the
Control PC board. If the display is still in
error, either the Control PC board or LEM
(Current Transducer) may be faulty.
Perform the Current Transducer Test.

POWER WAVE 455/POWER FEED 10

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F-75

TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the
power board or the control board.
This procedure takes approximately 15 minutes to perform.

MATERIAL NEEDED

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3/8 in. nutdriver
Phillips head screwdriver
Anti-static wrist strap

POWER WAVE 455/POWER FEED 10

F-75

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F-76

TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.22 — CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT.
COMPARTMENT
COVER

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CONTROL
BOARD

REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.

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3. Perform the Capacitor Discharge
Procedure.
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F-76

4. Observe all static electricity precautions.
5. Using the 3/8 in. nutdriver, remove the
PC board compartment cover. Refer to
Figure F.22.

POWER
BOARD

6. Remove the eight molex plugs from the
control board.
7. Remove the two molex plugs and white
and black wires with quick connects
from the power PC board.
8. Using the 3/8 in. nutdriver, remove the
two screws holding the rear of the
Control Box in place.
9. Clear the lead harnesses from the left
and right sides and carefully remove
the power and control PC board
assembly.
10. Using the Phillips head screwdriver,
remove either the power or the control
board from the PC board assembly.

POWER WAVE 455/POWER FEED 10

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F-77

TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT (continued)
INSTALLATION PROCEDURE
1. Install either the power or control board
to the PC board assembly and secure it
in place using the Phillips head mounting screws.

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2. Carefully slide the power and control
PC board assembly into place, making
sure to clear the lead harnesses on the
right and left side of the PC board compartment.

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F-77

4. Connect two molex plugs and black
and white wires with quick disconnects
to the power PC board.
5. Connect the eight molex plugs to the
control PC board.
6. Install the PC board compartment cover
using the 3/8 in. nutdriver.
7. Install the case top and sides using the
3/8 in. nutdriver.

3. Secure the rear of the control box in
place using two screws and the 3/8 in.
nutdriver.

POWER WAVE 455/POWER FEED 10

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F-78

NOTES

POWER WAVE 455/POWER FEED 10

F-78

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F-79

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE

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MATERIALS NEEDED

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3/8 in. nutdriver
Wire cutters
Wire splicer or soldering equipment

POWER WAVE 455/POWER FEED 10

F-79

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F-80

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (continued)

FIGURE F.23 — AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE.
H1
POWER BOARD
RECTIFIER BRIDGE

CB4

RECONNECT
TERMINALS
H2
H3
H4
H5

X1
MAIN
CONNECTOR
X4
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X3
X5

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MOUNTING
SCREW
(2X)

REMOVAL PROCEDURE

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1. Remove input power to the Power
Wave 455.

FAN
MOTOR
LEADS

5. Remove leads X1 and X2 from the
power board rectifier bridge. Refer to
Figure F.23.

2. Using the 3/8 in. nutdriver, remove the
case top, sides and input access panel.

6. Cut X3 and X5 from the fan motor
leads. Leave enough lead length to
splice in the new transformer leads.

3. Perform the Capacitor Discharge
Procedure.

7. Remove lead X4 from the main contactor coil terminal.

4. Using the 3/8 in. nutdriver, remove the
case back.

POWER WAVE 455/POWER FEED 10

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F-81

TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
8. Cut the X3 lead that is connected to the
input board. Leave enough lead length
to splice in the new transformer lead.
9. Locate, label, and remove primary lead
H1 from circuit breaker CB4.

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10. Label and remove primary leads H2,
H3, H4, and H5 from the reconnect terminals on the reconnect panel. Note
lead placement for reassembly.

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F-81

11. Using the 3/8 in. nutdriver, remove the
two mounting screws that hold the
transformer to the fan baffle and the
machine base.

and the machine base using the 3/8 in.
nutdriver.
3. Install the primary leads H2, H3, H4,
and H5 to the reconnect terminals on
the reconnect panel.
4. Connect primary lead H1 to circuit
breaker CB4.
5. Splice the new transformer lead with
the X3 lead connected to the input
board.
6. Connect lead X4 to the main contactor
coil terminal.

12. Cut any necessary cable ties and clear
the leads.

7. Splice the new transformer fan leads to
the fan motor leads X3 and X5.

13. Carefully remove the transformer from
the Power Wave 455.

8. Connect leads X1 and X2 to the power
board rectifier bridge.

REPLACEMENT PROCEDURE

9. Reposition any wire leads and install
wire ties as necessary.

1. Carefully place the transformer into the
Power Wave 455.

10. Install the case back using the 3/8 in.
nutdriver.

2. Install the two mounting screws that
hold the transformer to the fan baffle

11. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-82

NOTES

POWER WAVE 455/POWER FEED 10

F-82

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F-83

TROUBLESHOOTING AND REPAIR
MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT

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MATERIALS NEEDED

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3/8 in. nutdriver
5/16 in. nutdriver
Slot head screwdriver

POWER WAVE 455/POWER FEED 10

F-83

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F-84

TROUBLESHOOTING AND REPAIR
MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.24 — MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT.
MOUNTING
SCREW (3X)
X4/X4A
L3
L2
L1

601/601A
T3
T2

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REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.

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6. Remove the two small leads T1 and T3
from the quick disconnect terminals.

2. Using the 3/8 in. nutdriver, remove the
case top, sides, and input access
panel.

7. Remove leads 601, 601A, and X4, X4A
from the contactor coil terminals.

3. Perform the Capacitor Discharge
Procedure.

8. Remove leads L1A and L3A from the
contactor line side quick-disconnect terminals.

4. Using the slot head screwdriver,
remove the three input lines (L1, L2,
and L3) from the main contactor. Refer
to Figure F.24.

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remove the small T2 lead. Label leads
for reassembly.

5. Using the slot head screwdriver,
remove the three heavy leads (T1, T2,
and T3) from the input contactor. Also

9. Using the 5/16 in. nutdriver, remove the
three mounting screws holding the
input contactor to the metal housing
bracket.
10. Carefully remove the input contactor.

POWER WAVE 455/POWER FEED 10

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F-85

TROUBLESHOOTING AND REPAIR

F-85

MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued)
REPLACEMENT PROCEDURE
1. Carefully place the input contactor into
position.
2. Install the three mounting screws that
hold the input contactor to the metal
housing bracket using the 5/16 in.
nutdriver.

5. Install the two small leads T1 and T3 to
the quick-disconnect terminals.
6. Install the three input lines (L1, L2 and
L3) to the main contactor using the slot
head screwdriver.
7. Install the three heavy leads (T1, T2
and T3) from the input contactor using
the slot head screwdriver.

3. Connect leads L1A and L3A to the
contactor line side quick-disconnect
terminals.

8. Install the small T2 lead to the input
contactor.

4. Install leads 601, 601A, and X4, X4A
to the contactor coil terminals.

9. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-86

NOTES

POWER WAVE 455/POWER FEED 10

F-86

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F-87

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT

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MATERIALS NEEDED

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3/8 in. nutdriver
3/16 in. Allen wrench
Phillips head screwdriver

POWER WAVE 455/POWER FEED 10

F-87

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F-88

TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
FIGURE F.25 — INPUT RECTIFIER REMOVAL AND REPLACEMENT.
INPUT
RECTIFIER

A
B

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NEG (-)

POS (+)

REMOVAL PROCEDURE
1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top, sides, and input access
panel.

7. Carefully remove the module.

REPLACEMENT PROCEDURE
1. Clean heatsink surfaces.

3. Perform the Capacitor Discharge
Procedure.

2. Apply an even coating of joint compound (Penetrox A-13) to both the
heatsink and module mounting surfaces. The joint compound should be
0.002 in/0.005 in. thick per surface.

4. Locate and remove the RTV sealant
from the input rectifier connection terminals. Refer to Figure F.25.

3. Mount the module to the heat sink and
evenly torque the mounting screws
(with washers) to 44 in/lbs.

5. Label leads and using the Phillips head
screwdriver carefully remove the five
leads from the input rectifier terminals.
Note placement for reassembly.

4. Assembly the leads to the correct module terminals and torque to 26 in/lbs.

6. Using the 3/16 in. Allen wrench,
remove the two mounting screws and
washers from the rectifier module.

5. Apply RTV sealant to the rectifier connection terminals.
6. Install the case top, sides, and input
access panel using the 3/8 in. nutdriver.

POWER WAVE 455/POWER FEED 10

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F-89

TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER AND MODULE REMOVAL
AND REPLACEMENT

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-----------------------------------------------------------------------------------------------DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output rectifier assembly and individual rectifier module replacement.
This procedure takes approximately 35 minutes to remove and replace
the output rectifier and 5 minutes to remove and replace the rectifier
module.

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MATERIALS NEEDED
3/8 in. nutdriver
7/16 in. wrench
9/16 in. wrench
9/64 in. Allen wrench

POWER WAVE 455/POWER FEED 10

F-89

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F-90

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued)
FIGURE F.26 — OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT.

TRANSFORMER
LEADS
RECTIFIER
MODULE
THERMOSTAT

POSITIVE
OUTPUT
LEAD

HEATSINK

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HEATSINK
MOUNT
BOLTS (4X)

RECTIFIER ASSEMBLY
REMOVAL PROCEDURE

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1. Remove input power to the Power
Wave 455.
2. Using the 3/8 in. nutdriver, remove the
case top and sides.
3. Perform the Capacitor Discharge
Procedure.
4. Using the 9/16 in. wrench, remove the
positive output lead from the rectifier
heatsink. Refer to Figure F.26.

5. Using the 7/16 in. wrench, remove the
eight transformer leads from the rectifier modules. Label the leads and take
note of lead placement for reassembly.
Note that each screw has two flat
washers and one lock washer.
6. Remove leads #220 and #290 from the
rectifier thermostat.
7. Using the 7/16 in. wrench, remove the
four nuts and associated washers from
the heatsink mounting bolts. The heatsink assembly can be removed by carefully sliding the assembly forward and
removing the mounting bolts.

POWER WAVE 455/POWER FEED 10

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F-91

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT (continued)
RECTIFIER MODULE REMOVAL
AND REPLACEMENT
PROCEDURE
1. Using the 9/64 in. Allen wrench,
remove the cap screw from the center
of the rectifier module that is to be
replaced.

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2. Using the 7/16 in. wrench, remove the
two mounting bolts and associated
washers from the rectifier module to be
replaced.

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RECTIFIER ASSEMBLY
REPLACEMENT PROCEDURE
1. Position the assembly in place with the
mounting bolts.
2. Assemble the nuts and associated
washers to the mounting bolts.
3. Using the 7/16 in. wrench, tighten the
four nuts on the mounting bolts.
4. Replace leads #220 and #290 to the
thermostat.

3. Remove the faulty module.
4. This module requires special mounting
considerations to prevent warping of
the base plate. The heatsink surfaces
must be clean and flat. Apply a thin,
even coating of thermal compound,
(Penetrox A13) 0.004 to 0.010 inches
thick. Keep the compound away from
the area of the mounting holes.
5. Press the new module firmly against
the heatsink while aligning the mounting holes. Start all three screws two to
three turns by hand.

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F-91

6. Tighten each of the outer screws to
between 5 and 10 in/lbs.

5. Connect the eight transformer leads to
the correct rectifier modules. Tighten
the screws (with two flat washers and
one lock washer) to between 30 and 40
in/lbs. Do not stress the terminals
when making these connections.
6. Apply a thin coat of Penetrox A13 to the
heatsink where the positive output lead
attaches.
7. Attach the positive output lead to the
heatsink using the 9/16 in. wrench.
8. Install the case top and sides using the
3/8 in. nutdriver.

7. Tighten the center screw to between 12
and 18 in/lbs.
8. Tighten each of the outer screws again,
this time to between 30 and 40 in/lbs.

POWER WAVE 455/POWER FEED 10

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F-92

NOTES

POWER WAVE 455/POWER FEED 10

F-92

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F-93

TROUBLESHOOTING AND REPAIR

FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE

Power Source Error Interpretation Guide

Start

(Semi Automatic PW-455, PW455/STT)
If the PS Status light is flashing any combination of red and green,
errors are present in the PW-455.

Perform the Contactor Test.
Perform the Switch
Board Test on both
sides.

Codes 32, 33, 34,
and 35?

Pass

Perform Input Board Test.

UI previously recognized by the system is no
longer communicating, but power appears to
be present at the UI. Check for intermittent
connections in the communication path
(pins A and B in the control cable, wires 541
and 542 in both the UI and FH).

Perform the Input Rectifier Test.

Fail

(For Codes 10555 and Below)

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

Code 12?

UI Display and
Status light on?

N
N

Replace as Necessary.

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Replacement board(s) must have
identical part number (including the
"dash number").

Weld Table Error is present.
Codes 21,
22, or 23?

Both Switch boards are reporting an undervoltage error.

Y
Check the "All Modes" dipswitch in the UI, typically
SW2-8 (refer to dipswitch settings specified for the
software version loaded in the UI).

Check Input Voltage.
Perform the Input Board Test.
Code 32 and
33?

Check for proper reconnect position.

Code 31?

Look for faulty undervoltage connections from the Switch board(s) to the
Control board (+5VDC = normal, 0VDC = fault).

Replace Output
Rectifier Modules as
Required

Any of the following
codes:
32, 33, 34, or 35?

Look for faulty overvoltage connections from the Switch
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).

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Thermal Error (generally accompanied by a thermal error light):

Code 36?
Code 32 and
34?

Invalid error combination. Check for
faulty overvoltage and undervoltage
connections from the Switch
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).

Perform the Switch Board
Test on Side "A" (left side
facing the front of
machine)

Pass

Check continuity of thermostat circuit. Thermostats are connected
in series, so open circuit reading indicates tripped thermostat or
faulty connection
Check operation of the cooling fan.

Check for excessive dirt build up in heatsink fins etc.

Fail

Replace the Switch Board
Replacement board(s) must have
identical part number (including
the "dash number").

Check main capacitor for a short circuit
condition.
Check for faulty overvoltacge and
undervoltage connections from the Switch
board(s) to the Control board
(+5VDC = normal, 0VDC = fault).

Soft Start failure.
Generally accompanied by under and over voltage errors
(32-35), because the system is unable to charge the
main capacitors to an acceptable voltage level.
Code 37?

Y
Follow the branch for under and over voltage errors
(32-35) to test the Input Bd., Switch Bd., and main
contactor operation.

Code 33 and
35?

Perform the Switch Board
Test on Side "B" (right
side facing the front of
machine)

Pass
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.

Fail

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The current transformer (CT)
feedback signal to the control
board is too high. Look for a
short in the transformer or
primary side of the machine.

Check for proper reconnect position.

