Lincoln Electric POWER WAVE POWER WAVE WELDING SYSTEMS User manual

POWER WAVE WELDING SYSTEMS
WITH POWER FEED 10 AND 10 DUAL
™
™
Premium MIG Welding Systems

2
R
R
LISTED
170G
UL
Simple. Innovative. Technologically
Advanced. These are all words that
describe the Power Wave welding
systems. These next generation
systems utilize Waveform Control
Technology™ for the finest welding
arc in the industry.
POWER SOURCE
The Power Wave 455 is a high
efficiency inverter designed for
unprecedented ease of use and
performance.
Sophisticated software in the unit
controls the welding waveform for
reduced arc spatter, fumes, and an
exceptionally smooth arc.
WIRE FEEDER
The Power Feed 10 and the Power
Feed 10 Dual set the standard for
easy to use, rugged wire feeders.
They are perfectly matched for use
with the Power Wave 455, resulting in
a simple, high performance welding
package that is built to last.
SYSTEM WIDE
• Power Wave welding performance
in a simple, easy to use system.
• Set-up flexibility with one control
cable that connects any combination
of equipment.
• Control cables can connect as
extension cords up to 200 feet.
• Can be easily upgraded from simple
to high capabilities.
• Flexible platform can be easily
changed from bench to boom, CV
to Pulse, etc.
• Spacious inverter design for easy
service.
• 3 year warranty on parts and labor.
• Manufactured under a quality
system certified to ISO9002
requirements.
CONTROLS
• All controls are located on the wire
feeder to eliminate confusion.
• Control box is removable for bench
or boom mounting.
• Two large displays and knobs for
gloved hands.
• Presettable wire feed speed or
amps, and voltage or trim. Actual
values displayed while welding, and
for 5 seconds after welding has
stopped.
• Capable of running from basic CV to
high performance pulse programs.
• English or metric display.
• Control upgrades in less than
5 minutes.
WIRE FEEDER
• Four driven rolls in a heavy duty
drive system. No tools needed for
wire size changeover.
• Split wire guide for trouble-free
loading and feeding. Perfect wire
alignment and support.
• Powerful drive motor for large wires
and high speeds in one model.
• Tachometer feedback for precise
wire feeding.
• Wire reel stand holds 10-60 lb. wire
packages on a 2” spindle. Bench
feeder mounts on power source.
Power Feed 10 may be used with or
without optional swivel platform.
ADVANTAGE
LINCOLN
The Power Feed 10 and the Power
Feed 10 Dual wire feeders feature
easy to understand controls and the
Lincoln four driven roll feed head.
These wire feeders have the strength
and speed for the most demanding
feeding applications, whether it’s for
high speed or for large diameter wires.
Choose Power Feed 10 Dual when
applications require two different wires
to be utilized with no changeover time.
POWER WAVE WELDING SYSTEMS

