Powerwave 450 - Manual

Operator’s Manual
Power Wave R450 ®
For use with machines having Code Numbers:

12644, 12645, 12712*, 12713,
12714, 12847, 12848, 12849,
13203, 13386, 13387
Register your machine: Need Help? Call 1.888.935.3877

www.lincolnelectric.com/register to talk to a Service Representative
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
Save for future reference
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
Date Purchased no later than the following business day.
For Service outside the USA:

Code: (ex: 10859) Email: [email protected]
Serial: (ex: U1060512345)

*
IM10421-C | Issue Date May-22

© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
WARNING PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 10/08/2021
SAFETY
with hot engine parts and igniting. Do not spill fuel when filling
SECTION A: tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
WARNINGS 1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.
Keep hands, hair, clothing and tools away
CALIFORNIA PROPOSITION 65 WARNINGS from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
WARNING: Breathing diesel engine exhaust 1.e. In some cases it may be necessary to remove safety guards to
exposes you to chemicals known to the State perform required maintenance. Remove guards only when
of California to cause cancer and birth defects, necessary and replace them when the maintenance requiring
or other reproductive harm. their removal is complete. Always use the greatest care when
• Always start and operate the engine in a working near moving parts.
well-ventilated area. 1.f. Do not put your hands near the engine fan. Do not attempt to
• If in an exposed area, vent the exhaust to the outside. override the governor or idler by pushing on the throttle control
• Do not modify or tamper with the exhaust system. rods while the engine is running.
• Do not idle the engine except as necessary. 1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
For more information go to disconnect the spark plug wires, distributor cap or magneto wire
www.P65 warnings.ca.gov/diesel as appropriate.
1.h. To avoid scalding, do not remove the radiator
WARNING: This product, when used for welding or pressure cap when the engine is hot.
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause 1.i. Using a generator indoors CAN KILL YOU IN
MINUTES.
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.) 1.j. Generator exhaust contains carbon monoxide. This is a poison
you cannot see or smell.
WARNING: Cancer and Reproductive Harm 1.k. NEVER use inside a home or garage,
www.P65warnings.ca.gov EVEN IF doors and windows are open.
1.l. Only use OUTSIDE and far away from

ARC WELDING CAN BE HAZARDOUS. PROTECT windows, doors and vents.
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. 1.m. Avoid other generator hazards. READ
MANUAL BEFORE USE.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
ELECTRIC AND
that you purchase a copy of “Safety in Welding & Cutting - MAGNETIC FIELDS MAY
ANSI Standard Z49.1” from the American Welding Society, BE DANGEROUS
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current flowing through any conductor
is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF).
St. Clair Avenue, Cleveland, Ohio 44117-1199. Welding current creates EMF fields around welding cables
and welding machines
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE 2.b. EMF fields may interfere with some pacemakers, and
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
FOR ENGINE POWERED which are now not known.
EQUIPMENT. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
1.a. Turn the engine off before troubleshooting 2.d.1. Route the electrode and work cables together - Secure
and maintenance work unless the them with tape when possible.
maintenance work requires it to be running.
2.d.2. Never coil the electrode lead around your body.
1.b. Operate engines in open, well-ventilated areas or vent the engine 2.d.3. Do not place your body between the electrode and work
exhaust fumes outdoors. cables. If the electrode cable is on your right side, the
1.c. Do not add the fuel near an open flame welding work cable should also be on your right side.
arc or when the engine is running. Stop the 2.d.4. Connect the work cable to the workpiece as close as pos-
engine and allow it to cool before refueling to sible to the area being welded.
prevent spilled fuel from vaporizing on contact 2.d.5. Do not work next to welding power source.
Safety 02 of 04 - 10/08/2021
SAFETY
ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the fume.
• DC Manual (Stick) Welder. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
• AC Welder with Reduced Voltage Control.
hardfacing (see instructions on container or SDS)
3.c. In semiautomatic or automatic wire welding, the electrode, or on lead or cadmium plated steel and other
electrode reel, welding head, nozzle or semiautomatic welding metals or coatings which produce highly toxic
gun are also electrically “hot”. fumes, keep exposure as low as possible and
3.d. Always be sure the work cable makes a good electrical within applicable OSHA PEL and ACGIH TLV limits
connection with the metal being welded. The connection should using local exhaust or mechanical ventilation
be as close as possible to the area being welded. unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
3.e. Ground the work or metal to be welded to a good electrical (earth) outdoors, a respirator may also be required.
ground. Additional precautions are also required when
3.f. Maintain the electrode holder, work clamp, welding cable and welding
welding machine in good, safe operating condition. Replace on galvanized steel.
damaged insulation. 5. b. The operation of welding fume control equipment is affected by
3.g. Never dip the electrode in water for cooling. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between the level should be checked upon installation and periodically
two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8.
phosgene, a highly toxic gas, and other irritating products.
5.d. 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.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 10/08/2021
SAFETY
WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
• Away from areas where they may be struck or subjected
and the operating information for the equipment being used.
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe 7.f. Valve protection caps should always be in place and hand tight
Practices for the Preparation for Welding and Cutting of except when the cylinder is in use or connected for use.
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society 7.g. Read and follow the instructions on compressed gas cylinders,
(see address above). associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
6.e. Vent hollow castings or containers before heating, cutting or the Compressed Gas Association, 14501 George Carter Way
welding. They may explode.
Chantilly, VA 20151.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area. FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Safety 04 of 04 - 10/08/2021
ELECTROMAGNETIC g) the immunity of other equipment in the environment. The user
shall ensure that other equipment being used in the
environment is compatible. This may require additional
COMPATIBILITY (EMC) protection measures;
CONFORMANCE h) the time of day that welding or other activities are to be carried
Products displaying the CE mark are in conformity with European out.
Community Council Directive of 15 Dec 2004 on the approximation The size of the surrounding area to be considered will depend on the
of the laws of the Member States relating to electromagnetic structure of the building and other activities that are taking place.
compatibility, 2004/108/EC. It was manufactured in conformity with The surrounding area may extend beyond the boundaries of the
a national standard that implements a harmonized standard: EN premises.
60974-10 Electromagnetic Compatibility (EMC) Product Standard for
Arc Welding Equipment. It is for use with other Lincoln Electric
equipment. It is designed for industrial and professional use. METHODS OF REDUCING EMISSIONS
Public Supply System
INTRODUCTION Welding equipment should be connected to the public supply system
according to the manufacturer’s recommendations. If interference
All electrical equipment generates small amounts of electromagnetic
occurs, it may be necessary to take additional precautions such as
emission. Electrical emission may be transmitted through power
filtering of the system. Consideration should be given to shielding
lines or radiated through space, similar to a radio transmitter. When
the supply cable of permanently installed welding equipment, in
emissions are received by other equipment, electrical interference
metallic conduit or equivalent. Shielding should be electrically
may result. Electrical emissions may affect many kinds of electrical
continuous throughout its length. The shielding should be connected
equipment; other nearby welding equipment, radio and TV reception,
to the welding power source so that good electrical contact is
numerical controlled machines, telephone systems, computers, etc.
maintained between the conduit and the welding power source
Warning: This Class A equipment is not intended for use in enclosure.
residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties Maintenance of the Welding Equipment
in ensuring electro-magnetic compatibility in those locations, due to The welding equipment should be routinely maintained according to
conducted as well as radiated disturbances. the manufacturer’s recommendations. All access and service doors
and covers should be closed and properly fastened when the
welding equipment is in operation. The welding equipment should
INSTALLATION AND USE not be modified in any way except for those changes and
The user is responsible for installing and using the welding adjustments covered in the manufacturer’s instructions. In
equipment according to the manufacturer’s instructions. particular, the spark gaps of arc striking and stabilizing devices
If electromagnetic disturbances are detected then it shall be the should be adjusted and maintained according to the manufacturer’s
responsibility of the user of the welding equipment to resolve the recommendations.
situation with the technical assistance of the manufacturer. In some Welding Cables
cases this remedial action may be as simple as earthing (grounding)
The welding cables should be kept as short as possible and should
the welding circuit, see Note. In other cases it could involve
be positioned close together, running at or close to the floor level.
constructing an electromagnetic screen enclosing the power source
and the work complete with associated input filters. In all cases Equipotential Bonding
electromagnetic disturbances must be reduced to the point where Bonding of all metallic components in the welding installation and
they are no longer troublesome. adjacent to it should be considered. However, metallic components
Note: The welding circuit may or may not be earthed for safety bonded to the work piece will increase the risk that the operator
reasons. Follow your local and national standards for installation and could receive a shock by touching these metallic components and
use. Changing the earthing arrangements should only be authorized the electrode at the same time. The operator should be insulated
by a person who is competent to assess whether the changes will from all such bonded metallic components.
increase the risk of injury, e.g., by allowing parallel welding current
return paths which may damage the earth circuits of other Earthing of the Workpiece
equipment. Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, e.g., ship’s hull
or building steelwork, a connection bonding the workpiece to earth
ASSESSMENT OF AREA may reduce emissions in some, but not all instances. Care should be
Before installing welding equipment the user shall make an taken to prevent the earthing of the workpiece increasing the risk of
assessment of potential electromagnetic problems in the injury to users, or damage to other electrical equipment. Where
surrounding area. The following shall be taken into account: necessary, the connection of the workpiece to earth should be made
by a direct connection to the workpiece, but in some countries
a) other supply cables, control cables, signaling and telephone
where direct connection is not permitted, the bonding should be
cables; above, below and adjacent to the welding equipment;
achieved by suitable capacitance, selected according to national
b) radio and television transmitters and receivers; regulations.
c) computer and other control equipment; Screening and Shielding
d) safety critical equipment, e.g., guarding of industrial equipment; Selective screening and shielding of other cables and equipment in
e) the health of the people around, e.g., the use of pacemakers the surrounding area may alleviate problems of interference.
and hearing aids; Screening of the entire welding installation may be considered for
f) equipment used for calibration or measurement; special applications.
ECO design information
The equipment has been designed in order to be compliant w ith the Directive 2009/125/EC and the Regulation
2019/1784/EU.
Efficiency and idle pow er consumption:
Efficiency w hen m ax pow er