Machine configured
for 230V?

Pass

Fail

Check the Input Voltage.
Code 34 and
35?

Perform Output
Rectifier Test

N
If the symptom is intermittent, Check the operation of the main contactor.

Both Switch boards are reporting an overvoltage error.

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UI previously recognized by the system is no
longer communicating, and no power appears to
be present at the UI. Check for intermittent
connections in the +40 VDC path (pins D and E
in the control cable, wires 540 and 500 in both
the UI and FH).

Reload known good Weld Software.

Other Codes?
Replace the Switch
BoardReplacement board(s)
must have identical part number
(including the "dash number").

Finish

EXCEPTION:
Reoccuring fatal errorscan sometimes be caused by overloading the system. As an
example this could occur in earlier versions of PS software when rapidly changing from
one head to the another on a multi-head system (i.e. PF10x2). Adding a minimum (0.1
seconds) of preflow time to each head or upgrading the operating system shoudl
generally solve the problem.

Key:
PS = Power Source
UI = User Interface (Control
Box)
FH = Feed Head

POWER WAVE 455/POWER FEED 10

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F-94

TROUBLESHOOTING AND REPAIR

FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE

Alternate CC Configuration:
Grid Load (300A / 30V)
Mode = 200
Current = 300
Arc Control = 0

Performance Test Configuration (USE STD
STUD)**
GMAW (.045 Steel - 3/8" Plate)
Mode = 5
WFS =400 ipm
Voltage = 28V
Gas =90/10 ArCO2
Arc Control= 0
** Configuration may be altered based on available
materials. A spray procedure was selected for

Performance Troubleshooting Guide

Alternate CV Configuration:
Grid Load (300A / 30V)
Mode = 201
Voltage = 30V
Arc Control = 0
Note: Mode 201 requires an
electrode sense lead (67).

(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)

Turn On

A NOTE ON VOLTAGE SENSING:
Y

All CV and Pulse modes utilize the electrode sense lead (lead #67) built into the control cable.
As with any sense lead it's performance is only as good as the worst connection.
For diagnostic purposes, an external sense lead can be used to bypass the entire electrode
sense network. This can be accomplished by removing the front cover of the PW-455, and
connecting a lead (20 AWG minimum) from pin 5 of the exposed 6 pin UI molex connector (P6),
to the feedplate on the feeder.

All Status Lights green?
UI functional with no
errors displayed? FH
functional?

See Functional
Troubleshooting
Guide

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Matches Display
Value +/- 1V

Under load as defined previously:
Check for actual voltage at the PS
Control PC Bd., from P20-8 to P20-2
(P20-8 to P20-4 if using a remote work
sense lead)

The Power Source Control PC Board is interpreting voltage correctly, but
there is a bad or incorrect connection in the feedback path.

Using the appropiate measuring
equipment, compare the Actual Current,
Voltage, and WFS to the readings
displayed on the UI

Increase or Decrease the
output settings as
required to achieve a
stable output.

Does not match
Display Value +/- 1V

Check to make sure the weld polarity matches the Electrode Sense
Polarity dipswitch in the FH (SW-7). The default setting is electrode
positive.

Perform tachometer test.
N

Do you get output
from the machine
(can you weld)?

On "-3" and higher vintage PS Control PC Boards the Voltage
feedback can be calibrated. Perform the "Voltage Calibration
Procedure".

Return to Master TOC

Motor running full
speed regardless of
WFS setting?

Does FH gear ratio
dipswitch setting match
pinion gear size?

Perform the Voltage
Sense PC Board Test.

If unable to calibrate, replace the Control PC Board. Please note the
statement regarding test meter accuracy, and follow all applicable
board replacement procedures when replacing this board.

Test being
performed in Mode
200?

Under load as defined
previously: Check for actual
voltage at the PS Control PC
Bd., from P20-6 to P20-2.

Check for proper Drive Rolls.

Verify software is correct version
(PF-10 vs.PF-11).

ALL VOLTAGE MEASUREMENTS SHOULD BE MADE
AT THE SOURCE OF THE VOLTAGE FEEDBACK.
The source of voltage feedback is mode dependent. Mode
200 senses voltage from the output studs of the machine.
Modes 5 and 201 sense from the Conductor Block on the
feeder to the negative stud of the machine, unless the
Voltage Sense Plug (P26) is removed from the Control PC
Bd., inwhich case the remote work sense plug is used
instead of the negative stud.

The PS Control PC Board is NOT interpreting voltage correctly.
N

Actual vs Displayed
Voltage:
+/-1 Volt?**
Y

The PS Control PC Board is NOT interpreting current correctly.
Check the connections at P21 on the Control PC Board. Particularly the
signal pins (1 and 6).

Actual vs Displayed
Current:
+/- 10 Amps?**

Perform the PS
Current Transducer
Test

Depending on the magnitude of the descrepency, the current feedback
can be calibrated. Perform the "Current Calibration Procedure".

Pass

If unable to calibrate, and the connections are OK, replace the Control PC
Board. Please note the statement regarding test meter accuracy, and
follow all applicable board replacement procedures when replacing this
board.

Fail
Y
Does not match
Display Value +/- 1V

Replace the current
Transducer.

The Power Source Control PC Board is interpreting voltage
correctly, but there is a bad connection in the feedback path.
Check connections in the electrode sense path (wire #206) from
P20-6 on the Control PC Board to the electrode(+) stud inside of
the PS.
Check the work sense path (wire #202) from P20-2 on the Control
PC Board to the Work Stud.

STT Machine?

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Correct FH
Dipswitch
setting.

Check for proper Drive Roll tension.
Actual vs Displayed
WFS:
+/-10 ipm?**
OK

Return to Section TOC

Repair / replace as
necessary.

Check the work sense path (wire #202) from P20-2 on the PS Control PC
Board to the Work Stud, or (wire #21) from P20-4 to the remote work
sense lead depending on the configuration.

Return to Section TOC

Key:
PS = Power Source
UI = User Interface (Control
Box)
FH = Feed Head

Check connections in the entire electrode sense path (wire #67) from the
2 pin output connector on the Voltage Sense PC Board, through the FH
wiring harness, control cable(s), UI wiring harness (if system is
configured with the UI between the FH and PS), and up to P20-8 on the
Control PC Board inside of the PS.

Matches Display
Value +/- 1V

**Note: The accuracy of measuring equipment
plays a significant role.Generally speaking,
meters of reasonable accuracy should give
readings within the stated limits. The intent
here is to establish proper performance, not
absolute accuracy.

Activate output (trigger the welding
output).

STT Performance Test Configuration (USE STT STUD)**
GMAW (.045 Steel - 1/4" Plate)
Mode = 117
WFS =170 ipm
Trim = 1.00
Gas =CO2
Arc Control= 0
** Configuration may be altered based on available
materials, but basic waveshape should remain the same.
!!CANNOT BE TESTED WITH STATIC GRID LOAD!!

The STT portion of the system
is operating properly

The PS Control PC Board is NOT interpreting voltage correctly.

Using the Arc Scope function in
Wave Designer / Wave Surfer, or
an oscilloscope equiped with a
current probe, capture an STT
waveform, and compare it to the
sample STT waveform (shown at
right).

Are the wave shapes
similar, and does current
drop in the middle of the
pulse as indicated?

On "-3" and higher vintage PS Control PC Boards the Voltage
feedback can be calibrated. Perform the "Voltage Calibration
Procedure".
If unable to calibrate, replace the Control PC Board. Please note the
statement regarding test meter accuracy, and follow all applicable
board replacement procedures when replacing this board.

N
The system is monitoring and
controlling WFS, Voltage,
and Current correctly.
Performance checks OK.

The STT Chopper PC Board appears to be shorted, and therefore,
the resulting current waveform does not drop in the middle of the
pulse as indicated in the Sample STT Waveform
Disconnect J10 from the STT Chopper PC Board, and make
another test weld. If the same symptoms result, perform the STT
chopper PCBD test. If the machine noodle welds, the problem is
related to the control signal from the Control PC Board.

The STT Chopper PC Board appears to be "open".
Check for 18Vac at J10 pins 1 & 4 on the STT Chopper Board.
N

Does the machine
noodle weld ( low output)?

Check for loose or broken connections. Inspect the PC board for physical
damage
Perform the STT Chopper Board Test.

POWER WAVE 455/POWER FEED 10

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F-95

TROUBLESHOOTING AND REPAIR

FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE

Functional Troubleshooting Guide

See UI Error
Chart for
additional error
codes.

Error 006?

(Semi Automatic PW-455, PW455/STT)
(For Codes 10555 and Below)

Error 100?
Turn On
Y

Main UI Display
panel on?

Status Light on the PS
on?

UI Status
on?

Condition of
Status Light?

Other
At this point, voltage is being supplied to the UI Control
Board, and the on board supply is properly converting it to
12Vdc. This has been verified by the condition of the Status
light and by measurement at the display.

Solid Green

Y
Y
Communication Fault.
Check Wiring and
Linc-Net Cables for
open circuit

Solid
Red

Condition of
Status light

Go To PS
Error
Interpretation
Guide.

Flashing
Red and Green

Return to Master TOC

Verify 12 VDC is being
supplied to UI Display
PCBD (J1 pin 7 to 8)

Flashing Green

Return to Section TOC

Errors on UI
Display?

PS Status
on?

Select a CV
Mode

Can you adjust
WFS and Voltage?

At this point, voltage is being supplied to the UI Control
Board, and the on board supply is properly converting it to
12Vdc, which has been verified at the display.

Verify all connections to the PS Control Board
N

5 Green LED's lit on
the PS Control
Board?

Perform Power Board test to verify correct
voltage levels

Errors on UI
Display?

Does Wire feed when
you pull the trigger?

Check For
40VDC at UI
Control Board

Y
Reload the PS Software. If Problem still
exists, replace PS Control Board.

Verify 12 VDC is being
supplied to UI Display
PCBD (J1 pin 7 to 8)

Is there OCV from the
brass block to the work stud
with the trigger pulled

Y
Look for open
circuit in the
PS secondary

There is a remote possibility that a multiple fault exists in
the harness from the Display to the UI Control board, or in
any combination of the following: The harness, the Display
board, and the Status light.

Not OK

System is functional. If
performance problems
exist see System
Performance
Troubleshooting guide

Check PS breaker (CB1), Linc-Net
cables, wiring in UI and PS.
+40 VDC section of Power Board
may be malfunctioning, Perform
Power Board test

UNHEALTHY STATUS LIGHT WITH BLANK DISPLAY:
Improper system configuration (dipswitch settings) can result in
mapping errors that cause PS to continuously issue a system reset
command. The result is the UI gets stuck in a reset loop, usually
accompanied by a blank display with a green and/or red flashing
status light. Correct the system configuration.

Verify no Limits are set.

Check the connections on wires 541 & 542, and pins A & B in the
Linc-Net control cable.

Check/repair harness between:
Run Power
Board Test

Check Harness for UI Control Board
to the Dislay Panel (specifically the
wires to the Encoder Board.

The Power Board and the Control Board.
- AND/OR The Power Board and the wire feeder
receptacle (S1), including the output
circuit breaker (CB1).

Pass

Fail

Was 60-80 VDC at Power
Board input connector

The Status light is not functioning, so the most likely
problem is that the UI Control board is "lost".Try reloading
the UI Software. If problem still exists, Replace the Control
board.

Return to Master TOC

There is a remote possibility that the Communications
Hardware on the UI Control board is not functioning
properly.

Check connections from UI Control Board to
Display panel. If the display and Status light are
still not functioning, remove P4 from the UI
Control Board.
Check for 12 VDC at J4 pins 1 to 4 , and J4
pins 3 to 8 on the UI Control board. If voltage is
not present, replace UI Control Board

Check Status Light and harness

Errors on UI
Display?

Return to Section TOC

System is stuck in Remapping loop.
Most likely cause is the loss of the
+5Vcan Supply. Check J27 on PS
Control Board, check Power Board,
Etc.

Because the Status light indicates a healthy condition, the
problem is most likely in the harness from the Display to
the UI Control board or in the Display board itself. Check the
harness, and run the Display Panel Check.

UI software may be corrupt. Reload UI soft ware

Run The Dual Encoder PC Board
Test

FH does not appear to have power.

Replace the
Power Board.
FH Status On?

Check +40 VDC connections on
pins "D" & "E" of the Linc Net
receptacle in the FH.

N
Y

Voltage at the Power
Board Capacitor?

Check/repair harness
between the Power
Board and the Capacitor.

Return to Master TOC

Return to Section TOC

Voltage at the input to
the Rectifier?

Be sure the trigger is engaged long enough to overcome any set preflow
delay, or turn the preflow timer off.
Check trigger circuit operation from the gun to the FH Control Board.

Green

Perform the Drive Motor Test to verify motor voltage is present when the
trigger is pulled.

Input power does not appear to be
supplied to aux. transformers
Check input power, check reconnect,
check Breakers, check Line Switch, etc.

Check for 60 to 80 VDC at the
Output of the rectifier. If present,
check harness from rectifier to
Capacitor. If not replace rectifier

A rapidly flashing red Status light indicates the node needs to be
reprogrammed.

The FH has detected no activity from the
communication network.
Red
Check the connections on wires 541 & 542, and pins
A & B in the Linc-Net control cable.

Flashing

Flashing Red

Check the continuity of the Shutdown circuit in the FH (wires
570 & 571). If the path between these wires is interrupted the
FH will not operate and the Status light will flash red while all
other nodes appear normal.

FH Status
Condition?

FH Status
Condition?
Flashing
Red and Green

FH has a motor
overcurrent/overtemperature
error.

Flashing Green

Check the system configuration.
If the FH is not recognized as part of a valid group, or if
improper dipswitch settings result in a duplicate or invalid
network assignment, a mapping error will be generated.