TECHNICAL
SPECIFICATIONS
Rated DC Output Input Amps at Rated DC Output
Product Ordering Input AC Amps/Volts/ 208 230 380 415 460 575 Output Weight Dimensions
Name Information Voltage Duty Cycle Range (net) HxWxD
Power K1517-5 208/230/460 60 Hz: 5-570 247 lbs. 26 x 20 x 33 in.
Wave 3 Phase 450/38/100% 70 65 -- -- 35 -- Amps (112 kg) (660 x 508 x
455 50/60 Hz 570/40/60% 87 82 -- -- 48 -- 838 mm)
50 Hz:
400/38/100% 72 67 -- -- 36 --
500/43/60% 79 74 -- -- 41 --
K1517-2 460/575 450/38/100% -- -- -- -- 36 30 254 lbs.
3 Phase 570/43/60% -- -- -- -- 48 40 (115 kg)
60 Hz
K1517-3 380-415 CE 400/36/100% -- -- 36 33 -- -- 5-520 256 lbs.
3 Phase 500/40/60% -- -- 48 44 -- -- Amps (116 kg)
50 Hz
Wire Speed Wire Size Range Dimensions
Ordering Range in. (mm) Net H x W x D
Power Feed 10 Information IPM (m/min) Solid Cored Weight in. (mm)
(1) Includes wire drive, control box, 8 ft. Linc-Net™ control
and weld cable, and wire reel stand.
(2) Includes wire drive, control box, 8 ft. and 25 ft. Linc-Net
control cables.
(3) Requires wire drive to control box Linc-Net cable:
For 8-9 ft. boom: K1543-16
For 10-18 ft. boom: K1543-25
(4) Boom ready wire feeder for installation on a Zipline boom. See
bulletin E8.201.
Control Box Only (3) K1539-2
12 ft. Zipline Ready Pkg.(4) K1538-5
16 ft. Zipline Ready Pkg.(4) K1538-6
Wire Drive Only (3) K1540-2
Power Feed 10 Dual
Low Speed Gear
50-800 ipm
(1.2 - 20.3 m/min)
High Speed Gear
75-1200 ipm
(1.9 - 30.5 m/min)
(Both gears
included)
Low Speed Gear
50-800 ipm
(1.2 - 20.3 m/min)
High Speed Gear
75-1200 ipm
(1.9 - 30.5 m/min)
(Both gears
included)
BOOM READY MODELS:
16-18 ft. Generic K1538-4
Boom Package(2)
BENCH MODEL(1) K1541-2 .023-3/32 .035-1/8
(0.6-2.4) (0.9-3.0)
.023-1/16 .035-5/64
(0.6-1.6) (0.9-2.0)
.023-3/32 .035-1/8
(0.6-2.4) (0.9-3.0)
.023-1/16 .035-5/64
(0.6-1.6) (0.9-2.0)
62 lbs. 18.5 x 13.5 x 30.5 (1)
(28.1 kg) (470 x 343 x 775)
106 lbs. 20 x 23 x 34 (1)
(48 kg) (508 x 584 x 864)
8.5 lbs. 13 x 8.5 x 4
(3.8 kg) (330 x 216 x 102)
30 lbs. 7.6 x 12.9 x 13.7
(13.6 kg) (193 x 328 x 348)
Wire Drive Only (3) K1685-1
12 ft. Zipline Ready Pkg.(4) K1683-2
16 ft. Zipline Ready Pkg.(4) K1683-3
BOOM READY MODELS:
16-18 ft. Generic K1683-1
Boom Package(2)
BENCH MODEL(1) K1686-1
54 lbs. 8.8 x 10 x 16.5
(24.5 kg) (222 x 254 x 419)
3
POWER SOURCE
WIRE FEEDER

4
A CLOSER LOOK
Large, Easy To Read
Digital Meter
Large, Easy To Use
Voltage/ Trim
Control
Large, Easy To Use
Wire Feed Speed/
Control Amperage
Dual Head Select Panel
(Standard on Power Feed 10 Dual Models)
Optional Procedure Control
Panel Area
Optional Process Control
Panel Area
Weld Mode Selector Switch
(Standard on Power Feed 10 and 10 Dual)
Power Feed 10 Dual Control Box
Power Wave 455/Power Feed 10 - Industry Standard
This is the ideal system for MIG and flux-cored welding.
Power Wave 455 power source . . . . . .K1517-5
Power Feed 10 wire feeder. . . . . . . . . .K1541-2
.045 Drive Roll Kit . . . . . . . . . . . . . . . . .KP1505-045S
Magnum 400 Gun & Cable asbly . . . . .K471-21(1)
Gas Regulator, Adjustable . . . . . . . . . .K586-1
Power Wave 455/Power Feed 10 - Deluxe Pulse
System
For the ultimate in pulsing performance, this system
provides the options and flexibility needed for multiple
processes and pulsing.
Power Wave 455 power source . . . . . .K1517-5
Power Feed 10 wire feeder . . . . . . . . . .K1541-2
Undercarriage . . . . . . . . . . . . . . . . . . .K1570-1
Dual Procedure/Memory Panel . . . . . . .K1542-9
MSP2 Pulse Panel . . . . . . . . . . . . . . . .K1542-12
Swivel Platform . . . . . . . . . . . . . . . . . . .K1557-1
.045 Drive Roll Kit . . . . . . . . . . . . . . . . .KP1505-045S
Magnum 400 Gun & Cable asbly . . . . .K471-21(1)
Gas Regulator, Adjustable . . . . . . . . . .K586-1
SYSTEM
SELECTION
Power Wave 455/Power Feed 10 Dual - Deluxe Pulse
System
Power for those demanding jobs. A dual feeder for running
two different wires from the same power source.
Power Wave 455 power source . . . . . . . . .K1517-5
Power Feed 10 Dual wire feeder . . . . . . . . .K1686-1
Undercarriage . . . . . . . . . . . . . . . . . . . . . . .K1570-1
MSP2 Pulse Panel . . . . . . . . . . . . . . . . . . .K1542-12
.045 Drive Roll Kit . . . . . . . . . . . . . . . . . . . .KP1505-045S
1/16” Cored Drive Roll Kit . . . . . . . . . . . . . .KP1505-1/16C
Magnum 400 Gun & Cable asbly . . . . . . . .K471-21(1)
Magnum 550 Gun & Cable asbly . . . . . . . .K598-7
Gun Receiver Bushing for Magnum 550 . . .K1500-3
Gun Connector Kit for Magnum 550 . . . . . .K613-7
Gas Regulator, Adjustable . . . . . . . . . . . . . .K586-1(2)
Typical MIG welding systems.
(1) Fully assembled, no gun connector required.
(2) Two required.