Nam e consum ption / Idle pow er Equivalent m odel
consum ption
Pow er Wave R450 CE 86% / 34.1W No equivalent model
Idle state, follow instructions to test idle mode:

1. Connect an Ethernet cable from the port on the machine to a laptop and start up the machine.
2. Open the Pow er Wave Manager and configure the connection to the machine that is plugged in through the
Ethernet.
3. Check the box for the ‘System Hibernation Timer’ to allow the machine to enter hibernation mode. Set the
Hibernation Timer to 15 minutes (the low est it can go). Wait 15 minutes and once the fans stop spinning the
machine is in Hibernate Mode (Idle State).
4. The machine needs to be turned off and back on to come out of the hibernation mode
Efficiency;
The Efficiency procedure itself requires the use of a grid. Pow er Wave Manager can be dow nloaded from
pow erw avesoftware.com along w ith the Pow er Wave Manager instruction. The Pow er Wave Manager instructions
explain how to test a machine using a resistive load. This is described in section 6 under calibration.
The value of efficiency and consumption in idle state have been measured by method and conditions defined in the
product standard EN 60974-1
Manufacturer’s name, product name, code number, product number, serial number and date of production can be read
from rating plate and serial number label.
Typical gas usage for MIG/MAG equipment:

Wire DC electrode positive
Wire Feeding Gas flow
Material type diam eter Current Voltage Shielding Gas
[m /m in] [l/m in]
[m m ] [A] [V]
Carbon, low alloy
0,9 - 1,1 95 - 200 18 - 22 3,5 – 6,5 Ar 75%, CO2 25% 12
steel
Aluminum 0,8 - 1,6 90 - 240 18 - 26 5,5 – 9,5 Argon 14 - 19
Austenitic stainless Ar 98%, O2 2% /
0,8 - 1,6 85 - 300 21 - 28 3-7 14 - 16
steel He 90%, Ar 7,5% CO2 2,5%
Copper alloy 0,9 - 1,6 175 - 385 23 - 26 6 - 11 Argon 12 - 16
Magnesium 1,6 - 2,4 70 - 335 16 - 26 4 - 15 Argon 24 - 28
Tig Process:
In TIG w elding process, gas usage depends on cross-sectional area of the nozzle. For comonly used torches:
Helium: 14-24 l/min
Argon: 7-16 l/min
Notice: Excessive flow rates causes turbulence in the gas stream w hich may aspirate atmospheric contaminantion into
the w elding pool.
ECO design information 1 ECO design information

Notice: A cross w ind or draft moving can disrupt the shielding gas coverage, in the interest of saving of protective gas
use screen to block air flow .
End of life
At end of life of product, it has to be disposal for recycling in accordance w ith Directive 2012/19/EU (WEEE), information
about the dismantling of product and Critical Raw Material (CRM) present in the product, can be found at:
w ww.lincolnelectriceurope.com
R450 CE
6
4
1
2
2, 6
5 7 3
Item Component Material for recovery CRM Selective treatment