Key:
PS = Power Source
UI = User Interface (Control
Box)
FH = Feed Head

POWER WAVE 455/POWER FEED 10

Return to Master TOC

G-1

ELECTRICAL DIAGRAMS

G-1

TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTIONELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
POWER WAVE 455 WIRING DIAGRAM - CODE 10372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
POWER WAVE 455 WIRING DIAGRAM - CODE 10555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
POWER WAVE 455 WIRING DIAGRAM - CODE 10553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
POWER FEED 10 CONTROL BOX WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
POWER FEED 10 WIRE DRIVE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
POWER FEED 10 MACHINE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10372. . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10555. . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
POWER WAVE 455 MACHINE SCHEMATIC - CODE 10553. . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . G-11
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . G-12
POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . G-13
POWER WAVE 455 POWER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14
POWER WAVE 455 INPUT PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15
POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10372 & 10555. . . . . . . . . . . . G-16
POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10553 . . . . . . . . . . . . . . . . . . . G-17
POWER FEED 10 MOTHER CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . G-18
POWER FEED 10 CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19
POWER FEED 10 DISPLAY PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-20
POWER FEED 10 ENCODER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-21
POWER FEED 10 VOLTAGE SENSE PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . G-22

Return to Section TOC
Return to Master TOC

Return to Section TOC

Return to Master TOC

Return to Section TOC
Return to Master TOC

Return to Section TOC

NOTES

POWER WAVE 455/POWER FEED 10

LEFT SIDE OF MACHINE
CONTROL BOARD
TO
TP3

202

TO J20

206

212
213

214

52A
51

218

54A

51A

221

67B

222

52A

223

224

J22

TO
J20

226
2B

228

10
1

S3
RS232

253

254

4
5

CONNECTOR

FRONT OF MACHINE

6
251

J23

CB1
10A CIRCUIT
BREAKER

TO
L2

231
232

233

234
503

406

238

239

405

604

404

506

403

BOARD

3
4

WORK

J24

ELECTRODE

225
223

222

J31

228

THERMAL

226

7
8

221

J31

LED
RECT.
THERM.

MAIN CHOKE
L1
J22

MAIN TRANSFORMER
LEFT SIDE

J27

9
11

274

273

SECONDARY

OUTPUT RECT
TO
J40
J50
J60

(TOP

LEFT)

POS

J32

NEG

TO
STATUS
LED

SECONDARY

PRIMARY

(BOTTOM

LEFT)

2
253

254

THERM.
224A

290

Return to Master TOC

PRIMARY

(BOTTOM

RIGHT)

238

TO SWITCH

J60

BD #2

2.7
10W

POWER BD RECTIFIER

12
14

273
274

TO
S1
J31

TP5

2
SECONDARY

PRIMARY

(TOP

RIGHT)

J61

3
4
5

J28

NEG
NEG

POS
POS
POS

N.A.

TO
J32
POWER
BD.
RECT.

.022
800V

RIGHT SIDE

TO CURRENT

N.D.

17
20D

TO J61
H1D

(TOP)
2

TO CB3
612B

LOAD

SW1
POWER

LINE
3

TO CONTACTOR
L1A
TO CONTACTOR
L3A

216

212

211

213

TRANSDUCER

AC2

AC1

FAN THERM
TO J60

TO
RECT
THERM

19D

4
P81

W
R
(115V)

AUXILIARY
TRANSFORMER
#2

P90
CURRENT

AC3

TO J61

TRANSFORMER

TO
S4
CB2
1

Return to Master TOC

Return to Section TOC

ELECTRODE

TO RECONNECT PANEL

CB4

H5
(440-460)
H4
(380-415)
H3
(220-230)
H2
(200-208)
H1

H5A

H4A

H3A

H2A

601

CR1

601A

290

X4
TO AUX #1
FAN THERM

224A

TO SW1

X4A

TO SW1
L1A

L3A

T0
RECT
THERM

206

TO
CR1

H1D

TO MAIN TRANS

TO TP3

POS

SW1

TO RECONNECT SWITCH

.05/600V

NEG

612

7
8

TO J21
TP2
C2

POS

SWITCH BOARD #2

THERMAL LED (Y)
TO J22

TO J20

STATUS LED (R/G)
TO J24

INPUT
RECTIFIER

J50

BD #1

F1
2.7
10W

3
4

TO SWITCH
F1

NEG

SWITCH

TO J23

NEG

2
3
4

TO
RECONNECT

231

N.D.

AUX. #1
C3

TO
J23
CR1
AUX #1

TO CURRENT

N.A.

232

TRANSFORMER
TO

604

.022
800V

POS

601

INPUT BOARD

SECONDARY

TO J21

RECT.

224

TO FAN THERM

J27

214
CURRENT

218

6
J26

TRANSFORMER

TO
J81
CB2

TO MAIN TRANS

TO RECONNECT

TRANSFORMER

4
32

220

19C

FAN
16

TO CURRENT

TO
J22

TO AUX #1

13 14
20C

TRANSFORMER

11 12

TO CURRENT

110V RECEPTACLE

NEG
TO INPUT RECT

BD #1

251

440-460V

TO SWITCH

380-415V

SWITCH BOARD #1

.022
800V

TO SWITCH BD #1
20C

20D

TRANSFORMER

.022

2.7
10W

J40
TO SWITCH BD #2

800V

200-208V
220-230V

'A'

REAR OF MACHINE

J25

TO AUX #1
H2

N.D.

TO SW1

N.C.

POS
TO INPUT RECT

TO CURRENT
2.7
10W

TO SWITCH BD #1
19C

TO
C3

RECONNECT PANEL

19D

TO SWITCH BD #2

PRIMARY

BREAKER

RECONNECT SWITCH

N.B.

TO J23

TRANSFORMER

TO
S4
J81

THIS AREA VIEWED FROM REAR OF MACHINE
TO CURRENT

10
31

BREAKER

CB2
10A CIRCUIT

6A CIRCUIT

H1
TO AUX #1

1
2
3

612

CB1

POWER

TP3

235

CB4

612A

TO
CT
P90

220

1
2

TO
J25

225

6
7

TO CB3

RECONNECT PANEL

150 5W

21A

J61

CB4

FAN
THERMOSTAT

1
2
3

H2A

506

S2
VOLTAGE
SENSE
RECEPTACLE

H2
H1

239

53A

INTERFACE

216

H3A
H3

AUX #2

235

H1A
TO P80

5
7

51BK

H4A
H4

406

211

2
3

H5A
H5

404

(200-208)
H1

405

67A

(24V)
R
(115V)

J21

50WT

67B

P6
USER

POWER BOARD

J60

H3
(220-230)
H2

54A

CR1
FAN

233

TO
J27
P6
CB1
J20

H4
(380-415)

X3
X3

234

WORK
ELECTRODE

H5
(440-460)

U
(51V)

10
11

S2
S1

67A

POWER BOARD

403

J20

TO CB1

POWER BD. RECTIFIER

.05/600V

C1
TP1

AUXILIARY TRANSFORMER #1

503

WORK

53A

Return to Master TOC

TO CB4
612A

21A

51A

Return to Section TOC

202

CB3
10A CIRCUIT
BREAKER

TO SW1
612B

Return to Master TOC

Power Wave 455 Wiring Diagram - Code 10372

S1
WIRE
FEEDER
RECEPTACLE

Return to Section TOC

G-2

ELECTRICAL DIAGRAMS

Return to Section TOC

G-2

TO SUPPLY LINES
TO AUX #1
CB3

H1A
TO A SYSTEM GROUND PER

NOTES:

NATIONAL ELECTRICAL CODE.

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 VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.D. MAY NOT APPEAR ON ALL MACHINES.

RIGHT SIDE OF MACHINE

ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK

COMPONENT VALUES:

G=GREEN

CAPACITORS=MFD/VOLTS

N=BROWN
R=RED
U=BLUE
W=WHITE

RESISTORS=OHMS/WATTS

J25

J27,J28
J32,J40
J50,J81

J21,J60

J22,J61

J24,J31

J20,J26

J23
1

CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)

3-19-99D

G3051

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER WAVE 455/POWER FEED 10

LEFT SIDE OF MACHINE

TO J20
202

CONTROL BOARD
TO TP3

1
2

202A
TO R1

.05/600V
TP1

J20

67A

54A

J27

52
51

J21A

53A

224A
1

CHOKE

212
213

214
216

7
8

218

TO AUX#1

TO J21A

POWER BOARD

211

3
2

212

50WT

216

CB1

CB3

612

H1
TO AUX #1

TO SOLID STATE RELAY
444
X5
TO AUX#1

J25
251

TO
J23

L2
POWER BD

TP3

225
226

228

220

273

POS

231

NEG

232

NEG

233

234

235

503

406

238

239
405

11
12

604
404

506

WORK

403

OUTPUT RECT

J40
J50

800V

2.7
10W

800V

J60

J24

SOLID STATE RELAY

TO
J81
CB2

J25

CHOKE
THERM

POWER BD RECTIFIER

2
3

253

254

NEG

NEG
+

10
11

TO
S4

J81

2.7
10W

800V

STATUS LED (R/G)
TO J24

NEG

TO
C3

273

SECONDARY
(TOP
RIGHT)

CR1
J23
AUX #1
TO

POS
POS

POS

J32

PRIMARY
(TOP
RIGHT)

SWITCH

3
4

CR1

612

SWITCH BOARD #2

N.D.

TO J61

TO J60

J31
15 16
TO CURRENT
TRANSFORMER

17 18
20D

19D

X4
TO AUX #1
TO RECONNECT SWITCH
TO SW1

TP2

P81

W
R

(440-460)
H4
(380-415)
H3

TO RECONNECT PANEL

TO J61
H1D

(TOP)
2

TO CB3
612B

LOAD
LINE
1

TO CONTACTOR
L1A

N.A.

L3A

H5A

H4A

TO SW1
L1A

H3A

H2A

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.

RIGHT SIDE OF MACHINE

AUX #1

H1A
TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.
J27,J28
J32,J40

ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODING
B=BLACK

COMPONENT VALUES:

G=GREEN

CAPACITORS=MFD/VOLTS

N=BROWN

RESISTORS=OHMS/WATTS

J50,J81

J25

J21A,J21B
J60

J24,J31

J22,J61

J23

W=WHITE

J20,J26

R=RED
U=BLUE

CB3

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

V
TO SUPPLY LINES

AUXILIARY TRANSFORMER #2

NOTES:

N.D MAY NOT APPEAR ON ALL MACHINES.
TO CONTACTOR

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

TO TP3
A

(115V)

CB2

Return to Master TOC

CR1

TO MAIN TRANS

3
4

601

L3A

ELECTRODE

AC1

.022
800V

C2
.05/600V

Return to Section TOC

AC2

AC3

CB4

POS

SW1

H1D

206

TO R1
206A

POS

NEG

7
J50

TO J20

INPUT
RECTIFIER

J61

BD #1

RECONNECT

231

NEG

TO SWITCH

J28

RIGHT SIDE
TO

238
232

TO J23

274

X3
604

5
7

TO CURRENT
TRANSFORMER

AUX. #1

2.7
10W

3
4

601

2
3
4
6

BD #2
17

THERMAL LED (Y)
TO J22

J60

TO SWITCH

N.A.

PRIMARY
(BOTTOM
RIGHT)

POWER BD RECT

2
J27

N.A.

406

1
SECONDARY
(BOTTOM
RIGHT)

.022

N.D.

15
1

INPUT BOARD

291

N.D.

CB2
10A CIRCUIT
BREAKER

218

206A

TO L7

CURRENT
TRANSFORMER

TO CURRENT

6
J26

TO RECONNECT SWITCH

TP7

ELECTRODE

NEG

WORK

TRANSFORMER
15

POS

THERM.

TO MAIN TRANS

202A

RECT.

224A

251

13 14
19C

20C

TRANSFORMER

BD #1
14

220

STATUS LED

11 12

214

224

TO CURRENT

NEG
TO INPUT RECT

SWITCH BOARD #1

TO SWITCH

TO J22

380-415V
440-460V

J40

PRIMARY
(BOTTOM
LEFT)

SECONDARY
(BOTTOM
LEFT)

.022
D3

20D

TRANSFORMER
12

N.D.

110V RECEPTACLE

TO SWITCH BD #1
20C

TO SWITCH BD #2

REAR OF MACHINE

200-208V
220-230V

'A'

TO CURRENT

.022

2.7
10W

TO AUX #1
H2

BD #2
18

1
2
3
4

PRIMARY
(TOP
LEFT)

TO SW1

N.C.

POS
TO INPUT RECT

TO SWITCH

TO
C3

SECONDARY
(TOP
LEFT)

J32

1
2

ELECTRODE

274

506

5
6

LED
RECT.
THERM.

5
6

239

J22

THERMAL

235

254

J31

224

TO SWITCH BD #1
19C

253

223

RECONNECT PANEL

19D

TO J23

TRANSFORMER
16

2
3
4

TO SWITCH BD #2
TO CURRENT

405

221

404

226

221
222

6
7

J31

J20

N.B.

RECONNECT SWITCH

MAIN TRANSFORMER
LEFT SIDE

J27

228

J22

222

233

223

7
8

TO
21A

CB1
10A CIRCUIT
BREAKER

225

3
4

403

2
3

FAN

THIS AREA VIEWED FROM REAR OF MACHINE

5
6

SW1
POWER

CB4
6A CIRCUIT
BREAKER

612A

H2A

J21B

52A

TO J61

CB4
RECONNECT PANEL

X3A
TO SOLID STATE RELAY

L2
51BK

AUX #2
H3A

TO FAN

P91

(115V)

P91
CURRENT
TRANSDUCER

503

67B

S3
RS232
CONNECTOR

(24V)
R

H1A
TO AUX #2

H4A

234

51A

H5A

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

54A

(380-415)

213

(440-460)
H4

CR1

U
(51V)

TO
J60

N.D.

5
6

291

X3A

TP4

TO FAN

211

2
3

MAIN CHOKE
L1

THERM.
444

S2
VOLTAGE
SENSE
RECEPTACLE

FRONT OF MACHINE

AUXILIARY TRANSFORMER #1
X1
TO POWER BD. RECTIFIER

P6
USER
INTERFACE

612A

TRANSFORMER

J20

CB3
10A CIRCUIT
BREAKER

612B

TO RECT THERM

CURRENT

SOLID
STATE
RELAY

67B

ELECTRODE

51A

Return to Master TOC

206

7
8
10

CB1
POWER BD

53A

Return to Master TOC

21A

TO SW1

TO CB4

WORK

5
C1

52A

Return to Section TOC

WORK

202

TO
J24

Return to Master TOC

Power Wave 455 Wiring Diagram - Code 10555

S1
WIRE
FEEDER
RECEPTACLE

Return to Section TOC

G-3

ELECTRICAL DIAGRAMS

Return to Section TOC

G-3

CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)

3-19-99D

G3051-1

Return to Master TOC

Return to Section TOC

G-4

ELECTRICAL DIAGRAMS

Power Wave 455 Wiring Diagram - Code 10553
LEFT SIDE OF MACHINE
CONTROL BOARD
CB3
10A CIRCUIT
BREAKER
AUXILIARY TRANSFORMER #1

SOLID
STATE
RELAY

WORK

CB4
6A CIRCUIT
BREAKER

MAIN CHOKE
L1

S1
WIRE
FEEDER
RECEPTACLE

L7
N.D.