5
OPTIONAL
CONTROL PANELS
DUAL PROCEDURE PANEL
This panel stores two procedures in memory. The user may
select procedure “A” or “B” at the switch with a separate gun
mounted switch, or while welding with any welding gun.
Order K1542-5.
DUAL PROCEDURE / MEMORY
Six different welding procedures and processes may be stored
for recall. Includes Dual Procedure. Memories 2-6 may be
accessed with an “open air” trigger pull using any welding gun.
Order K1542-9.
DUAL PROCEDURE / MEMORY
Four welding procedures and processes may be stored for
recall. Includes Dual Procedure for each wire drive. Gun 1 and
2 have 2 procedures each, and each have access to 4 more
from memory.
Order K1542-13.
DUAL HEAD SELECT PANEL
Allows control box (K1539-2) to control two separate wire
drives (K1540-2). Comes standard with Power Feed 10 Dual .
Optional on Power Feed 10.
Order K1542-14
PROCEDURE CONTROL PANELS
POWER FEED 10
POWER FEED 10 DUAL

6
M PANEL
This optional control panel allows the user to select the type of
output desired: CV-MIG/CV Gas-Shielded, Flux-Cored
(Outershield,Metal-Cored), Flux-Cored (Innershield), or CC-
Stick (Soft)/Gouge. The “Arc Control “ varies inductance in the
CV modes and arc force in the CC-Stick mode.
Order K1542-6.
MSP2 PANEL
This optional control panel has the complete setup selections
of the MX panel. This panel also adds synergic CV and pulse
welding programs. Required to use Wave Designer software.
Order K1542-12.
MX2 PANEL
This optional control panel adds CC-Stick (crisp) mode and a
flexible welding setup.
Shielding gas preflow: 0.1 to 2.5 seconds or OFF.
Run-in wire feed speed: Adjustable for optimum start 75 to 150
inches per minute or OFF.
Arc Control: Inductance control adjusts arc characteristics to
operators preference.
Burnback: Time the arc stays on after the wire feed stops. 0.1
to 0.25 seconds or OFF.
Post Flow: Time the shielding gas flows after the weld stops.
0.1 to 10.0 seconds or OFF.
Crater Fill: Allows a second procedure used in the 4-step
trigger mode. Use for aluminum crater fill welding or a
second procedure.
Order K1542-11.
OPTIONAL
CONTROL PANELS
PROCESS CONTROL PANELS
POWER FEED 10 & 10 DUAL

NEW WIRE DRIVE
ADVANTAGES
• Four gear driven rolls. No tools
needed to snap rolls on or off. Each
roll has two grooves of the same
size to double feed life.
• Revolutionary Split Wire Guide
precisely aligns and supports wire
through the entire system.
Maximizes support and minimizes
problems.
• Two piece split wire guide construc-
tion provides easy access for
inspection, cleaning or changing to
different wire sizes.
• User can change external speed
range gear quickly. Feeder can be
low speed/high torque or high
speed.
• Entire feed head can be removed
for fast, easy servicing. Ideal for
production shops where downtime
must be minimized.
• Simple, symmetric design of feed
heads allows for quick removal and
replacement.
• Feed head assembly can rotate to
minimize gun cable kinks and
bends. Reduces gun stresses and
improves feedability.
• Incoming bushings are available to
accept guide bushings and conduits
often used with larger pay-off wire
packages.
• Simple wire drive roll pressure
adjustment knob with indicator bar.
• Rugged electrically insulated door
protects drive system with simple
positive locking.
• Gun receiver bushing provides low
cost adapters for Magnum or com-
petitive guns, along with easy inter-
changeability, better mechanical
support and reliable electrical
current transfer.
Entire wire path
is visible for
easy access.
Drive rolls flip up
for easy access.
Removable
outer wire guide
for easy access
to wire.
Changeable
external gear for
quick speed
range change.
7