1 Enclosure Steel - -
2 Heat sink, 4 total Aluminum Si, 38 g -
Mg, 64 g
3 Rail, 4 total Aluminum Si, 21 g -
Mg, 14 g
4 Handle, 2 total Aluminum Si, 118 g -
Mg, 1 g
5 Output terminal Brass - -
6 PC board, 7 total - - Required
7 Choke Copper - -
Internal cables
8 External cables – not shown Copper - Required
Reference: P-1258-A, code 12848
ECO design information 2 ECO design information

TABLE OF CONTENTS
INSTALLATION .............................................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS .....................................................................................................................................A-1
LIFTING ............................................................................................................................................................A-5
STACKING ............................................................................................................................................................A-5
TILTING ............................................................................................................................................................A-5
INPUT AND GROUND CONNECTIONS ..........................................................................................................................A-5
MACHINE GROUNDING...............................................................................................................................................A-5
HIGH FREQUENCY PROTECTION .................................................................................................................................A-5
INPUT CONNECTION ..................................................................................................................................................A-6
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS.....................................................................................................A-6
INPUT VOLTAGE SELECTION ......................................................................................................................................A-6
RECOMMENDED WORK CABLE SIZES FOR ARC WELDING ..........................................................................................A-9
GENERAL GUIDELINES .............................................................................................................................................A-9
CABLE INDUCTANCE AND ITS EFFECTS ON WELDING ..............................................................................................A-10
REMOTE SENSE LEAD SPECIFICATIONS ...................................................................................................................A-10
VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS ......................................................................A-12
CONTROL CABLE CONNECTIONS .............................................................................................................................A-14
OPERATION ................................................................................................................................................SECTION B
POWER-UP SEQUENCE ..............................................................................................................................................B-1
DUTY CYCLE ............................................................................................................................................................B-1
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL ...............................................................B-1
PRODUCT DESCRIPTION ............................................................................................................................................B-2
RECOMMENDED PROCESSES AND EQUIPMENT .........................................................................................................B-2
PROCESS LIMITATIONS .............................................................................................................................................B-2
EQUIPMENT LIMITATIONS..........................................................................................................................................B-2
CASE FRONT CONTROLS .........................................................................................................................................B-3
CASE BACK CONTROLS ............................................................................................................................................B-4
COMMON WELDING PROCEDURES ............................................................................................................................B-5
DEFINITION OF WELDING MODES ..............................................................................................................................B-5
BASIC WELDING CONTROLS ......................................................................................................................................B-5
SMAW (STICK) WELDING ...........................................................................................................................................B-6
GTAW (TIG) WELDING ...............................................................................................................................................B-6
CONSTANT VOLTAGE WELDING .................................................................................................................................B-6
PULSE WELDING........................................................................................................................................................B-6
OPTIONS / ACCESSORIES.............................................................................................................................SECTION C
MAINTENANCE .............................................................................................................................................SECTION D
ROUTINE MAINTENANCE............................................................................................................................................D-1
PERIODIC MAINTENANCE...........................................................................................................................................D-1
CALIBRATION SPECIFICATION....................................................................................................................................D-1
TROUBLESHOOTING......................................................................................................................................SECTION E
DIAGRAMS .................................................................................................................................................SECTION F
Parts List .........................................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice.

For most current Instruction Manuals, go to parts.lincolnelectric.com.
3
POWER WAVE® R450 INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE® R450

POWER SOURCE-INPUT VOLTAGE AND CURRENT
Duty Idle Power Factor @
Model Input Voltage ± 10% Input Amperes
Cycle Power Rated Ouput
K3451-1
K3451-2 100 % 208/230/1
57/52 .89/.87
Code 13386 Rating 50/60 Hz 500
and Above Watts
Max.
40 %
K3451-1 208/230/400*460/575/3 80/73/41/37/29 (Fan
Rating
K3451-2 50/60 Hz On) .95
All Codes 100 % (Includes 380V to 415V) 60/54/31/27/21
Rating
RATED OUTPUT
INPUT GMAW SMAW GTAW-DC
VOLTAGE/PHASE/
FREQUENCY 40% 60% 100% 40% 60% 100% 40% 60% 100%
300 275 300
208/1/50/60 - - - - - -
Amps Amps Amps
230/1/50/60 - - 29 Volts - - 31 Volts - - 22 Volts
200-208/3/50/60
230/3/50/60 550 450
500 550 500 450 550 500 450
Amps Amps
380-415/3/50/60 Amps Amps Amps Amps Amps Amps Amps
41.5 36.5
39 Volts 42 Volts 40 Volts 38 Volts 32 Volts 30 Volts 28 Volts
460/3/50/60 Volts Volts
575/3/50/60
RECOMMENDED INPUT WIRE AND FUSE SIZES1
INPUT MAXIMUM INPUT CORD SIZE3 TIME DELAY FUSE
VOLTAGE/PHASE/ AMPERE RATING AND AWG SIZES OR BREAKER2
FREQUENCY DUTY CYCLE (mm2) AMPRERAGE
208/1/50/60 57A, 100% 4 (25) 80
230/1/50/60 52A, 100% 6 (16) 80
200-208/3/50/60 80A, 40% 4 (25) 100
230/3/50/60 73A, 40% 4 (25) 90
380-415/3/50/60 41A, 40% 8 (10) 60
460/3/50/60 37A, 40% 8 (10) 45
575/3/50/60 29A, 40% 10 (7) 35
Idle power is less than 50 watts when in Hibernation mode4

1. Based on U.S. National electrical Code
2. Also called " inverse time" or "thermal / magnetic" circuit breakers; circuit breakers that have a delay in tripping action that
decreases as the magnitude of the current increases
3. Type SO cord or similar in 30° C ambient at effective current rating of unit.
4. If supported by the robotic controller software version.
A-1
TECHNICAL SPECIFICATIONS - Power Wave® R450 CE

Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @
Rated Output
40% rating
230/400*460/575 73/41/37/29
K3455-1 50/60 Hz 300 Watts Max. .95
K3455-2 100% rating (includes 380V to 415V) (fan on)
59/31/27/21
RATED OUTPUT
VOLTAGE/PHASE/
40% 60% 100% 40% 60% 100% 40% 60% 100%
FREQUENCY
230/3/50/60
380-415/3/50/60 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps
460/3/50/60 41.5 Volts 39 Volts 36.5 Volts 42 Volts 40 Volts 38 Volts 32 Volts 30 Volts 28 Volts
575/3/50/60*
RECOMMENDED INPUT WIRE AND FUSE SIZES 1
INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