P91
CURRENT
TRANSDUCER

FAN

POWER BOARD
THIS AREA VIEWED FROM REAR OF MACHINE

TO SWITCH BD #2
18

OUTPUT RECT

S3
RS232
CONNECTOR

SECONDARY
(TOP
LEFT)

PRIMARY
(TOP
LEFT)

TO SWITCH BD #2
17

TO SWITCH BD #1
14

SWITCH BOARD #1
2.7
10W

CB1
10A CIRCUIT
BREAKER

N.C.
TO AUX #1

TO BOTTOM RIGHT PRI
17B
18B

TO SWITCH BD #1

.022

SECONDARY
(BOTTOM
LEFT)

PRIMARY
(BOTTOM
LEFT)

'A'

440-460V
550-575V

TO TOP RIGHT PRI
13A
14A
TO BOTTOM LEFT PRI

.022
800V

N.D.
2.7
10W

TO TOP RIGHT PRI
13B
14B
TO BOTTOM LEFT PRI

800V

REAR OF MACHINE

INPUT BOARD
32
TO
J81
CB2

Return to Master TOC

TO SW1

18A

TO TOP LEFT PRI

110V RECEPTACLE

Return to Section TOC

RECONNECT PANEL

TO BOTTOM RIGHT PRI
17A

TO TOP LEFT PRI

FRONT OF MACHINE

Return to Master TOC

Return to Section TOC

N.B.

RECONNECT SWITCH

MAIN TRANSFORMER
LEFT SIDE

S2
VOLTAGE
SENSE
RECEPTACLE

2.7
10W

.022

SECONDARY
(BOTTOM
RIGHT)

PRIMARY
(BOTTOM
RIGHT)

800V

N.D.

CB2
10A CIRCUIT
BREAKER

TO SWITCH
BD #1

TO SWITCH
BD #2

POWER BD RECTIFIER

NEG

N.D.

INPUT
RECTIFIER

POS

NEG
SECONDARY
(TOP
RIGHT)

2.7
10W

PRIMARY
(TOP
RIGHT)

AC2

AC3

AC1

SWITCH BOARD #2

.022
800V

POS

RIGHT SIDE

TO J61

N.D.

TO J60

601

CR1
X4
TO AUX #1
TO SW1

TO SW1
L1A

L3A

Return to Master TOC

Return to Section TOC

TO SUPPLY LINES

N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT
VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.

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

ELECTRODE

VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION.

(TOP)

AUXILIARY TRANSFORMER #2

N.D. MAY NOT APPEAR ON ALL MACHINES.

TO A SYSTEM GROUND PER
NATIONAL ELECTRICAL CODE.

RIGHT SIDE OF MACHINE
SW1
POWER

3-19-99D

G3051-2

Power Feed 10 Control Box Wiring Diagram

USER

512B

INTERFACE

565

564

500F

566

567

DISPLAY

568

P.C. BOARD

569

12 3 4 5 6 7 8

550

512C

500

552

550

(J3)

N.A.
7

ENCODER

500C

9
10

554

556

512A

558

LOWER

557

500D

OPTION

559

560

511

561

9
10

562

500E

3 4

(J1)

N.A.
3 4

(P7)
N.B.
N.D.

541A

542A

400A

542A

542

500A

500

67
540A

(USED FOR
BENCH SET
UP)

541D
542D

R.F.
TOROID

500D
540D

(J7 ON WIRE DRIVE OR ON INPUT RECEPTACLE SHOWN)
N.B.

541A

540A

541

540

R.F.
TOROID

540D
500D
D

541D
542D
B

A
BOTTOM
PANEL

MIDDLE
PANEL

(J6)

LINC-NET
OUTPUT
RECEPTACLE

NOTES:
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.

(J8)

LINC-NET

TOP
PANEL

B W

N.E.

563

500A

512C

555

1 2 3 4

Return to Master TOC

N.A.

STATUS LED

553

1 2 3 4

RED/GREEN
N.C.

(J2)

1 2 3 4 5 6 7 8

P.C. BOARD

500C

N.F.

DUAL

7
8

(J1)

N.A.

551

512

540
500

(J4)

Return to Master TOC

Return to Section TOC

OFF

12 3 4 5 6 7 8

1 2 3 4 5 6 7 8

S2
ON

9
10

541
542

N.F.

512
500

N.A.
S1

(J1)

N.E.

552
551

(J5)

556

BOARD

UPPER
OPTION

553
554

MOTHER

OFF

Return to Section TOC

G-5

ELECTRICAL DIAGRAMS

Return to Master TOC

Return to Section TOC

G-5

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

INPUT

N.D. TO FEEDER HEAD OR OPTIONAL INPUT LINC-NET RECEPTACLE.

RECEPTACLE

N.E. THE OPTION INSTALLED MAY NOT HAVE ALL OF THE SHOWN WIRES. SEE THE

(OPTIONAL FOR
BOOM SET UP)

OPTION'S WIRING DIAGRAM FOR ADDITIONAL INFORMATION.
N.F. CAVITY NUMBERING SEQUENCE AS VIEWED FROM EDGE OF PC BOARD, COMPONENT
SIDE DOWN.
N.G. MAY NOT BE PRESENT ON CODE 10494 OR PRIOR MACHINES.

(OPTIONAL)

Return to Master TOC

Return to Section TOC

400D

400C

400B

ELECTRICAL SYMBOLS PER E1537.

= CHASSIS CONNECTION

LEAD COLOR CODING
CONTROL BOX

B - BLACK
W - WHITE

N.G.

9-11-98D
L10586

R.F.
TOROID

DUAL
PROCEDURE
TRIGGER

(J1)

541A

512

560

558

512A
N.D.

N.D.

N.E.
B

R.F.

RED/GREEN
STATUS LED
N.C.

67A
511
400

U - BLUE
W - WHITE

552
551
553
541D

RECTIFIER

542D

BRIDGE

500D
540D
540A

552 553
GAS
SOLENOID

541A

540C

540B

541
542A
542

R.F.
TOROID
67
67

540
500A
500
540C

R.F.
TOROID

(J6)

540D
500D

540B

550

1 2 3 4 5 6 7 8 9 10

N.A.

= CHASSIS CONNECTION

R - RED

3 4

(J1)

B - BLACK

N.A.

LEAD COLOR CODING

541D
542D

(J2)

ELECTRICAL SYMBOLS PER E1537.

540
500

1 2 3 4

Return to Master TOC

(J3)
N.A.

N.E. MAY NOT BE PRESENT ON CODES 10494 AND PRIOR MACHINES.

511
1 2 3 4 5 6

556
557

512B

1 2

(J6) 1
N.A. 2

SHUT
DOWN

3 4

1 2 3 4

LEAD OF LED SOCKET.
N.D. TOGGLE SWITCHES SHOWN FROM CONNECTION SIDE OF SWITCH.

(J2)

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

B
571

OFF

N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.

560
570

2
6

N.A.

12 3 4 5 6 7 8

N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD.

559

SELECT P.C. BOARD

1
(J5)

555
512
558

541
542

(J2)

P.C. BOARD

554

CONTROL

1 2 3 4 5 6 7 8 9 10 1112

N.A.

Return to Master TOC

512A

TOROID

(J4)

Return to Section TOC

559

512B

VOLTAGE SENSE

1 2 3 4 5 6
400A

(J8)

554

N.E.

A C D E B
555

P.M.

MOTOR/GEARBOX

(J7)
N.B.

COLD INCH/
GAS PURGE

2 STEP/
4 STEP

IF USED

67
540A

550

TO USER
INTERFACE

GUN
RECEPTACLE

542A
500A

551

557

556

TACH

67A

INPUT ELECTRODE CABLE

Return to Master TOC

VOLTAGE SENSING
CONNECTION

1 2

Return to Master TOC

Power Feed 10 Wire Drive Wiring Diagram

(J1)

Return to Section TOC

G-6

ELECTRICAL DIAGRAMS

1 2 3 4 5 6

Return to Section TOC

G-6

(J9)

LINC-NET

INPUT

OUTPUT

RECEPTACLE

RECEPTACLE
(OPTIONAL)

9-11-98D
L10587

G-7

ELECTRICAL DIAGRAMS

POWER FEED 10 MACHINE SCHEMATIC

540

+40 VDC

7J1

500

9J1

+40 VDC

4J2

0 VDC

3J2

3J7

J6 OPTIONAL
OUTPUT
RECEPTACLE

67
L2

540D

540

L10

0 VDC

(BENCH)

+40 VDC

L2
0 VDC

542

540

500D

500

541A

1P7

500D

L7
6J7

1J2

COMMUNICATION -

1J1

COMMUNICATION +

2J1

541D

ELECTRODE
VOLTAGE SENSE
COMMUNICATION -

L8
4J7

3P7

542A

2J2

COMMUNICATION +

542D

COMMUNICATION +

+40 VDC

0 VDC

DISPLAY
P.C. BOARD

Return to Master TOC

Return to Section TOC

1J4

8J1

+12 VDC
0 VDC

MOTOR

2J4

TACH
B

3J4

1J1

542A

500A

INTERNAL HARNESS AND
CONNECTOR USED ONLY IF UNIT
CONFIGURED AS A BENCH FEEDER.

540A

1J7

6P7

3J7

540A

4J7

CONTROL BOX
USER INTERFACE PCB

5J7

* SERIAL

6J7

PERIPHERAL

TACH SIGNAL INPUT

0 VDC
B

8J5

(HIGH FOR GREEN)

1J4

* MOSI -

2J4

+12 VDC -

3J4

0 VDC -

4J4

* SCK -

5J4

* LATCH -

CATHODE
RED/GREEN

7J5

SHUT
DOWN

571

9J5

SIGNAL COMMON

STATUS LED

10J5

(HIGH FOR RED)

STATUS
LED

6J4

8J4

ENCODER 1, SIG. B -

9J4
10J4

ENCODER 2, SIG. B -

11J4

ENCODER 2, SIG. A -

+40 VDC

GUN
RECEPTACLE

GUN
CONTROLS

(P11) (J11)

L4
554

1J5

DUAL PROCESS,

PWM

OPEN = PROCESS A

CONTROL

556

11J5

SIGNAL COMMON

557

12J5

GUN TRIGGER,
CLOSE = FEED HOT WIRE
SIGNAL COMMON

L11
+ PWM
CONTROL

4J3

551

2/4 STEP

CONTROL

1J3

+12 VDC -

1J5

* MOSI -

2J5

* MISO -

3J5

0 VDC -

4J5

550

559
COLD INCH

6J5

7J5

PROC. B -

8J5

9J5

10J5

5J5

VOLTAGE SENSE
SELECT PCB

TRIGGER ACTION SELECT,
OPEN = 2 STEP
PURGE SIGNAL

+12 VDC

1J6

512B

1J1

6J5

PROC. A -

512A

560

5J5

* LATCH -

L12
- PWM

14J4

* SCK MOTOR

FEEDER
CONTROLS

552
550

500C

512

3J5

558

4J5

COLD INCH SIGNAL

VOLTAGE SENSE
SELECT SIGNAL

2J6

8
B
CATHODE
RED/GREEN

553
556

STATUS
W

LED

555
B
W

512B
565
564
500F
566

511

4J1

2J2

J6 INPUT
RECEPTACLE

3J1

1J2

ELECTRODE VOLTAGE
SENSE TO WELDER

2J3

* MISO -

3J3

0 VDC -

4J3
5J3
6J3

POT SUPPLY -

7J3

POT WIPER -

8J3

MODE 1 -

ASSEMBLY

1J3

* MOSI -

* LATCH -

ELECTRODE CABLE
WIRE DRIVE

+12 VDC -

* SCK -

CR1
67A

UPPER OPTION PANELS.
SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN.
DUAL PROCEDURE PANEL KIT
DUAL PROCEDURE / MENORY PANEL KIT

567
568
569

(SOLID STATE)
CR1

+12 VDC

PURGE

554

512A

DUAL
ENCODER
P.C. BOARD

RECEPTACLE.

TRIGGER

500

WITH J9 OPTIONAL OUTPUT

553

6J3

512C

CONFIGURED AS A BENCH FEEDER

SOLENOID
2J5

551

THRU CONTROL BOX WHEN

GAS

555

13J4

STATUS LED (HIGH FOR RED) -

FROM ADDITIONAL WIRE DRIVE

12J4

STATUS LED (HIGH FOR GREEN) -

ELECTRODE VOLTAGE SENSE

552

3J3

512

7J4

0 VDC -

ENCODER 1, SIG. A -

CONTROL SIGNAL
OPEN = FAULT

PROCESS

Return to Master TOC

+12 VDC -

570

500D

0 VDC

INTERFACE

STATUS LED

DUAL

Return to Section TOC

4J2

500D

550

+40 VDC

542A

3J1

5J1

4J1

0 VDC

3J1

2J1

4J1

CIRCUIT SUPPLY

COMMUNICATION -

COMMUNICATION +

5P7

553

WIRE DRIVE PCB

L10

556

+40 VDC

540D

1J1

10J1

541A

4J1

2J1

540C

541A

+40 VDC

555

6J1

+40 VDC

512C

540B

RECTIFIER

3J2

500C

BLOCKING

4P7

540D

1J1

500A

7J1

2J2

542

8J1

COMMUNICATION +

1J7

L1
542D

VOLTAGE SENSE

L8
542D

6J1

1J2

512

COMMUNICATION -

541

551

COMMUNICATION +

541

500

ELECTRODE

542

541D

3J1

5J1

L1
542

67
(BOOM)

541D

4J1

COMMUNICATION -

5J1

L7
3J1

552

COMMUNICATION +

541

2J1

7J1

L1
COMMUNICATION -

8J1

J9 OPTIONAL
OUTPUT
RECEPTACLE

WIRE DRIVE CONTROL PCB

6J1

J6 INPUT
RECEPTACLE

J8 OPTIONAL
INPUT RECEPTACLE.
IF CONFIGURED AS BOOM, CONNECTS VIA
ARCLINK CABLE FROM WIRE DRIVE (J9)
OR POWER WAVE 455.

554

Return to Master TOC

Return to Section TOC

G-7

MODE 3 POT COMMON -

9J3
10J3
11J3

512A
558
557
500D

LOWER OPTION PANELS.
SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN.
CV/GOUGE PANEL (STD)

559

"M" PANEL KIT

560

"MSTT" PANEL KIT

511

"MX2" PANEL KIT

561
562

"MSP2" PANEL KIT

563
500E

12J3

J9 OPTIONAL
OUTPUT
RECEPTACLE
ELECTRODE VOLTAGE
SENSE FROM

Return to Master TOC

Return to Section TOC

ADDITIONAL WIRE DRIVE

NOTES:
OPTIONAL OUTPUT RECEPTACLE IS REFERENCED (J9) ON WIRE DRIVE AND
(J8) ON USER INTERFACE CONTROL BOX.