MAGNUM GUNS
The following guns come pre-assembled
with liner and gun connector that is
compatible with the Tweco #2-#4 gun
receiver bushing (K1500-2). They con-
nect directly to the standard Power Feed
10 and 10 Dual. Gun cables are 15 ft.
length:
K471-21 Magnum 400 .035-.045
K471-22 Magnum 400 .052-1/16”
K471-23 Magnum 400 1/16-5/64”
K497-20 Magnum 200 .025-.030
K497-21 Magnum 200 .035-.045
FEED PLATE GUN
RECEIVER BUSHINGS
One of the following Gun Receiver
Bushings is required for connecting
gun and cable assemblies to the
feed plate.
Feed Plate Gun Receiver
Bushing K1500-X.
K1500-2 comes standard with
feed head (as shown).
Connector Kit for
Magnum Guns
(K466-10 or K613-7)
K1500-3 K1500-4K1500-2K1500-1
K1500-1 Gun Receiver
Bushing (Optional)
• Magnum 200, 300 and 400
gun and cable assemblies
with K466-1 connector kit.
• Lincoln Innershield®gun and
cable assembly.
• Fast-Mate™gun and cable
assembly with K489-2
Fast-Mate Adapter Kit.
• Magnum 550 gun and cable
assembly with K613-1.
K1500-2 Gun Receiver
Bushing(1) (Standard)
• Magnum 200 and 400 fully
assembled guns (K497-2X
and K471-2X). See below.
• Magnum 200, 300 and 400
gun and cable assemblies
with K466-10 connector kit.
• Guns with Tweco®#2, #3
and #4 connectors.
(1) This gun receiver bushing
comes standard with each
feed head.
K1500-3 Gun Receiver
Bushing (Optional)
• Magnum 550 gun and cable
assembly with K613-7
connection.
• Guns with Tweco #5
connectors.
K1500-4 Gun Receiver
Bushing (Optional)
• Magnum 200, 300 and 400
gun and cable assemblies
with K466-3 connector kit.
• Guns with Miller® connectors
(for new, longer connectors).
K489-7 Fast Mate Gun
Receiver Bushing
• Magnum gun and cable
assemblies with Fast Mate
connectors.
K489-7
8

4 Roll, and Split Wire Guide
Solid Steel Wire, Smooth V Groove
.023-.030 (0.6-0.8mm) Solid KP1505-030S
.035 (0.9mm) Solid KP1505-035S
.040-.045 (1.0-1.2mm) Solid KP1505-045S
.052 (1.4mm) Solid KP1505-052S
1/16” (1.6mm) Solid KP1505-1/16S
Cored Steel Wire, Knurled V Groove
.030-.035 (0.8-0.9mm) Cored KP1505-035C
.040-.045 (1.0-1.2mm) Cored KP1505-045C
.052 (1.4mm) Cored KP1505-052C
1/16” (1.6mm) Cored KP1505-1/16C
7/64” (2.8mm) Hardfacing (Smooth U Groove) KP1505-7/64H
Cored or Solid Steel Wire, Knurled V Groove
.068-.072 (1.8mm) KP1505-068
5/64” (2.0mm) KP1505-5/64
3/32” (2.4mm) KP1505-3/32
7/64” (2.8mm) cored only KP1505-7/64
.120-1/8” (3.2mm) cored only KP1505-120
Aluminum Wire, Smooth U Groove
.035 (0.9mm) KP1507-035A
.040 (1.0mm) KP1507-040A
3/64” (1.2mm) KP1507-3/64A
1/16” (1.6mm) KP1507-1/16A
3/32” (2.4mm) KP1507-3/32A
DRIVE ROLLS AND
SPLIT WIRE GUIDE KITS
KP1505
KP1507
For Aluminum Wires For Solid and Cored Wires
9