VOLTAGE / PHASE/ AMPERE RATING AND AWG SIZES OR BREAKER 2
FREQUENCY DUTY CYCLE (mm2) AMPERAGE
230/3/50/60 73A, 40% 4 (21) 90

380-415/3/50/604. 41A, 40% 8 (10) 60
460/3/50/604. 37A, 40% 8 (10) 45
575/3/50/60 29A, 40% 10 (7) 35

* For voltages higher than 460V or applications outside the European union replace input cord with properly rated cable.
4. Supplied K3389-1 input cord for these input applications only. For all others consult chart and connect per electrical code.
5. Is supported by the robotic controller software version.
A-2
TECHNICAL SPECIFICATIONS - POWER WAVE® R450 CCC

Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @
Rated Output
40% rating
400*460/575 41/37/29
K3456-1 50/60 Hz 500 Watts Max. .95
100% rating (includes 380V to 415V) (fan on)
31/27/21
RATED OUTPUT
VOLTAGE/PHASE/
40% 60% 100% 40% 60% 100% 40% 60% 100%
FREQUENCY
380-415/3/50/60
460/3/50/60 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps
575/3/50/60 41.5 Volts 39 Volts 36.5 Volts 42 Volts 40 Volts 38 Volts 32 Volts 30 Volts 28 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES 1
INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

VOLTAGE / PHASE/ AMPERE RATING AND AWG SIZES OR BREAKER 2
FREQUENCY DUTY CYCLE (mm2) AMPERAGE
380-415/3/50/60 41A, 40% 8 (10) 60

460/3/50/60 37A, 40% 8 (10) 45
575/3/50/60 29A, 40% 10 (7) 35

4. If supported by the robotic controller software version.
A-3
TECHNICAL SPECIFICATIONS - ALL MODELS

WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)
Mean Peak
GMAW
GMAW-Pulse 40-550A 60V 73V
FCAW
GTAW-DC 5-550A 24V 36V
SMAW 60V 63V
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3451-1, K3451-2,
22.45 in ( 570 mm) 14.00in ( 356 mm) 24.80in ( 630mm) 150 lbs (68 kg)*
K3455-1, K3455-2,
K3456-1
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20C to 40C) Environmentally Hardened: -40°F to 185°F (-40C to 85C)
IP23 155º(F) Insulation Class
* Weight does not include input cord.
A-4
INSTALLATION TILTING
Place the machine directly on a secure, level surface or on a
SAFETY PRECAUTIONS recommended undercarriage. The machine may topple over if this
Read this entire installation section before you start installation. procedure is not followed.
WARNING INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the POWER WAVE®
ELECTRIC SHOCK can kill. R450. Installation should be made in accordance with the
• Only qualified personnel should perform appropriate National Electrical Code, all local codes and the
this installation. information in this manual.
• Turn the input power OFF at the
disconnect switch or fuse box before WARNING
working on this equipment. Turn off the input power to
any other equipment connected to the welding system FALLING EQUIPMENT
at the disconnect switch or fuse box before working on can cause injury.
the equipment. • Lift only with equipment of adequate
• Do not touch electrically hot parts. lifting capacity.
• Always connect the POWER WAVE® R450 grounding • Be sure machine is stable when lifting.
lug to a proper safety (Earth) ground. • Do not operate machine while suspended when lifting.
SELECT SUITABLE LOCATION MACHINE GROUNDING

The POWER WAVE® R450 will operate in harsh environments. The frame of the welder must be grounded. A ground terminal
Even so, it is important that simple preventative measures are marked with a ground symbol is located next to the input power
followed in order to assure long life and reliable operation. connection block.
• The machine must be located where there is free circulation See your local and national electrical codes for proper grounding
of clean air such that air movement in the back, out the sides methods.
and bottom will not be restricted.
• Dirt and dust that can be drawn into the machine should be HIGH FREQUENCY PROTECTION
kept to a minimum. The use of air filters on the air intake is Locate the POWER WAVE® R450 away from radio controlled
not recommended because normal air flow may be restricted. machinery. The normal operation of the POWER WAVE® R450
Failure to observe these precautions can result in excessive may adversely affect the operation of RF controlled equipment,
operating temperatures and nuisance shutdown. which may result in bodily injury or damage to the equipment.
• Keep machine dry. Shelter from rain and snow. Do not place
on wet ground or in puddles.
FCC REGULATORY STATEMENT
• Do not mount the POWER WAVE® R450 over combustible
surfaces. Where there is a combustible surface directly under This equipment has been tested and found to comply with the
stationary or fixed electrical equipment, that surface shall be limits for a Class B digital device. For FCC ID number see the
covered with a steel plate at least .060” (1.6mm) thick, which complete regulatory statement at the beginning of this manual.
shall extend not less than 5.90” (150mm) beyond the
equipment on all sides.
LIFTING
Both handles should be used when lifting POWER WAVE® R450.
When using a crane or overhead device a lifting strap should be
connected to both handles. Do not attempt to lift the
POWER WAVE® R450 with accessories attached to it.
STACKING
The POWER WAVE® R450 cannot be stacked.
A-5
WARNING
Only a qualified electrician should connect
the input leads to the POWER WAVE® R450.
Connections should be made in accor-
dance with all local and national electrical
codes and the connection diagrams. Failure to do so
may result in bodily injury or death.
INPUT CONNECTION
(See Figure A.1)
Use a three-phrase supply line. A 1.40 inch diameter access hole

with strain relief is located on the case back. Route input power
cable through this hole and connect L1, L2, L3 and ground per
connection diagrams and National Electric Code. To access the
input power connection block, remove three screws holding the
access door to the side of the machine.
ALWAYS CONNECT THE POWER WAVE GROUNDING LUG (LOCATED
AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH)
GROUND.
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to Specification Section for recommended fuse, wire sizes
and type of the copper wires. Fuse the input circuit with the
recommended super lag fuse or delay type breakers (also called
"inverse time" or "thermal/magnetic" circuit breakers). Choose
input and grounding wire size according to local or national
electrical codes. Using input wire sizes, 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 SELECTION

The POWER WAVE® R450 automatically adjusts to work with
different input voltages. No reconnect switch settings are required.
WARNING
The POWER WAVE® R450 ON/OFF switch is
not intended as a service disconnect for this
equipment. Only a qualified electrician
should connect the input leads to the
POWER WAVE® R450. Connections should be made in
accordance with all local and national electrical codes
and the connection diagram located on the inside of the
reconnect access door of the machine. Failure to do so
may result in bodily injury or death.
A-6
FIGURE A.1 - for K3455-1 & K3455-2