WIRE COLOR CODE
B = BLACK
U = BLUE
R = RED
W = WHITE

8-14-98F

G3602

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10

N.A.

RECONNECT
SWITCH

AC3

POS

19C

216

CR1
L1

SWITCH BOARD #1 (LEFT)

208-230V

211

380-460V

213

INPUT
RECTIFIER

212

3181

19A

N.A.

19D

4J90

2J90

1J90
+15V

TRANSDUCER
211

AC1

NEG

20C

MAIN TRANSFORMER T1

20A

.022u
800V

2.7

212

10W

L1A

C4
403

601

+
A

450V

3J40

213

3400uF

.022u
800V

216

10W

CURRENT FEEDBACK

2J21

+15V

3J21

-15V

6J21

CONTROL BOARD COMMON

RS232 RECEIVE

3J25

RS232 TRANSMIT

4J25

253

254

406

6J40

404

H1D

233

1J40

12
405

2J60

10W

RS232 COMMON

OUTPUT DIODES

800V

206

202

N.A.

10J61

2J61

- ELECTRODE VOLTAGE SENSE

S2 VOLTAGE SENSE
RECEPTACLE
1

C1/TP1

320V
160J

600V

WORK VOLTAGE SENSE

21A

4J20

T1
4
15

4J60

604

PRECHARGE RELAY

214
C

4J61

16
3J60

SINGLE

238

3400uF

DETECT

8J60

218

503

231

506

AUX. RECONNECT

239

200-208V
220-230V

380-415V

440-460V

PRIMARY CURRENT SENSE

503

506

6J50

4J50

7J22

THERMAL LED

9J22

THERMAL

450V

3J50

THERMAL LED

YELLOW

234
234

PRIMARY CURRENT SENSE

8J21

235
235

4J21

PHASE

1J50

239

6J23

IGBT DRIVE (+)

13J23

IGBT DRIVE (-)

5J23

CAPACITOR C5 OVERVOLTAGE (LOW=RUN)

4J23

CAPACITOR C5 UNDERVOLTAGE (LOW=RUN)

9J23

CONTROL BOARD COMMON

LED

5J50

403

406

404

233

405

Return to Master TOC

2J20

ELECTRODE

.05uF

+13V

+ELECTRODE VOLTAGE SENSE

MAIN CHOKE L1

SWITCH BOARD#2 (RIGHT)

6J61

6J20

10W

CURRENT

MAIN CONTACTOR CONTROL

Return to Master TOC

2.7

232

8J61

150V

SENSE
5J60

251

1J25

TP3

D1-D4

PRIMARY

5J40

+13V

612

160J

80J
.022u

320V

600V

2.7

INPUT BOARD
1J60

800V

4J40

N.A.

.022u

C2/TP2
.05uF

X4A

612B

ELECTRODE

2.7

601A

OFF

224A

224

290

220

14J23

IGBT DRIVE (+)

7J23

IGBT DRIVE (-)

12J23

3J23

10J23

4J22

10J22

CAPACITOR C4 OVERVOLTAGE (LOW=RUN)

CAPACITOR C4 UNDERVOLTAGE (LOW=RUN)

CONTROL BOARD COMMON

THERMOSTAT (CLOSE TO 10J22 TO RUN)

THERMOSTAT (CLOSE TO 4J22 TO RUN)

OUTPUT RECTIFIER

601A

X4A

THERMOSTAT

270 OHM,5W

STATUS LED (HI FOR RED)

2J24

STATUS LED (HI FOR GREEN)

4J24

1W
RED/GREEN

FAN THERMOSTAT

STATUS

238

604

N.A.

231

POWER BOARD

232

8J23

+13V

11J23

PRECHARGE CONTROL

1J23

PHASE DETECT (5V=RUN)

2J23

MAIN CONTACTOR CONTROL

LED

S1 WIRE FEEDER

AUXILIARY
TRANSFORMER T1
H5
H5A

(440-460)

RECEPTACLE

X4
0V

612

(380-415)

H4A

TESTVa
24V

H3
(220-230)

H3A

CB4

(200-208)

H2A

POS

1J32

POS

2J32

X5
X1

POS

65VDC

52V

WELD AND

25000uF/100V

Vcc(+15)

FAN
115V

NEG

H5A

612A

H4A

NOT USED

ARCLINK +

+5Va

7J31

GND a

4J31

-15Va

3J31

225

221

222

223

274

273

5J22

FEEDER VOLTAGE SENSE

+15V

5J27

1J27

67A

8J20

1J22

+5V

2J22

CONTROL BOARD COMMON

3j22

-15V

ARCLINK -

ARCLINK +

C ELECTRODE SENSE

D +40VDC

0VDC

5J32

11J31

CAN
c

12J31

4J27

+5V ARCLINK +5V

3J27

ARCLINK COMMON
L2

+5Ve

6J31

RS232

(200-208)

10A
H1A

CONTROL

(115V)
1

CB3

1J31

2J31

+5Vc

10A

(220-230)

ARCLINK -

+15Va

P81
4

H2A

NOT USED

CURRENT

CB2

(380-415)

H3A

8J31

(440-460)

612B

4J32

TRANSFORMER T2

P80

Return to Master TOC

1J21

13
20D

CR1

SW1
POWER

Return to Section TOC

CONNECTOR

CURRENT

3J90

NEG

GND

-15V

I OUT

AC2

Return to Section TOC

S5 RS232

CONTROL BOARD

L3A

Return to Master TOC

POWER WAVE 455 MACHINE SCHEMATIC - CODE 10372

Return to Section TOC

G-8

Enhanced Diagram

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-8

5J31

226

228

6J22

RS232 +5V

8J22

RS232 COMMON

0VDC FEEDER

51BK

RECEPTACLE

+40VDC FEEDER

50WT

50
CB1 10A

ELECTRICAL SYMBOLS PER E1537

NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.

THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY

THE LINCOLN ELECTRIC CO.

AND IS

NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF

THE LINCOLN ELECTRIC CO.

UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" ")t TO AGREE

XA
11-14-97A

THE LINCOLN ELECTRIC CO.

WITH PUBLISHED STANDARDS.

EQUIP.

INVERTER WELDERS

TYPE

CLEVELAND, OHIO U.S.A.

3-19-99D

SCALE
DR BK/JLV

SUBJECT

MACHINE SCHEMATIC

NONE

DATE 3-22-96

SHT.
CHK

REF.

SUP'S'D'G

NO.

3181

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10

3181-1

CR1
L1

N.A.

INPUT
LINE
FILTER

SWITCH BOARD #1 (LEFT)

INPUT
RECTIFIER
AC3

N.A.

POS

L1B

S5 RS232
CONNECTOR

CONTROL BOARD
AC2

NEG

V
AC1

NEG

MAIN TRANSFORMER T1

NEG

.022u
800V

2.7
10W

RS232 RECEIVE

3J25

RS232 TRANSMIT

4J25

253

254

13
L3B

CR1

403

601

3J40

406

C4
(CAP "A")
3400uF
450V

.022u
800V

L1A

L3A

2.7
10W

1J40

2.7
10W

RS232 COMMON

D1-D4

PRIMARY

202

Return to Master TOC

P91
H4B

2J60

1J60

I OUT

-15V

GND

600V

2
216

211
216

211

212

213

212

MAIN CONTACTOR CONTROL

8J61

10J61

16
C5
(CAP "B")
3400uF
450V

+13V
4J60

604

503

214

218

503

506

3J60

235

6J50

235

6J21

1J21

CONTROL BOARD COMMON

WORK VOLTAGE SENSE

16
234

4J50

21A

4J20

CURRENT FEEDBACK

3J21

-15V

2J21

+15

4J21

PRIMARY CURRENT SENSE

8J21

PRIMARY CURRENT SENSE

THERMAL LED

7J22

THERMAL LED

9J22

YELLOW

6J23

IGBT DRIVE (+)

13J23

IGBT DRIVE (-)

506
15

4J61

THERMAL

3J50

PRECHARGE RELAY

SINGLE

2J61

6J61

612

S2 VOLTAGE SENSE
RECEPTACLE
1

320V
160J

232

- ELECTRODE VOLTAGE SENSE

C1/TP1
.05uF

+13V
5J60

2J20

ELECTRODE

MAIN CHOKE L1

4J91

INPUT BOARD

1J91

SWITCH BOARD#2 (RIGHT)

3J91

H1D

2J91

N.A.

+15V

N.A.

OFF

+ELECTRODE VOLTAGE SENSE

202A

SENSE
612B

6J20

CURRENT

SW1
POWER

20
206

2.7
10W

251

1J25

TP3
150V
80J

R1
50

.022u
800V

160J

600V

TRANSDUCER

5J40

320V

.05uF

OUTPUT DIODES

405

ELECTRODE

C2/TP2

4J40

233

.022u
800V

206A

6J40

404

213

Return to Master TOC

POWER WAVE 455 MACHINE SCHEMATIC - CODE 10555

SWITCH
LEAD
FILTER

Return to Section TOC

G-9

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-9

5J23

CAPACITOR C5 OVERVOLTAGE (LOW=RUN)

4J23

CAPACITOR C5 UNDERVOLTAGE (LOW=RUN)

9J23

CONTROL BOARD COMMON

LED

238

234

PHASE

239

1J50

DETECT
8J60

231

239

5J50

403

406

404

233

405

Return to Master TOC

Return to Section TOC

SOLID
STATE
RELAY
X3A

220

CHOKE

IGBT DRIVE (-)

12J23

CAPACITOR C4 OVERVOLTAGE (LOW=RUN)

3J23

CAPACITOR C4 UNDERVOLTAGE (LOW=RUN)

10J23

CONTROL BOARD COMMON

4J22

THERMOSTAT

10J22

THERMOSTAT

(NORMALLY CLOSED)

THERMOSTAT
3R

444

IGBT DRIVE (+)

7J23

OUTPUT RECTIFIER

THERMOSTAT

3W
-

12J24

FAN CONTROL (+)

10J24

FAN CONTROL (-)

STATUS LED (HI FOR RED)

2J24

STATUS LED (HI FOR GREEN)

4J24

1W
RED/GREEN
STATUS
LED

238

604

N.A.

231

POWER BOARD

232

8J23

+13V

11J23

PRECHARGE CONTROL

1J23

PHASE DETECT (5V=RUN)

2J23

MAIN CONTACTOR CONTROL

N.B.

AUXILIARY

S1 WIRE FEEDER
RECEPTACLE

TRANSFORMER T1
H5
(440-460)

H5A

X4
0V

H4B

(380-415)

H4A

24V

(220-230)

H3A

115V

TESTVa

Vcc(+15)

POS

65VDC

52V
H1

612A

H5A

H4A

NEG

H2A

2J31

+5Va

7J31

CURRENT
CONTROL

GND a

4J31

-15Va

3J31

5J32

352

351

(115V)
1

10A
1

11J31

CAN

12J31

+5Ve

6J31

5J31

RS232

H2
(200-208)

H1A

4J32

1J31

+15Va

+5Vc

(220-230)

CB3

NEG

CB2
P81
6

8J31

H4
(380-415)

H3A

WELD AND

NEG

(440-460)

612B

1J32

2J32

C3
25000uF/100V

TRANSFORMER T2
P80

POS

H2
(200-208)

H2A

444

FAN

NOT USED

ARCLINK -

5J27

NOT USED

ARCLINK +

1J27

X3A

CB4
6A

225

221

222

223

274

273

226

228

5J22

1J22

FEEDER VOLTAGE SENSE

+15V

67A

8J20

+5V

2J22

CONTROL BOARD COMMON

3j22

-15V

4J27

+5V ARCLINK +5V

3J27

ARCLINK COMMON

ARCLINK -

ARCLINK +

ELECTRODE SENSE

D +40VDC

0VDC

N.B.

L4
6J22

RS232 +5V

8J22

RS232 COMMON

350

S4
220V
RECEPTACLE

0VDC FEEDER

+40VDC FEEDER

51BK

50WT

50
CB1 10A

NOTES :

ELECTRICAL SYMBOLS PER E1537

N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE
ONLY. ALL COMPONENTS ARE NOT SHOWN.
N.B. L4 IS WOUND ON ONE COMMON CORE.

EMS

Return to Master TOC

224

291

TP4

612

Return to Section TOC

224A

14J23

THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY

THE LINCOLN ELECTRIC CO.

AND IS

NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF

THE LINCOLN ELECTRIC CO.

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS
.02
ON 3 PLACE DECIMALS IS
.002
ON ALL ANGLES IS
.5 OF A DEGREE
MATERIAL TOLERANCE (" t") TO AGREE

Ch'ge. Sht. No.
XB-UF
12-4-98

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

3-19-99D

WITH PUBLISHED STANDARDS.

DR JLV

EQUIP.

INVERTER WELDERS

TYPE

MACHINE SCHEMATIC

SUBJECT

SCALE

NONE

DATE

11-7-97

SHT.
CHK B.S.

REF.

G3181

SUP'S'D'G

NO.

3181-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10

POWER WAVE 455 MACHINE SCHEMATIC - CODE 10553
3181-2

Return to Master TOC

G-10

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-10

N.A.

SWITCH BOARD #1 (LEFT)

INPUT
RECTIFIER

CR1

N.A.

S5 RS232
CONNECTOR

CONTROL BOARD
N.C.

N.A.

INPUT BOARD
+

S2 VOLTAGE SENSE
RECEPTACLE

N.A.

Return to Master TOC

Return to Section TOC

SWITCH BOARD#2 (RIGHT)

AUX. RECONNECT

Return to Master TOC

Return to Section TOC

SOLID
STATE
RELAY

N.A.

POWER BOARD

N.B.

S1 WIRE FEEDER
RECEPTACLE

N.B.

(115V)

H1A

NOTES :
N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE ONLY.

EMS

Return to Master TOC

Return to Section TOC

ALL COMPONENTS ARE NOT SHOWN.
N.B. L2 IS WOUND ON ONE COMMON CORE.
N.C. T1 PRIMARY CONNECTIONS SHOWN FOR REFERENCE ONLY.
SEE WIRING DIAGRAM FOR 460/575 SWITCHING.

THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY

THE LINCOLN ELECTRIC CO.

AND IS

NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF

THE LINCOLN ELECTRIC CO.

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS
.02
ON 3 PLACE DECIMALS IS
.002
ON ALL ANGLES IS
.5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE

Ch'ge. Sht. No.
XA
12-18-98A

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

3-19-99D

WITH PUBLISHED STANDARDS.

DR JLJ

EQUIP.

INVERTER WELDERS

TYPE

MACHINE SCHEMATIC

SUBJECT

SCALE

NONE

DATE

11-4-98

SHT.
CHK K.J.