10
RECOMMENDED
OPTIONS
SPINDLE ADAPTER
For 14 lb. (6 kg) Innershield Coils
Permits 14 lb. (6 kg) Innershield
electrode coils to be mounted on 2”
(51mm) O.D. spindles. Order K435.
COIL ADAPTER
60 lb. Coil Adapter
Adapts 60 lb. Lincoln coils of
electrode to 2” (51mm) spindle.
Order K1504-1.
K363P
K1504-1
Water Connection Kit
Includes quick connect fittings on
front and back of wire drive for use
with water-cooled guns and Magnum
Coolers. Kit provides for one gun.
Order K590-6.
Swivel Platform
Mounts to the lift bail on the power
source and bottom of the Power
Feed 10. Wire feeder may be lifted off
if needed. Compatible with Light Duty
Caster Kit. Includes “lazy susan” parts
tray. Order K1557-1. (Power Feed
10 only.)
Plastic Wire Cover
Protects wire from dust and dirt and
provides electrical isolation.
For up to 44 lb. wire packages,
Order K1634-1.
For up to 60 lb. wire packages,
Order K1634-2.
K1557-1
K438
These come standard with both
bench and boom versions of the
Power Feed 10 and Power Feed 10
Dual wire feeders. The Linc-Net con-
trol cable has several advantages over
existing control cables:
• Common cable for all parts - The
same cable can be used between
the power source and wire feeder in
a bench system and between the
power source, control box and wire
drive in a boom system.
LINC-NET
CONTROL CABLES
• Extension cord flexibility - These
control cables can be connected
end-to-end for length flexibility. A
single, custom length cable is no
longer needed.
• Extended lengths - These cables
can be connected up to 200 ft.
between any 2 components. This
allows more flexibility in locating the
power source and wire feeder.
Ordering Information:
Linc-Net Receptacles
Provides Linc-Net receptacles for
converting a Power Feed 10 bench
model to a boom model.
Order K1548-1.
Control Cable Only
K1543-8 8 ft. cable length
K1543-16 16 ft. cable length
K1543-25 25 ft. cable length
K1543-50 50 ft. cable length
K1543-100 100 ft. cable length
Control and Weld Cables (4/0 size)
K1544-8 8 ft. cable length
K1544-16 16 ft. cable length
K1544-25 25 ft. cable length
K1544-50 50 ft. cable length
TM
60 lb. (27.2 kg) Adapter
Adapts 50-60 lb. (22.7-27.2 kg)
Lincoln Readi-Reel coils of electrode
to 2” (51mm) spindle. Order K438.
READI-REEL ADAPTERS
30 lb. (14 kg) Readi-Reel Adapter
Adapts 22-30 lb. (10-14 kg) Lincoln
Readi-Reel coils of electrode to 2”
(51mm) spindle. Order K363P.

Caster Kit - Light Duty
Mounts to the wire reel stand on the
Power Feed 10 and Power Feed 10
Dual. Allows for easy movement of
wire feeder. Order K1556-1.
Insulated Lift Bail
Allows the entire wire
feeder to be hung from
a crane or hook.
Order K1555-1.
(Power Feed
10 only.)
Undercarriage
Includes mounting frame, front cast-
ers, rear wheels and handle for hand
towing. Order K163.
Feed Plate Incoming Bushing
Connects directly to Magnum plastic
conduit (not included), for use in boom
systems, long distances, or large pay-
off packages.
For .025-1/16” wire, Order K1546-1.
For 1/16-1/8” wire, Order K1546-2.
K1546-1
K683-3
11
RECOMMENDED
OPTIONS
Undercarriage
Platform undercarriage for mounting
two gas cylinders at rear of welder.
Order K1570-1.
Wire Straightener
For use with 10-Series wire drives or
separately mounted. Straightens
cored wire up to 1/8” (3.2mm) and
solid wire up to 3/32” (2.4mm).
Incoming and outgoing bushings are
compatible with existing incoming and
gun receiver bushings.
Order K1733-1.
Dual Procedure Switch
Allows the use of two welding proce-
dures with one Lincoln Magnum gun.
15 ft. (7.6m). Must be used with
optional Dual Procedure Panel or Dual
Procedure with Memory Panel.
Order K683-3.
Gas Guard Regulator
For CO2and Argon blend gases.
Reduces surge caused by excess
pressure in supply hose. Includes
adjustable flow regulator with remov-
able adjustor key. Used with standard
regulator. Kit provides for one gun.
Order K659-1.
K1556-1
K1733-1

THE
LINCOLN ELECTRIC
COMPANY
Local Sales and Service through Global
Subsidiaries and Distributors
Cleveland, Ohio 44117-1199 U.S.A
TEL: [phone]
FAX: [phone]
WEB SITE: www.lincolnelectric.com
CC/CV Welders
E5.160 12/99
DISTRIBUTED BY:
SOFTWARE
Wave Designer Software
Wave Designer software allows you to
program your own waveforms. It puts
the power of waveform control in your
hands, allowing you to customize
Lincoln’s highly successful welding
waveforms to meet your exact needs.
Once you have made the simple
connection from your PC to your
Power Wave 455, designing a wave-
form is easy.
Two software packages are available:
Wave Designer Software
Permits manipulation of several wave
shape parameters including peak
current, background current, peak
pulse width and pulse. Allows for
optimization of arc length.
Order K1705-1.
Wave Designer Pro Software
All the features of Wave Designer, plus
Arc Scope™, the arc analysis tool for
those who need to monitor more than
voltage and current. Arc Scope also
tracks arc power, arc resistance and
energy input. Order K1705-2.
For more information, request
literature S2.20.
Customer Assistance Policy
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment.
Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for
advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time.
Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We
expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such informa-
tion or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our
products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of,
and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying
this type of fabrication methods and service requirements.