GROUND CONNECTION
CONNECT GROUND
LEAD PER LOCAL AND
NATIONAL ELECTRIC CODE
CONNECT EACH PHASE OF A

THREE-PHASE CONDUCTOR
HERE
CE FILTER
INPUT CORD
STRAIN RELIEF
ROUTE INPUT CORD THROUGH
RELIEF AND TWIST NUT TO TIGHTEN INPUT POWER
ACCESS DOOR
On some models, toroids are on the power cord. When replacing

the power cord, it is important to put the toroids on the new power
cord in the same location and with the same number of turns.
FIGURE A.1 for K3451-1, K3451-2, K3456-1
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
INPUT CORD STRAIN RELIEF

ROUTE INPUT CORD POWER CONNECTION BLOCK
THROUGH RELIEF AND CONNECT EACH PHASE OF A THREE-PHASE
TWIST NUT TO TIGHTEN CONDUCTOR HERE
INPUT POWER
ACCESS DOOR
A-7
GMAW (MIG) WELDING

An ArcLink compatible wire feeder is recommended for Mig weld-
ing. Refer to Figure A.3 for the connection details.
FIGURE A.3
Feeder
Torch
Flowmeter
Dress Out
Kit
Ethernet
Electrode Cable
Control
Cable
Water
Work Cable
Work Piece Avoid excessive lengths and

do not coil excess cable
Remote Sense Lead
A-8
RECOMMENDED WORK CABLE SIZES FOR ARC • Route all cables directly to the work and wire feeder, avoid
WELDING excessive lengths and do not coil excess cable. Route the
Connect the electrode and work cables between the appropriate electrode and work cables in close proximity to one another
output studs of the POWER WAVE® R450 per the following to minimize the loop area and therefore the inductance of the
guidelines: weld circuit.
• Always weld in a direction away from the work (ground)
CAUTION connection.
Table A.1 shows copper cable sizes recommended for different
Negative electrode polarity operation WITHOUT use of a currents and duty cycles. Lengths stipulated are the distance from
remote work sense lead (21) requires the Negative the welder to work and back to the welder again. Cable sizes are
Electrode Polarity attribute to be set. See the Remote increased for greater lengths primarily for the purpose of
Sense Lead Specification section of this document for minimizing cable drop.
further details.
For additional Safety information regarding the electrode and work
cable set-up, See the standard “SAFETY INFORMATION” located in
the front of this Instruction Manual.
GENERAL GUIDELINES
• Select the appropriate size cables per the “Output Cable
Guidelines” below. Excessive voltage drops caused by
undersized welding cables and poor connections often result
in unsatisfactory welding performance. Always use the
largest welding cables (electrode and work) that are practical,
and be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicates undersized
cables and/or bad connections.
TABLE A.1 - RECOMMENDED CABLE SIZES - RUBBER COVERED COPPER - RATED 167°F (75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

PERCENT DUTY
AMPERES
CYCLE
0 TO 50 FT. 50 TO 100 FT. 100 TO 150 FT. 150 TO 200 FT. 200 TO 250 FT.
200 100 2 2 2 1 1/0

250 100 1 1 1 1 1/0
300 100 2/0 2/0 2/0 2/0 3/0
400 100 3/0 3/0 3/0 3/0 4/0
450 100 3/0 3/0 4/0 4/0 2-3/0
500 60 2/0 2/0 3/0 3/0 4/0
550 40 2/0 2/0 3/0 3/0 4/0
** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may require cables larger
than recommended, or cables rated higher than 167°F (75°C).
A-9
If the auto sense lead feature is disabled and remote

voltage sensing is enabled but the sense leads are
CABLE INDUCTANCE AND ITS EFFECTS ON
missing or improperly connected extremely high welding
WELDING
outputs may occur.
Excessive cable inductance will cause the welding performance to
degrade. There are several factors that contribute to the overall
inductance of the cabling system including cable size, and loop General Guidelines for Voltage Sense Leads
area. The loop area is defined by the separation distance between
the electrode and work cables, and the overall welding loop Sense leads should be attached as close to the weld as practical,
length. The welding loop length is defined as the total of length of and out of the weld current path when possible. In extremely
the electrode cable (A) + work cable (B) + work path (C) (See sensitive applications it may be necessary to route cables that
Figure A.5). contain the sense leads away from the electrode and work
welding cables.
To minimize inductance always use the appropriate size cables,
and whenever possible, run the electrode and work cables in close Voltage sense leads requirements are based on the weld process
proximity to one another to minimize the loop area. Since the most (See Table A.2)
significant factor in cable inductance is the welding loop length, TABLE A.2
avoid excessive lengths and do not coil excess cable. For long Electrode Voltage Sensing (1) Work Voltage Sensing (2)
work piece lengths, a sliding ground should be considered to keep Process
67 lead 21 lead
the total welding loop length as short as possible.
GMAW 67 lead required 21 lead optional (3)
GMAW-P 67 lead required 21 lead optional (3)
REMOTE SENSE LEAD SPECIFICATIONS
STT4 67 lead required 21 lead required
Voltage Sensing Overview
FCAW 67 lead required 21 lead optional (3)
The best arc performance occurs when the POWER WAVE® R450 GTAW Voltage sense at studs Voltage sense at studs
has accurate data about the arc conditions.
(1) The electrode voltage sense lead (67) is automatically enabled by the weld
Depending upon the process, inductance within the electrode and process, and integral to the 5 pin ArcLink control cable (K1543-xx).
work cables can influence the voltage apparent at the studs of the (2) When a work voltage sense lead (21) is connected the power source will auto-
welder, and have a dramatic effect on performance. Remote matically switch over to using this feedback (if the auto sense feature is
voltage sense leads are used to improve the accuracy of the arc enable).
(3) Negative polarity semi-automatic process operation WITHOUT use of a remote
voltage information supplied to the control pc board. Sense Lead
Kits (K940-xx) are available for this purpose. work sense lead (21) requires the Negative Electrode Polarity attribute to be set.
(4) STT requires an STT or Advanced Module.
The POWER WAVE® R450 has the ability to automatically sense
when remote sense leads are connected. With this feature there
are no requirements for setting-up the machine to use remote
sense leads. This feature can be disabled through the Weld
Manager Utility (available at www.powerwavesoftware.com) or
through the set up menu (if a user interface is installed into the
power source).
CAUTION
FIGURE A.5
POWER
WAVE
R450 A
WORK
B
A-10
Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the ArcLink
control cable and is always connected to the wire drive feed plate
when a wire feeder is present. Enabling or disabling electrode
voltage sensing is application specific, and automatically
configured by the active weld mode.
CAUTION
If the auto sense lead feature is disabled and the weld
polarity attribute is improperly configured extremely high
welding outputs may occur.
Work Voltage Sensing