REF.

G3181-1

SUP'S'D'G

NO.

3181-2

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER WAVE 455/POWER FEED 10

Return to Master TOC

G-11

ELECTRICAL DIAGRAMS

POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (1 of 3)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-11

NOTE:

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

POWER WAVE 455/POWER FEED 10

Return to Master TOC

ELECTRICAL DIAGRAMS

G-12

POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (2 of 3)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-12

NOTE:

FEED 10

Return to Master TOC

ELECTRICAL DIAGRAMS

G-13

POWER WAVE 455 CONTROL PC BOARD SCHEMATIC (3 of 3)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-13

NOTE:

FEED 10

POWER WAVE 455 POWER PC BOARD SCHEMATIC
INVERTER POWER SUPPLIES

4.7

TRANS

+5Va

WELD & CURRENT CONTROL

+15Va

WELD & CURRENT CONTROL

-15Va

WELD & CURRENT CONTROL

+40Vf

+40Vwf
C12
.0047

SEC.

10W

R39

BRD
D20

400V

600V

TP1

WIRE FEEDER

comF

50V

15J

100

100
10W

+5Vc

CAN

+5Ve

RS 232

Wire

WIRE FEEDER POWER
100

15A

100

10W

600V

10W

100V

D21

AMPH.

"WT"

.47mH

15A

CTRL

R51

USE

R50

VOLTAGE

R40

GND

R43

3026

Return to Master TOC

G-14

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-14

10W

CTRL

Feeder

"BK"

comF

J31
10

J31

Return to Master TOC

J31

Test Points
8

J31

WELD & CURRENT CONTROL
R33

46VAC

.47

320V

630Vdc

160J

C36

R14

25V

+40Vwf

PROTECTION CIRCUIT

3A
600V

C13

GND

C26

0.1

+5Va

TESTVa

50V

500mA

600V

7
OUT

J31

4.7
35V

J32

2.21K

1mH

OUT

J31
2.21K

35V

OVER/DOUBLE VOLTAGE

270

C25

43V

17V

1mH

4.7

DZ5

1.00K

0.1

243

50V

ADJ

0.1
50V

DZ6

1.00K

C20

D11

30V

3.3V

R42

Vcc(+15)

C19

0.1

2.21K

35V

50V

R12

R13

1.50K

-15Va

0.1

GND

50V

J31

1N4936

1mH

4.7

1N4936

D10

1.0A

2.21K

D26

1.50K

SWITCH_GND

0.1
50V

comF

C10

R11

DZ1

35V

J32

3A
600V

400V

4.75K

D3
1N4007

D9
SEC.

1N4007

C16
4.7

43V

Vcc(+15)

TP2

Rect.& Filtered

DZ4

.001

1500

3A
600V

R25

1500

R26

65 Vdc +/- 20%

J32

500mA

C15

5W
1

+15Va

Return to Section TOC

Vcc(+15)
TESTVa

OUT

D22

4.7

10W

J31

C31
D14
30V

GND

D15

INV IN

1.0A
30V

N.I. IN

R17

2.43K

0.1

20V

C34

20V

4.7
35V

4
5

R20

3.32K
C23

C28

22p

100p

100V

II+

OUTB

PWM

V+

Vc
GND

V-

OUTA

COMP

SYNC

SG3846

C27

68.1K

15.0K

R19

820p
50V

SEC.

1mH

D17
D16

C14
35V
1000

1N4936

681

D24

C11

C32

Vin + Vc

0.1

GND
INV IN

12.1K

N.I. IN

R35

1N4936

30V

C30

10.0
D

R45
D25
1.0A
30V

R46

R44
10.0

.0022

400V

38A

G
S

10.0

250V

30mA

16V
SEC.

D13

T1
8t

1mH

1N4936

.1
7W

R27

R28

OUT

J31

3.32K

R24

R23

3.32K

R55

3.32K

R53

R54

3.32K

R52

3.32K

1N4936
.1

150
D12

C8
4.7
35V

GND

C24

0.1

50V

C29
0.1
5

50V
J31

2.21K

R34

VOLTAGE

+5Ve

D23

RS232
DZ3
1W

475

PRI. CURRENT
FEEDBACK

FEEDBACK

J31

1.0A

50V

OUT

D19

4.7

15.0K

0.1
50V

50V

750

0.1

10W

R31

GND

Vcc(+15)

2700p

R30

OUT

J31

1N4936

C17

+40Vwf

50V

6
5

0.1

1N4936

D18

PRI.

475

C33

82.5K

133K

R18

SHUT
Vin

Vref

R32

R22

22.1K

R37

CLIM

R36

R21

Board

125mA

CAN

16V

R38

50V

1.50K

250V

DZ2

C18

1.8

10.0

Control

+5Vc

C21
C22

R48

400V
38A

R47

R41

Return to Master TOC

Return to Section TOC

Vcc(+15)

R49
10.0

OUT

.0022

1.0A

R16

0.1
50V

R15

C35
Vin + Vc

PRIMARY SWITCHING CIRCUIT

Return to Master TOC

Return to Section TOC

SWITCH_GND

NOTES :
N.A.

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

GENERAL INFORMATION

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

LAST NO. USED

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
ELECTRICAL SYMBOLS PER E1537

NUMBER.

MFD ( .022/50V

CAPACITORS =
RESISTORS = Ohms (
DIODES =

1A, 400V

1/4W

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

R- 55

X- 8

T- 1

C- 36

Q- 3

TP- 2

D- 26

DZ- 6

L- 8

SUPPLY

VOLTAGE NET

POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION

FILE: G3026_2E1
Ch'ge.Sht.No.

XC-RW

NOTE:

SCALE
DR.

DATE

INVERTER WELDERS

TYPE

CLEVELAND, OHIO U.S.A.

11-14-97A
12-4-98A

EQUIP.

THE LINCOLN ELECTRIC CO.

SUBJECT

SCHEMATIC, POWER PCB

NONE

2-21-97

CHK.

SHT.
SUP'S'D'G.

NO.

G 3026

POWER WAVE 455/POWER FEED 10

Return to Master TOC

G-15

ELECTRICAL DIAGRAMS

POWER WAVE 455 INPUT PC BOARD SCHEMATIC
M 17921

Return to Section TOC

G-15

PRE-CHARGE CONNECTIONS

CONTACTOR OUTPUT

J60
2

10
2

J61

CONTACTOR

COIL CONNECT

CR1
4

TP1

TP3

J60
1

660V

250J

TP2

J60

CONTACTOR CONTROL

VAC

100

10W

100

10W

660V

CR2

J60

R22

660V
250J

R11

3.01K

R12

3.01K

R13

3.01K

R14

3.01K

R15

3.01K

R16

3.01K

R17

3.01K

R18

3.01K

R19

3.01K

+13V

R20

10W

PRE-CHARGE CONTROL

3.01K

100

10W

R24

100

3.01K

R25

J60

3.01K

10W

R23

100

10W

3.01K

100

CR2

R21

R10

3.01K

+13V FROM CONTROL BOARD

J61
8

+13V

CR1

TP4

Input

CR2

250J

3.01K

Return to Master TOC

475

OCI1

CNY17-3V

1500V
2

J60

SINGLE PHASE DETECT

CENTER LEG TO OUTSIDE LEG OF INPUT
C1
.022

267K

Return to Section TOC

J61

50V

GENERAL INFORMATION

UNUSED PINS

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537

J61

J60

J61

Return to Master TOC

Return to Section TOC

J61
5

J61
7

J61
9

J60
7

RESISTORS = Ohms (

NOTES :
N.A.

DIODES =

1A, 400V

1/4W

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

CR- 2

D-

TP- 4

VOLTAGE NET

FRAME CONNECTION
THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

ON HOLES SIZES PER E-2056

OCI- 1

COMMON CONNECTION

NUMBER.

ON 2 PLACE DECIMALS IS + .O2

C-

POWER SUPPLY SOURCE POINT

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

UNLESS OTHERWISE SPECIFIED TOLERANCE

R-

SUPPLY

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

ON 3 PLACE DECIMALS IS + .OO2

NOTE:

MFD ( .022/50V

CAPACITORS =

EARTH GROUND CONNECTION

FILENAME: M17921_3DA

THE LINCOLN ELECTRIC CO.

Ch'ge.Sht.No.

11-14-97

SCALE
DR.

JLV

DATE

INVERTER WELDERS

TYPE

CLEVELAND, OHIO U.S.A.

2-27-98L
12-4-98A

EQUIP.

THE LINCOLN ELECTRIC CO.

XB-RW

SUBJECT

SCHEMATIC, INPUT PCB

NONE
5-17-96

CHK.

SUP'S'D'G.

SHT.
NO.

M 17921

POWER WAVE 455/POWER FEED 10

G-16

ELECTRICAL DIAGRAMS

150K

GATE
4

DRIVE
19
C2

C10

C14

C15

.22

1000V

R15

R14

R13

50V

10.0

R12

.0047
DZ2

R18

R17

15V

10.0

R16

11
14
17

G4
G5

C1
.01

2000V

TL431

1000V
E1
3

E3
6

C11

2.8K
C6

REF

35V

E5
15

6.19K

18.2K

562

10.0

RECONNECT

+15V

NOTES :

Return to Master TOC

OVERVOLTAGE
PROTECTION

10K

DZ7

R28

Return to Section TOC

V450

L 9904
SHT.
NO.

SWITCH SCHEMATIC

EARTH GROUND CONNECTION

NONE

CHK.

5.1V
1W

MATERIAL TOLERANCE ("t") TO AGREE

1.00K

3-27-98G

1.00K

ON ALL ANGLES IS + .5 OF A DEGREE

1.00K

G1
G2

11-14-97A

1.00K

15V

332K

ON HOLES SIZES PER E-2056

10.0

TRANSFORMER
PRIMARY

ON 2 PLACE DECIMALS IS + .O2

R19

0.01

ON 3 PLACE DECIMALS IS + .OO2

DZ1

6.2V

Ch'ge.Sht.No.

10.0

R24

+15V

R25

DZ3

150K

UNLESS OTHERWISE SPECIFIED TOLERANCE

R20

DR.

15.0K

2500

11/12 OR 15/16

10.0

+15V

1000V
A2

R26

2500

FILTER
CAPACITOR

C13

.22

.0047

A1
A1

C12

C1
6

GATE

R11

R31

NUMBER.

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

PWM

2500

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

FRAME CONNECTION

SUP'S'D'G.

GENERAL INFORMATION

R32

1
3

R30

Return to Master TOC

RESISTORS

1000V

2-10-97

.0047

ELECTRICAL SYMBOLS PER E1537

BLEEDER

C9
A2
A1

DATE

3-19-99C

R10

2500

WITH PUBLISHED STANDARDS

R33

TRANSFORMER
PRIMARY

SCALE

13/14 OR 17/18

10.0

TYPE

EQUIP.

SUBJECT

R39

COMMON CONNECTION

2000V

CLEVELAND, OHIO U.S.A.

THE LINCOLN ELECTRIC CO.

FILENAME: L9904-4EA

VOLTAGE NET

.01

10.0

15V

D3
1000V

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

R40

N.A.

10.0

G2
G3

(UNLESS OTHERWISE SPECIFIED)

16
C5

1A, 400V

DZ6

R38

50V

R37

R35

.0047

R41

13
C4

DIODES =

1.00K

UNLESS OTHERWISE SPECIFIED)

1.00K

7
C2

1/4W

1.00K

UNLESS OTHERWISE SPECIFIED)

10.0
1.00K

15V

MFD ( .022/50V

0.01

DZ5

R42

CAPACITORS =

10.0
W1

POWER SUPPLY SOURCE POINT

LABELS

R43
DZ4

RESISTORS = Ohms (

10.0
6.2V

SUPPLY

2
A-

7
1

2
DZ-

X-

T-

15
C-

43
R-

D-

LAST NO. USED

RECONNECT

B
R34

Return to Section TOC

OCI-

POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10372 & 10555

R36

Return to Master TOC

Return to Section TOC

G-16

(VOLTAGE PROTECTION)
(Pre-charge Shut-off)

1.82K

1.21K
5

CNY17-3V
6

R21

3.32K

OCI1

R23

221

R29

TO CONTROL BD.

R27

221
1

OCI2

10K

TO CONTROL BD.

CNY17-3V
2

(VOLTAGE PROTECTION)

C2
50V

.022

(Trigger Loop)

267K

C4
681K

R22

J9
2

.022
50V

Return to Master TOC

+15V

C5
X2
LM224

L 9904

Return to Section TOC

J9
3

NOTE: 203,206 BOLT ON WITH FILTER CAPS

NOTE:

POWER WAVE 455/POWER FEED 10

221K
+15V

.0047
1000V

R17
10.0

1600V

1000V
E1

TL431
-

2.8K
C6

L 10666
SHT.
NO.
SUP'S'D'G.

INVERTER WELDERS

SCHEMATIC, SWITCH PCB

EARTH GROUND CONNECTION

FRAME CONNECTION

B.S.

TYPE

DATE

NONE
SCALE

2-10-97

CHK.

35V

562

6.19K

R16

16.5K

RECONNECT
C

+15V

NOTES :

Return to Master TOC

SUBJECT

EQUIP.

REF

10.0

OVERVOLTAGE
PROTECTION

10K
R28

DZ7
5.1V
1W

J9
221

(VOLTAGE PROTECTION)
(Pre-charge Shut-off)

1.82K

1.21K
5

CNY17-3V
6

J9
R21

3.32K

OCI1

R23

TO CONTROL BD.

R29

R27

Return to Section TOC

COMMON CONNECTION

POWER SUPPLY SOURCE POINT

VOLTAGE NET

2
X-

DZ3
D-

1.50K

WITH PUBLISHED STANDARDS

10.0

MATERIAL TOLERANCE ("t") TO AGREE

.0047
50V

15V

R18

R15

R14

R13

R12

DZ2

.047

12-18-98A

1.00K

C1
A1

332K

ON HOLES SIZES PER E-2056

1.00K

ON 2 PLACE DECIMALS IS + .O2

1.00K

10.0

ON 3 PLACE DECIMALS IS + .OO2

1.00K

15V

R19

ON ALL ANGLES IS + .5 OF A DEGREE

DZ1

R11

10.0

6.2V

R24

+15V

TRANSFORMER
PRIMARY

Ch'ge.Sht.No.

R20

R45

10.0

11/12 OR 15/16

DZ3

2500

R25

15.0K

R26

DR.

CAPACITOR

FILTER

C10

2500
R31

LC/JLV

UNLESS OTHERWISE SPECIFIED TOLERANCE

GATE

CLEVELAND, OHIO U.S.A.

2500

THE LINCOLN ELECTRIC CO.