While most applications perform adequately by sensing the work
voltage directly at the output stud, the use of a remote work
voltage sense lead is recommended for optimal performance. The
remote WORK sense lead (21) can be accessed through the four-
pin voltage sense connector located on the control panel by using
the K940 Sense Lead Kit. It must be attached to the work as close
to the weld as practical, but out of the weld current path. For more
information regarding the placement of remote work voltage
sense leads, see in this section entitled "Voltage Sensing
Considerations for Multiple Arc Systems."
Negative Electrode Polarity

The POWER WAVE® R450 has the ability to automatically sense
the polarity of the sense leads. With this feature there are no set-
up requirements for welding with negative electrode polarity. This
feature can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com) or through the set up
menu (if a user interface is installed into the power source).
A-11
VOLTAGE SENSING CONSIDERATIONS FOR

MULTIPLE ARC SYSTEMS If Sense Leads ARE Used:
Special care must be taken when more than one arc is welding • Position the sense leads out of the path of the weld current.
simultaneously on a single part. Multiple arc applications do not Especially any current paths common to adjacent arcs. Current
necessarily dictate the use of remote work voltage sense leads, from adjacent arcs can induce voltage into each others current
but they are strongly recommended. paths that can be misinterpreted by the power sources, and
If Sense Leads ARE NOT Used: result in arc interference.
• Avoid common current paths. Current from adjacent arcs can • For longitudinal applications, connect all work leads at one end
induce voltage into each others current paths that can be of the weldment, and all of the work voltage sense leads at the
misinterpreted by the power sources, and result in arc inter- opposite end of the weldment. Perform welding in the direction
ference. away from the work leads and toward the sense leads.
(See Figure A.6)
FIGURE A.6
CONNECT ALL SENSE
LEADS AT THE END
DIRECTION OF THE WELD.
OF TRAVEL
CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.
A-12
• For circumferential applications, connect all work

leads on one side of the weld joint, and all of the work voltage
sense leads on the opposite side, such that they are out of the
current path.
(See Figure A.7)
FIGURE A.7
POWER
SOURCE
#1
POWER
SOURCE
#2
POWER
POWER SOURCE
SOURCE #2
#1
POWER
SOURCE
#1
POWER
SOURCE
#2
A-13
CONTROL CABLE CONNECTIONS

General Guidelines
Genuine Lincoln control cables should be used at all times (except
where noted otherwise). Lincoln cables are specifically designed
for the communication and power needs of the Power Wave® /
Power Feed™ systems. Most are designed to be connected end
to end for ease of extension. Generally, it is recommended that
the total length not exceed 100ft. (30.5m). The use of non-
standard cables, especially in lengths greater than 25 feet, can
lead to communication problems (system shutdowns), poor motor
acceleration (poor arc starting), and low wire driving force (wire
feeding problems). Always use the shortest length of control cable
possible, and DO NOT coil excess cable.
Regarding cable placement, best results will be obtained when
control cables are routed separate from the weld cables. This
minimizes the possibility of interference between the high currents
flowing through the weld cables, and the low level signals in the
control cables. These recommendations apply to all commu-
nication cables including ArcLink® and Ethernet connections.
Product specific Installation Instructions

Connection Between Power Source and ArcLink® Compatible
Wirefeeders (K1543, K2683 – ArcLink Control Cable)
The 5-pin ArcLink control cable connects the power source to the
wire feeder. The control cable consists of two power leads, one
twisted pair for digital communication, and one lead for voltage
sensing. The 5-pin ArcLink connection on the Power Wave® R450
is located on the rear panel (See Case Back Controls in the
Operation Section). The control cable is keyed and polarized to
prevent improper connection. Best results will be obtained when
control cables are routed separate from the weld cables,
especially in long distance applications. The recommended
combined length of the ArcLink control cable network should not
exceed 200ft. (61.0m).
Connection Between Power Source and Ethernet

Networks
The POWER WAVE® R450 is equipped with an IP67 rated ODVA
compliant RJ-45 Ethernet connector, which is located on the rear
panel. All external Ethernet equipment (cables, switches, etc.), as
defined by the connection diagrams, must be supplied by the
customer. It is critical that all Ethernet cables external to either a
conduit or an enclosure are solid conductor, shielded cat 5e cable,
with a drain. The drain should be grounded at the source of trans-
mission. For best results, route Ethernet cables away from weld
cables, wire drive control cables, or any other current carrying
device that can create a fluctuating magnetic field. For additional
guidelines refer to ISO/IEC 11801. Failure to follow these recom-
mendations can result in an Ethernet connection failure during
welding.
A-14
POWER WAVE® R450 OPERATION
OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS

MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
Read this entire section of operating instructions WARNING OR
before operating the machine. CAUTION
WARNING
DANGEROUS
ELECTRIC SHOCK can kill. VOLTAGE
• Do not touch electrically live part or
electrode with skin or wet clothing.
• Insulate yourself from work and ground. POSITIVE OUTPUT
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards removed
or open. NEGATIVE OUTPUT
FUMES AND GASES can

HIGH TEMPERATURE
be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone. STATUS
WELDING SPARKS can cause fire PROTECTIVE

or explosion.
• Keep flammable material away.
GROUND
• Do not weld on containers that have held
combustibles.
COOLER
ARC RAYS can burn.
• Wear eye, ear, and body protection.
OUTPUT
Observe additional guidelines detailed in the
beginning of this manual. OPERATORS
MANUAL
POWER-UP SEQUENCE
WORK
When the POWER WAVE® R450 is powered up, it can take as long
as 30 seconds for the machine to be ready to weld. During this
time period the user interface will not be active.
CIRCUIT BREAKER
DUTY CYCLE
The duty cycle is based on a ten-minute period. A 40% duty cycle
represents 4 minutes of welding and 6 minutes of idling in a ten-
minute period. Refer to the technical specification section for the EXPLOSION
POWER WAVE® R450’s duty cycle ratings.
B-1
PRODUCT DESCRIPTION PROCESS LIMITATIONS

The POWER WAVE® R450 is a portable multi-process power The software based weld tables of the POWER WAVE® R450 limit
source with high-end functionality capable of Stick, DC TIG, MIG, the process capability within the output range and the safe limits
Pulsed MIG and Flux-Cored welding. It is ideal for a wide variety of of the machine. In general the processes will be limited to .030-
materials including aluminum, stainless, and nickel — where arc .052 solid steel wire, .030 -.045 stainless wire, .035 -1/16 cored
performance is critical. wire, and .035 - 1/16 Aluminum wire.
The POWER WAVE® R450 is designed to be a very flexible welding
system. Like existing Power Wave’s®, the software based archi- EQUIPMENT LIMITATIONS
tecture allows for future upgradeability. One significant change
from the current range of Power Wave® units is that the Ethernet Only ArcLink compatible semiautomatic wire feeders and users
communication feature is standard on the POWER WAVE® R450 interfaces may be used. If other Lincoln wire feeders or non-
which allows for effortless software upgrades through Lincoln wire feeders are used there will be limited process
Powerwavesoftware.com. A Devicenet option allows the POWER capability and performance and features will be limited.
WAVE® R450 to be used in a wide range of configurations and the The Power Wave R450’s are not compatible with the S-Series user
POWER WAVE® R450 is designed to be compatible with advanced Interface Kit.
welding modules like STT.
RECOMMENDED PROCESSES AND EQUIPMENT

The POWER WAVE® R450 is recommended for robotic and
semiautomatic welding. The Power Wave® R450 can be set up in
a number of configurations, some requiring optional equipment or
welding programs.
Recommended Processes
The POWER WAVE® R450 is a high speed, multi-process power
source capable of regulating the current, voltage, or power of the
welding arc. With an output range of 5 to 550 amperes, it supports
a number of standard processes including synergic GMAW,
GMAW-P, FCAW, FCAW-SS, SMAW, GTAW and GTAW-P on
various materials especially steel, aluminum and stainless.
B-2
CASE FRONT CONTROLS FIGURE B.1 for K3451-1, K3451-2, K3456-1

(See Figure B.1)
1. Status LED - (See Troubleshooting Section for operational
functions).
2. Thermal LED - Indicates when machine has thermal fault.
3. FEEDER Status LED - A two color LED that indicates system
errors. The Power Wave R450 is equipped with two
indicators. One is for the inverter power source, while the
other indicates the status of the feeder control system.
Normal operation is a steady green light. For more
information and a detailed listing, see the troubleshooting
section of this document or the Service Manual for this
machine. (See Troubleshooting Section for operational
functions.) 4
NOTE: The Power Wave R450 status light will flash green, and
sometimes red and green, for up to one minute when the 1
machine is first turned on. This is a normal situation as the

2
machine goes through a self test at power up.
4. Power Switch - Controls power to the POWER WAVE® R450. 3
7
5. NEGATIVE WELD OUTPUT
6. POSITIVE WELD OUTPUT
7. Voltage Sense Connector - Allows for separate remote
electrode and work sense leads.
VOLTAGE SENSE PINS
5 6
Pin Lead Function
3 21 Work Voltage Sense FIGURE B.1- for K3455-1 & K3455-2
1 67E Electrode Voltage Sense
4
1
6
5
B-3
FIGURE B.2
Case BaCk Controls 6
(See Figure B.2)

1. 115 VAC RECEPTACLES (Optional Kit - K2829-1)
2. WIRE FEEDER RECEPTACLE (14 Pin) - Robotic wire feeder
connector (for 4R220, Power Feed 10 Robotic, etc).
3. DIFFERENTIAL I/O CONNECTOR - For (Optional) K2902-1 STT
1
or K2912-1 Advanced Module. 7
4. ArcLink OUTPUT CONNECTOR (5 PIN) - Provides power and

communication to ArcLink 8
periferals (semi-automatic feeder, Cool Arc 55S, etc).
5. Devicenet Kit (optional - K2827-2) - For PLC control.
6. 40V CIRCUIT BREAKER 2
7. Ethernet (SHIELDED) - For ArcLink XT enabled robot,

computer or network connection.
3
8. Internal I/O CONNECTOR - Terminal Strip for making simple
input signal connections. (See Figure B.2A)
4
The terminal strip is divided into three groups:
Group #1 - TRIGGER 5
Group #2 - FEED FORWARD/REVERSE

Group #3 - SHUTDOWN INPUTS
All inputs use "normally open" logic except the shutdown
group. The shutdown inputs use "normally closed" logic, and
are always enabled. Unused shutdowns must be tied to the
+15V supply for the shutdown group. Machines are shipped
from the factory with jumpers installed on both shutdown
inputs.
Shutdown 1 and shutdown 2 inputs are for weld system faults
and should not be used as emergency or safety shutdowns.
FIGURE B.2A
+15VDC - Group #1
+15VDC - Group #3
+15VDC - Group #2
Shutdown 1 Input
Shutdown 2 Input
Dual Procedure
Feed Reverse
Feed Forward
Gas Purge
2/4 Step
Trigger
12 11 10 9 8 7 6 5 4 3 2 1
B-4
COMMON WELDING PROCEDURES DEFINITION OF WELDING MODES

Making a Weld NON-SYNERGIC WELDING MODES
The serviceability of a product or structure utilizing the welding • A Non-synergic welding mode requires all welding process
programs is and must be the sole responsibility of the variables to be set by the operator.
builder/user. Many variables beyond the control of The Lincoln SYNERGIC WELDING MODES
Electric Company affect the results obtained in applying these
programs. These variables include, but are not limited to, welding • A Synergic welding mode offers the simplicity of single knob
procedure, plate chemistry and temperature, weldment design, control. The machine will select the correct voltage and
fabrication methods and service requirements. The available amperage based on the Wire Feed Speed (WFS) set by the
range of a welding program may not be suitable for all appli- operator.
cations, and the builder is and must be solely responsible for
welding program selection.
Choose the electrode material, electrode size, shielding gas, and
process (GMAW, GMAW-P etc.) appropriate for the material to be BASIC WELDING CONTROLS
welded. Weld Mode
Select the weld mode that best matches the desired welding
process. The standard weld set shipped with the POWER WAVE® Selecting a weld mode determines the output characteristics of
R450 encompasses a wide range of common processes that will the Power Wave® power source. Weld modes are developed with
meet most needs. If a special weld mode is desired, contact the a specific electrode material, electrode size, and shielding gas.
local Lincoln Electric sales representative. For a more complete description of the weld modes programmed
into the POWER WAVE® R450 at the factory, refer to the Weld Set
All adjustments are made through the user interface. Because of Reference Guide supplied with the machine or available at
the different configuration options your system may not have all of www.powerwavesoftware.com.
the following adjustments.
Wire Feed Speed (WFS)
See Accessories Section for Kits and Options available to use with
the POWER WAVE® R450. In synergic welding modes (synergic CV, GMAW-P), WFS is the
dominant control parameter. The user adjusts WFS according to
factors such as wire size, penetration requirements, heat input,
etc. The POWER WAVE® R450 then uses the WFS setting to adjust
the voltage and current according to settings contained in the
POWER WAVE®.
In non-synergic modes, the WFS control behaves like a
conventional power source where WFS and voltage are
independent adjustments. Therefore, to maintain proper arc
characteristics, the operator must adjust the voltage to
compensate for any changes made to the WFS.
Amps
In constant current modes, this control adjusts the welding
amperage.
Volts
In constant voltage modes, this control adjusts the welding
voltage.
Trim
In pulse synergic welding modes, the Trim setting adjusts the arc
length. Trim is adjustable from 0.50 to 1.50. 1.00 is the nominal
setting and is a good starting point for most conditions.
UltimArc™ Control
UltimArc™ Control allows the operator to vary the arc charac-
teristics. UltimArc™ Control is adjustable from –10.0 to +10.0
with a nominal setting of 0.0.
B-5
SMAW (STICK) WELDING CONSTANT VOLTAGE WELDING