DRIVE

ELECTRICAL SYMBOLS PER E1537

R32

221K

RESISTORS

GATE

BLEEDER

1000V

2500

GENERAL INFORMATION

.0047

R10

R33

TRANSFORMER
PRIMARY

T-

13/14 OR 17/18
C1

Return to Master TOC

2500

FILENAME: L10666_1AA

NUMBER.

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

10.0

1600V

1000V

R39

.047
1A

N.A.

C8
D3

(UNLESS OTHERWISE SPECIFIED)

R40

1A, 400V

DIODES =

50V

10.0

UNLESS OTHERWISE SPECIFIED)

.0047

15V

1/4W

R41

MFD ( .022/50V

1.00K

RESISTORS = Ohms (

R36

DZ6

1.00K
R38

1.00K

R35

1.00K

R37

10.0

CAPACITORS =

15V

R42

R44

DZ5

UNLESS OTHERWISE SPECIFIED)

10.0

PWM

C-

R43
DZ4

SUPPLY

2
A-

10.0

R-

RECONNECT

6.2V

LABELS

LAST NO. USED

OCI-

POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10553

R34

Return to Section TOC

G-17

ELECTRICAL DIAGRAMS

R30

Return to Master TOC

Return to Section TOC

G-17

221
1

OCI2

10K

TO CONTROL BD.

CNY17-3V
2

(VOLTAGE PROTECTION)

C2
50V

.022

(Trigger Loop)

267K

C4
681K

R22

J9
2

.022
50V

Return to Master TOC

+15V

C5
X2
LM224

L 10666

Return to Section TOC

J9
3

NOTE: 203,206 BOLT ON WITH FILTER CAPS

NOTE:

POWER WAVE 455/POWER FEED 10

POWER FEED 10 MOTHER CONTROL PC BOARD SCHEMATIC
3142

+5VN
+5V

ENCODER SUPPLY

540
+12.8 VDC

MOSI

2.67K

/Q1

GND

CLOCK 2
SET 2

X17

C23
0.1
50V

N.C.

54HC74

R21

26.7K

R20

4.75K

R19

PA5

RES

S-8054HN

C24

Vss

500D

C25

/SS

500D

/YO

/Y1

/G2A

/Y2

/Y3

/G2B

/Y4

/Y7

/Y5

GND

/Y6

SCK

MOLATCH

Vcc

X26

500D

+5VN

2.67K

10K

R17
+5V

LOLATCH

475

16
15

PB1

PA4

PB0

PA5

Vdd

PA6

PA7

9
10

Vss

+5V

R44

4.75K

R43

4.75K

R42

4.75K

R41

4.75K

R40

4.75K

R39

R38

4.75K

SCK

C22

S1LATCH

4.75K

R90

PE0

500D

S1 -1

S1 -2

S1 -3

S1 -4

S1 -5

S1 -6

S1 -7

S1 -8

CLK1

15
14

LOW

CAN

/QH

GND

+5V

S1MISO

74HC165

A14

/YO

A15

/Y1

/Y4

/Y7

/Y3

/G2A

/Y2

/G2B

/Y5

500D

+5V

Vcc

X12

S2 -1

S2 -2

S2 -3

S2 -5

S2 -4

S2 -6

S2 -7

S2 -8

7
8

/QH

/SS

PE4

PA3

PE5

PE6

A15

PA1

A12

PA0

A11

PA2

A14

PA4

AD0

A/D0

PA5

AD1

A/D1

VRH

AD2

A/D2

/IRQ

MOSI
SCK

I2a

LOMISO

/Ea

I3a

S1MISO

/Eb

I0b

I3b

I1b

GND

I2b

D18

D20

D21

D22

500N

A14
X7

1.82K

Vcc

AD3

A/D3

R/W

PE0

AD4

A/D4

N/C

PA6

AD5

A/D5

N/C

PD1

AD6

A/D6

N/C

PD0

AD7

A/D7

PA7

A12 2

A13

A10

/WC

GND

SEL

PA3

C47

X24

74AC138

22p

/IRQ

100V
8.0MHz

100V

4.75K

R35

3.32K

4.32K

A/D0

AD1

A/D1

500N

500N
+5VN

512

A/D2

A/D3

R/W

AD4

A/D4

N/C

CLK OUT

AD5

A/D5

N/C

/RESET

AD6

A/D6

N/C

/INT

AD7

A/D7

P1.0

P1.1

P1.2

A10

XTAL1

P1.3

XTAL2

P1.4

TX1

P1.5

P2.7

P1.6

P2.6

P1.7

RX1

P2.0

P2.3

P2.1

MODE1

P2.2

Vss2

RX0

MODE0

TX0

4.75K

44
12

P2.5

Vss1

MISO

R61
475

MOSI

R62

SCK
LATCH

R64

D28

D29

D30
500N

500N

/WC

SEL

512

+5V

ISO +5

+12.8 VDC

PE2
R65
3.32K

500D

C31
0.1
50V
500N

OCI1

C29

50V
NC

R70

3.32K

4.32K

MODE 3

POT COMMON

50V

500D

ISO COM

500D
+5V

ISO +5

X24

C33
.022

R75

13.7K

R74

R73

13.7K

R72

T1 B

R77

10.0

X20

50V

485

X24

C10

0.1

R59

475

R58
2

OCI2

X24

1N4936

512

D31

500D

VCC 8
A

/RE

6
7

GND 5

VFB

RT/CT

COMP 1

GND

X18

C40

Q3
18A

Vdd

D34

16V

X68C64

C11

0.1

50V

Vss

50V

54HC74

C50

X26

0.1

50V

MC68HC11E1
Vss

Vcc

PD0

R85

R83

1.50K

R79

1.3K

RED
DIAGNOSTIC
LED

BLACK

WHITE

50V

74AC138

C49

X22

0.1

74AC153

X13

0.1
50V

74HC165

C13
0.1
50V

X14
74HC165

C14
0.1
50V

X16
X68C64
Vss

PD1

2N4401

3.32K
C51

X23

C16

0.1

0.1
50V

50V

AN82527

Vss1

Vss2

X24
74AC04

R88

2N4401

3.32K

C52
0.1

500D

50V

GND

15V

GENERAL INFORMATION

S1
3300

2700p
50V

LED

R86

Vcc

X11

0.1

50V

MOLEX CONNECTORS

R-

N.A.

MFD ( .022/50V

CAPACITORS =

NOTES :
5

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537

500D

C42

C41

50V

R81
332

2700p

50V

OUT

50V

0.1

X19

C43

200V

1W
6

C6
HEXINV

0.1
50V

C38

C39

HEXINV

50V

Vcc

X6
C5

DZ1

2700p

50V

200V

26.7

R82

VREF

6.19K

150K

C37

DIAGNOSTIC

R84

R80

100V

R78

13.7K

C36

6
2

GREEN

+5VN

OUT

VCC

+12.8 VDC

ISO COM

D35

BUS H

512
+12.8 VDC

+12.8 VDC

+5V

BUS H

512

1N4936

ISO COM

500D

+5V

BUS L

ISO COM

DZ3
6.2V
1W

500D
ISO COM

ISO COM

485

50V
Q2
2N4403
1

D32

0.1

50V

MC68HC705J1

C30

0.1

50V

74AC138

GND 5

15V

X10

C12

X12

0.1
C35

GND

9
3

OUT

35V

R87

R91

C34
4.7

T1 A

4.75K

13.7K

200V

R76

BUS L

681

VCC 8

1N4936

1N5402

R57

D33
D37
J2

R89

D36

DATA BUS

6.2V
1W

681

POWER SUPPLY

+5V

500N

1.00K

POWER BUS
4

ISO +5

SWITCHING

10.0K

+40 VDC

500N

DZ2

500N

ISO +5

500D

0.1

R69

MODE 1

R68

POT WIPER

C32

2N4403

POT SUPPLY

16.5K

500N

PE3

AN82527

R67

1.82K

0.1

X24

475
D27

X68C64

475

500D

540

R63
LOLATCH

A11

GND

D26

A12 2

D25

D24

475

D23

/DSACKO

OPTION

10K

Vcc

READY

LOWER

R60

AD3

/CS

+12.8 VDC

AD2

J5
J5

A11

X16

0.1

R95

PROC. B

R34

50V

130

22p

AD0

PROC. A

R33
PE0

C26

XTAL

X23

/IRQ

VRL

P2.4

LATCH

D19

475

MOLATCH

SCK

R31

475

Vcc

MOSI

R30

475
4

PA3

A15

MISO

R29

/SS

X24

74HC165

RESISTORS = Ohms (
DIODES =

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

1A, 400V

1/4W

C-

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

J1,J2

96
52
37

VOLTAGE NET

POWER SUPPLY SOURCE POINT

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

D-

SUPPLY

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

NUMBER.

COMMON CONNECTION
FRAME CONNECTION

NOTE:

SPARE

RESERVED

SPARE

( HD ID )

RESERVED

GROUP ID

( LSB )

ACCELERATION

( MSB )

ACCELERATION

SPARE

IPM / MPM

ACCELERATION

500N

RUN IN MODE

500D

MODE

500P

WFS DISPLAY

( EURO / US )

THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

4 STEP CONFIG.

Return to Master TOC

D17

R32

D16

475

D15

74AC153

Vdd

MOMISO

GND

PE3

Vcc
CLK2

X14

R96
2

LOMISO

4.75K

R52

R51

4.75K

R50

4.75K

R49

4.75K

R48

4.75K

R47

R46

4.75K

R45

Return to Master TOC

SCK

500D

I1a

X22

500D

+5V

CLK1

MOSI

PE2

500D

SS/PL

PE7

MISO

OPTION

X68C64

C48

MC68HC11E1

/Y6

GND

500D

MISO

A13

500D

DIP SWITCH 2

XTAL

R//W

HIGH

D
C

A13

GND

CLK2

X13

PA7

DS2501

A13

A14

Vcc

PD0

X8
DATA

DECODE INFO

SS/PL

PA6
PD1

A15
1

PA5

35V

PA7

R13

4.75K
PA4
C44
1.0

R14
1.00K

R37

R12

+5V
PA6

MC68HC705J1

DIP SWITCH 1

J1AMISO

R66

PA2
PA3

100K

PB2

PE3
PE4

XTAL

EXTAL

I0a

R71

PE1

MISO
+5V

475

MOSI
500D

PA1

X10

PE2

+5V

10K

R55

SCK

50V

PB3

MODB

/XIRQ

Vcc

R54

0.1

5
6

J1AMISO

500D

PB4

PA0

/RESET

1.00K

PE4

/IRQ

PB5

R15

500N

/RESET

OSC2

10K

OSC1

1.00K

4.75K

500N

4.75K

Return to Master TOC

Return to Section TOC

4.75K

+5V

C21

R11

R10

4.75K

MODA

R24

Vss

4.75K

+5V

2.67K
C20

BURNBACK

MEMORY/DP

R28

R36

+5V

C19

+5V

4.75K

500N

2.67K

TRIMMER

500N
512

500N
+5VN

D14
J4

74AC138

4.75K

D13

+12.8 VDC

500N

LATCH

R27

D12

475

S1LATCH

SCK

R26

500N

ENCODER 2

MOSI

R25

C18

556

D11

475

D10

1.00K

SET 1

DATA 2

PA4

1.00K

RESET 2

R23

CLOCK 1

+5V

Vdd

1.82K

DATA 1

1.00K

R18

ENCODER 1

VCC

10K

D2
500N

X11

RESET 1

R22

J4
8

2.21K

+5VN

J4
7

Return to Section TOC

DISPLAY

+12.8 VDC

+5V

C17

Return to Section TOC

STD

512

4.75K

Return to Master TOC

G-18

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-18

10
7

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE

Ch'ge.Sht.No.

EQUIP.

THE LINCOLN ELECTRIC CO.

TYPE

CLEVELAND, OHIO U.S.A.

10-17-97A

SCALE

MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

EARTH GROUND CONNECTION

FILENAME: G3142_1BA

THE LINCOLN ELECTRIC CO.

DR.

DATE

SUBJECT

SWG USER INTERFACE
MOTHER BD. SCHEMATIC

NONE
2/15/96

CHK.

SUP'S'D'G.

SHT.
NO.

3142

POWER WAVE 455/POWER FEED 10

POWER FEED 10 CONTROL PC BOARD SCHEMATIC
3144

505

512

505

Vss

R22

1.30K

R40

10.0K

100
1

BHO

16
11

C16

AHO

DEL

Vdd

Vss

BHS

AHB

BLO

DIS

ALO

200V

15.0

100

R39

0.1
50V

.33

R37
C17

D3
1N4936
D4

C18
1.0

150

200V

35V

Q4
70A
60V

R41

0.05

500

1.30K
GP

505

SHUT DOWN

500

505

ST
TR

505
J5

R25

3.32K

B
D21

C50

825

R85

R89

4.75K

D20

R86

R84
2.21K
J5

1.00K

PA4

C12
1.0

DIP3

PE4

PE5

PE6

A15

PA1

A12

PA0

A11

PA4

A14

PA5

AD0

7
8

A/D1

C19

PA7

AD1

VRH

AD2

A/D2

VRL

AD3

A/D3

R/W

A/D4

N/C

A/D5

N/C

PD3

AD6

A/D6

N/C

PD0

AD7

A/D7

PD1

A12 2

R91

A13

A11

1.30K

DL1

C51
500

PD0

Vdd

COLD INCH

MC68HC11

20
17

A10

R51

V CC

OUT 6

V EE

D23
C22

512

/WC

SEL

512

TACH
CIRCUITRY

D25
505

D24

OFF

C24

47p
100V
500

22p

500

R13

R92
2.00K

/DSACKO

P1.2

XTAL1

P1.3

XTAL2

P1.4

TX1

P1.5

P2.7

P1.6

/Y4

P2.6

P1.7

RX1

P2.0

/G2A

/G2B

/Y5

GND

/Y6

/RE

485

P2.3

P2.1

MODE1

P2.2

Vss2

RX0

MODE0

TX0

P2.5

Vss1

Vcc

500

/Y1

/Y7

/Y3

/Y2

BUS L

GND 5

ISO COM
2

ISO +5

BUS H

DZ2
6.2V
1W

512

BUS H

J1
BUS H

DIAGNOSTIC
LED #1

540
GAS

OCI2

74AC138

DL1

2N4401

3.32K

50V
NC

2N4403

GAS
SOLENOID

R59

0.1
Q2

SOLENOID

C15

DRIVER

500

GND

500

BUS L

/YO

6.2V
1W

AN82527

DS2501

DATA BUS

DZ1

VCC 8

ISO COM

505

BLACK

ISO COM

505

X10

500

R94

CAN

4.75K

R15

8.0MHz

4.75K

DATA

37 P1.1

MEM

505

100V

OFF

AD7

/CS

3.32K

AD6

P1.0

2N4403

50V

/INT

4.75K
R14

/RESET

0.1

READY

22p

500
J5

C14

A13

C53

505

AD5

A14

130

R95

2.00K

500

AD4

CLK OUT

100V

4 STEP

R/W

A15

681

C52

R58

S1 -G

3.32K

AD3

TACH.

BLUE

R34

AD2

OCI1

1.00K

R12

PD2

C11

DECODE INFO

PD0

3.74K

R33

R27

500

AD1

475

GAS PURGE

AD0

R77

R26

1.00K

X21

P2.4

10.0K

2.00K

R11

512

Vcc

RED

500

500
1

0.1
50V

R55

X68C64
500

C23

15.0K

ISO +5
TA

505

D22

505

GND

3.32K

505

NULL
X5

500

1.00K

R10

35V

A10

500

J5
4

C21
1.0

50V

INPUT

S1 -B

INPUT

500

AD5

825

330p

Vcc

NULL

OP27

C20

A/D0

1.00K

PD4

DL2

R90

R49

35V

AD4

PD5

S1 -C

R50

100

PA3

/IRQ

10.0K

R47

PA2

5.62K

R46

PD2

A1FN

R45

PE3

500

PE2

PE0

475

512

PA6

4.75K

DIP2

R48

R54

DIP1

PE7

4.75K

S1 -A

R/W

XTAL

332

R83

PE1
EXTAL

R53

500

DIP3

2.21K

C47

13.7K

825

MODB

R52

R82

505

10.0K

505

4.75K

DIP2

S1 -D

R44

/XIRQ

R31

D19

MODA

R30

/RESET

R24

3.32K

Vss

4.75K

825

R81

4.75K

2.21K
J5

Return to Master TOC

ALI

BHB

AHS

500

D18

ISO COM

OUT

512

X11

500

R60

681

SWITCH

POWER BUS

540
+40 VDC

D10

R66

20t

500

15V

VOLTAGE

SENSE

500

505

LEAD

512

ISO COM

PA4

R65

4.75K

+12.8 VDC

CONTROL

1N4936

Vcc

26.7

X23

C33

R70

C31

50V

35V

OUT

R73

C36
18

C49

Vss2

C38

0.1

X68C64

50V

Vss

C39

74AC138

50V

C40

50V

C42

0.1
50V

OP27

MC68HC11
Vss

0.1

HIP4082IP

C43

VCC 8
C44

0.1
50V

C45

0.1

100K

0.1

50V

LM2901

50V

485
6

N.A.

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
1

N.B. A, B, C, POSITIONS ARE FOR THE SETTING OF THE GROUP ID.

500

THE H POSITION IS FOR SELECTING BETWEEN HIGH & LOW SPEED.

20V

-10VDC

500

NOTES :

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
C37
1.8

1.0

R76

50V

R75

2700p

X9
HEXINV

NUMBER.

1.50K

332

50V

C34

GND 5

500

ISO COM

15V

20t

R74

.0047

Vdd

+5 VDC

332
C32

50V

GND

25t

35V

Vss1

505
IN

C35
4.7

0.1

C30
4.7

0.1

AN82527
1N4936

DZ3
1W

50V

2N4401

X24
16V

2700p

C48

Vcc

D13

200V

10.0

R72

COMP 1

GND

R71

VFB

RT/CT

10.0

VREF

R88

Q9
18A

X21

D14

R67

10.0

6.19K

OUT

150K

R68

8.25K

63V

VCC

R69

Q10

R96
3.32K

D12

2200

-10VDC

500

GENERAL INFORMATION

MFD ( .022/50V

CAPACITORS =

LAST NO. USED

ELECTRICAL SYMBOLS PER E1537

(SWITCHES ARE SHOWN WITH GROUP ID = 0 & LOW MOTOR SPEED.)
(SEE THE OPERATING NAMUAL FOR ADDITIONAL INFORMATION.)

= SWITCH NOT USED

RESISTORS = Ohms (
DIODES =

MOLEX CONNECTORS

1A, 400V

1/4W

UNLESS OTHERWISE SPECIFIED)

LABELS

UNLESS OTHERWISE SPECIFIED)

(UNLESS OTHERWISE SPECIFIED)

X- 24

T- 1

C-

Q- 10

Y- 1

D-

DZ- 3

OCI- 2

VOLTAGE NET

POWER SUPPLY SOURCE POINT
COMMON CONNECTION

1N4936

S- 1

R-

SUPPLY

D15

NOTE:

POLARITY

HIGH SPEED

ELECTRODE SENSE

( LSB )

SPARE

HEAD ID

HEAD ID
( MSB )

HEAD ID

GROUP ID

( LSB )

500

GROUP ID

FRAME CONNECTION

GND

C29

GND

ISO +5

1N4936

GND

+40V

X9 E

500

GND

R97

ISOLATED

C28

C27
4.7

+40V

OUT

35V

16t

2N4401

3.32K

ISO +5
X22

R61

1N4936

+40V

500
512

DL2

C26

+40V

GND

D11

POWER SUPPLY

( MSB )

FEED

LED #2

J1
CIRCUIT

DIAGNOSTIC

SWITCHING

5.11K

Return to Master TOC

HIP4082IP

505

J5
1

Return to Master TOC

BLI

505

Return to Section TOC

BHI

uCOMPUTER

505
512

AHI

500

DUAL PROC.

500
500

R36

10.0K

R35

R21

26.7K

R20

4.75K

R19

1.00K

2.21K

10K

50V

R43

RES

S-8054HN

R80

6.81K

S1 -E

0.1

Q3
70A
60V

G
S

Vdd

X20

C46

D17

825

1N4936

R42

D2
D1
1N4936

1.82K

10K

R87

R18
9

R79

3.32K
J5

DIP1

S1 -H

R17

ON
OFF

CIRCUITRY

4.75K

2.21K

D16

825

R78

MOTOR

TRIGGER

1.00K

Return to Section TOC

505

Return to Section TOC

540

512
540

505

2.21K

Return to Master TOC

G-19

ELECTRICAL DIAGRAMS
G

Return to Section TOC

G-19

EARTH GROUND CONNECTION

FILENAME: G3144_1BA
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2

Ch'ge.Sht.No.

WITH PUBLISHED STANDARDS

SCALE
DR.

DATE

WIRE FEEDER

TYPE

CLEVELAND, OHIO U.S.A.

10-17-97A

ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE

EQUIP.

THE LINCOLN ELECTRIC CO.

SUBJECT

CONTROL P.C. BOARD SCHEMATIC

NONE
1-8-96

CHK.

SUP'S'D'G.

SHT.
NO.

G 3144

POWER WAVE 455/POWER FEED 10

DISP2

50V

500

Return to Master TOC

SCK

R9
475

.0047

J1
6

500

MOSI

R8
C7
50V

BANK4

BANK3

Vdd

BANK2

BANK1

.0047

10K

475

500

BANK5

DATA IN

/ENABLE

CLOCK

DATA OUT

Vss

MC14489

500

3
1

2
4

5
6

A
D

9
DISP8

DISP7

7
9
10

DISP6

7
9

VOLTS
LED3

TRIM
LED4

DISP5

NOTES :

50V

Return to Section TOC

J1
5

SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

C9
.0047

L 10276
SHT.
NO.
SUP'S'D'G.

POWER DRIVE WIRE FEEDER

N.A.

SCHEMATIC, STANDARD DISPLAY PCB

CHK.

WITH PUBLISHED STANDARDS

475

MATERIAL TOLERANCE ("t") TO AGREE

R10

ON ALL ANGLES IS + .5 OF A DEGREE

LATCH

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

R11

500

EARTH GROUND CONNECTION

FRAME CONNECTION

COMMON CONNECTION

POWER SUPPLY SOURCE POINT

DISP- 8

VOLTAGE NET

DR.

MC14489

SUPPLY

LED- 4

X- 5

C-

D-

R-

LED2

DISP1

10-17-97A

9
10

AMPS

Ch'ge.Sht.No.

LED1

ON HOLES SIZES PER E-2056

DATA OUT

WFS

ON 2 PLACE DECIMALS IS + .O2

ON 3 PLACE DECIMALS IS + .OO2

/ENABLE

DISP3

DISP4

UNLESS OTHERWISE SPECIFIED TOLERANCE

CLOCK

NUMBER.

NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE

Vss

GENERAL INFORMATION

Return to Master TOC

DATA IN

NONE

2/5/96

DATE

SCALE

BANK5

3
1

CTT

BANK1

TYPE

SUBJECT

CLEVELAND, OHIO U.S.A.

3
1

EQUIP.

THE LINCOLN ELECTRIC CO.

BANK2

FILENAME: L10276_1AB

(UNLESS OTHERWISE SPECIFIED)

1A, 400V

DIODES =

UNLESS OTHERWISE SPECIFIED)

Vdd

1/4W

MFD ( .022/50V

RESISTORS = Ohms (

BANK3

CAPACITORS =

BANK4

ELECTRICAL SYMBOLS PER E1537

UNLESS OTHERWISE SPECIFIED)

LABELS

LAST NO. USED

POWER FEED 10 DISPLAY PC BOARD SCHEMATIC

Return to Section TOC

G-20

ELECTRICAL DIAGRAMS

1.50K

Return to Master TOC

Return to Section TOC

G-20

+5VA
D1

R13

10.0

X1
IN

7805

OUT

0.1
MC14489

C1
4.7

50V

HEXINV

0.1

R12

512

1.50K

Vdd
J1

50V

GND

35V

15V

Vss

500

Return to Master TOC

500

Vdd

L 10276

Return to Section TOC

+5VB

R14

10.0

X2
IN

C5
4.7
35V

7805

C10

OUT

0.1
MC14489

GND

50V

C6
18
15V

Vss

500

NOTE:

POWER WAVE 455/POWER FEED 10

Return to Master TOC

POWER FEED 10 ENCODER PC BOARD SCHEMATIC
+5VDC
D9

J1
7

10.0

X1
IN

OUT

GND

C1
4.7

35V

15V

1
+
4

X
2

Return to Master TOC

D2
475

Return to Section TOC

G-21

ELECTRICAL DIAGRAMS
S 22920

Return to Section TOC

G-21

475
D3

ROTARY

ENCODER

.33mH
+5VDC

Return to Master TOC

1
+
4

X
2

475
D7

OPTICAL
ROTARY
ENCODER

THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

NOTES :
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD

MAY CHANGE

THE INTERCHANGEABILITY
THIS DIAGRAM MAY NOT
OR CIRCUITRY OF

A PRINTED

BOARD.

SHOW THE EXACT COMPONENTS

CONTROLS HAVING A COMMON

UNLESS OTHERWISE SPECIFIED TOLERANCE
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

NOTE:

ELECTRICAL SYMBOLS PER E1537

WITHOUT AFFECTING

OF A COMPLETE

ON HOLES SIZES PER E-2056

THE LINCOLN ELECTRIC CO.

FILENAME: S22920_2BB

LABELS

GENERAL INFORMATION
N.A.

Return to Master TOC

D6
475

Return to Section TOC

OPTICAL

J1
1

Return to Section TOC

CODE NUMBER.

Ch'ge.Sht.No.

XA
10-17-97

CAPACITORS =

MFD ( .022/50V

RESISTORS = Ohms (
DIODES =

1A, 400V

1/4W

SUPPLY

FRAME CONNECTION

VOLTAGE NET

UNLESS OTHERWISE SPECIFIED)
POWER SUPPLY SOURCE POINT

UNLESS OTHERWISE SPECIFIED)

EARTH GROUND CONNECTION

(UNLESS OTHERWISE SPECIFIED)

COMMON CONNECTION

EQUIP.

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

3-27-98D
DR.

JRF

DATE

SUBJECT

NONE

3-11-96

USER INTERFACE

TYPE

CHK.

DUAL ENCDR PCB SCHEM.

SUP'S'D'G.

SHT.
NO.

S 22920

POWER WAVE 455/POWER FEED 10

Return to Master TOC

G-22

ELECTRICAL DIAGRAMS

POWER FEED 10 VOLTAGE SENSE PC BOARD SCHEMATIC
S 23918

Return to Section TOC

G-22

TP1
J1
5

FRAME

BRASS BLOCK

#67 LEAD NETWORK

320V
160J
TP2

TO HEAD P.C.B.
320V

J1
475

Return to Master TOC

Return to Section TOC

160J

OCI1

.33mH

56
S

J1
R2

475

J1
6

OCI2

2
4

Return to Master TOC

Return to Section TOC

THE LINCOLN ELECTRIC CO.

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY

AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF

NOTES :
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD

MAY CHANGE

THE INTERCHANGEABILITY

Return to Master TOC

Return to Section TOC

THIS DIAGRAM MAY NOT
OR CIRCUITRY OF

A PRINTED

BOARD.

SHOW THE EXACT COMPONENTS

CONTROLS HAVING A COMMON

UNLESS OTHERWISE SPECIFIED TOLERANCE
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS

NOTE:

ELECTRICAL SYMBOLS PER E1537

WITHOUT AFFECTING

OF A COMPLETE

ON HOLES SIZES PER E-2056

FILENAME: S23918_3CA

LABELS

GENERAL INFORMATION
N.A.

THE LINCOLN ELECTRIC CO.

CODE NUMBER.

Ch'ge.Sht.No.
XA
10-17-97

CAPACITORS =

MFD ( .022/50V

RESISTORS = Ohms (
DIODES =

1A, 400V

1/4W

SUPPLY

VOLTAGE NET

FRAME CONNECTION

UNLESS OTHERWISE SPECIFIED)
POWER SUPPLY SOURCE POINT

UNLESS OTHERWISE SPECIFIED)

EARTH GROUND CONNECTION

(UNLESS OTHERWISE SPECIFIED)

COMMON CONNECTION

EQUIP.

THE LINCOLN ELECTRIC CO.

TYPE

CLEVELAND, OHIO U.S.A.
SCALE

10-9-98D

DR.

MAB

DATE

SUBJECT

NONE

6/9/98

SWG VOLTAGE SENSE SELECT

CHK.

SUP'S'D'G.

SCHEMATIC
SHT.
NO.

S 23918

POWER WAVE 455/POWER FEED 10

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Modify Date                     : 2009:11:05 13:19:57-05:00
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Title                           : svm135b.pdf
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Page Layout                     : SinglePage

EXIF Metadata provided by EXIF.tools

Lincoln Electric Power Wave Svm135 B Users Manual Svm135b

SVM135-B to the manual b7a4e6b5-c0b9-4995-809f-d4fe2b940037

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