The welding current and Arc Force settings can be set through a Synergic CV
Power Feed™ 84 or Power Feed™ 25M wire feeder. Alternatively
an optional Stick / Tig UI can be installed into the power source to For each wire feed speed, a corresponding voltage is prepro-
control these settings locally. grammed into the machine through special software at the
factory.
In a SMAW (STICK mode), Arc Force can be adjusted. It can be set
to the lower range for a soft and less penetrating arc charac- The nominal preprogrammed voltage is the best average voltage
teristic (negative numeric values) or to the higher range (positive for a given wire feed speed, but may be adjusted to preference.
numeric values) for a crisp and more penetrating arc. Normally, When the wire feed speed changes, the POWER WAVE® R450
when welding with cellulosic types of electrodes (E6010, E7010, automatically adjusts the voltage level correspondingly to maintain
E6011), a higher energy arc is required to maintain arc stability. similar arc characteristics throughout the WFS range.
This is usually indicated when the electrode sticks to the work- Non Synergic CV
piece or when the arc becomes unstable during manipulative
technique. For low hydrogen types of electrodes (E7018, E8018, In non-synergic modes, the WFS control behaves more like a
E9018, etc.) a softer arc is usually desirable and the lower end of conventional CV power source where WFS and voltage are
the Arc Control suits these types of electrodes. In either case the independent adjustments. Therefore to maintain the arc charac-
arc control is available to increase or decrease the energy level teristics, the operator must adjust the voltage to compensate for
delivered to the arc. any changes made to the WFS.
All CV Modes
GTAW (TIG) WELDING Pinch adjusts the apparent inductance of the wave shape. The
The welding current can be set through a Power Feed™ 84 or “pinch” function is inversely proportional to inductance.
Power Feed™ 25M wire feeder. Alternatively an optional Stick / Therefore, increasing Pinch Control greater than 0.0 results in a
Tig UI can be installed into the power source to control these crisper arc (more spatter) while decreasing the Pinch Control to
settings locally. less than 0.0 provides a softer arc (less spatter).
The TIG mode features continuous control from 5 to 550 amps
with the use of an optional foot amptrol. The POWER WAVE® R450 PULSE WELDING
can be run in either a Touch Start TIG mode or Scratch start TIG
mode. Pulse welding procedures are set by controlling an overall “arc
length” variable. When pulse welding, the arc voltage is highly
dependent upon the waveform. The peak current, back ground
current, rise time, fall time and pulse frequency all affect the
voltage. The exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters are known.
Voltage or Trim can be adjusted.
Trim adjusts the arc length and ranges from 0.50 to 1.50 with a
nominal value of 1.00. Trim values greater than 1.00 increase the
arc length, while values less than 1.00 decrease the arc length.
(See figure B.3)
FIGURE B.3
B-6
Most pulse welding programs are synergic. As the wire feed

speed is adjusted, the POWER WAVE® R450 will automatically
recalculate the waveform parameters to maintain similar arc
properties.
The POWER WAVE® R450 utilizes “adaptive control” to
compensate for changes in the electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip to the work
piece.) The POWER WAVE® R450 waveforms are optimized for a
0.75” stick-out. The adaptive behavior supports a range of stick-
outs from 0.50 to 1.25”. At very low or high wire feed speeds, the
adaptive range may be less due to reaching physical limitations of
the welding process.
UltimArc™ Control adjusts the focus or shape of the arc.
UltimArc™ Control is adjustable from -10.0 to +10.0 with a
nominal setting of 0.0. Increasing the UltimArc™ Control
increases the pulse frequency and background current while
decreasing the peak current. This results in a tight, stiff arc used
for high speed sheet metal welding. Decreasing the UltimArc™
Control decreases the pulse frequency and background current
while increasing the peak current. This results in a soft arc good
for out of position welding. (See Figure B.4)
FIGURE B.4
B-7
POWER WAVE® R450 ACCESSORIES
OPTIONS / ACCESSORIES
All Kits Options and Accessories are found on the Web site:
(www.lincolnelectric.com)
Welding Fume Extractors

Lincoln offers a wide range of fume extraction environmental sys-
tem solutions, ranging from portable systems easily wheeled
around a shop to shop-wide central systems servicing many dedi-
cated welding stations.
Request Lincoln publication E13.40
(See www.lincolnelectric.com)
C-1
POWER WAVE® R450 MAINTENANCE
MAINTENANCE
Safety Precautions
WARNING
ELECTRIC SHOCK can kill.
• Do not operate with covers removed.
• Turn off power source before installing or
servicing.
• Do not touch electrically hot parts.
• Turn the input power to the welding power source off at
the fuse box before working in the terminal strip.
• Only qualified personnel should install, use or service
this equipment.
See additional warning information throughout

this Operator’s Manual
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing out the
machine, using a low-pressure air stream, to remove accumulated
dust and dirt from the intake and outlet louvers, and the cooling
channels in the machine.
PERIODIC MAINTENANCE
Calibration of the POWER WAVE® R450 is critical to its operation.
Generally speaking the calibration will not need adjustment.
However, neglected or improperly calibrated machines may not
yield satisfactory weld performance. To ensure optimal
performance, the calibration of output Voltage and Current should
be checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the factory. Generally
the machine calibration will not need adjustment. However, if the
weld performance changes, or the yearly calibration check reveals
a problem, use the calibration section of thePower Wave Manager
to make the appropriate adjustments.
The calibration procedure itself requires the use of a grid, and
certified actual meters for voltage and current. The accuracy of
the calibration will be directly affected by the accuracy of the
measuring equipment you use. SVM251 VERIFICATION AND
CALIBRATION PROCEDURES includes detailed instructions at
www.powerwavesoftware.com.
D-1
POWER WAVE® R450 TROUBLESHOOTING
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions
detailed throughout this manual.
This Troubleshooting Guide is provided to help you locate and

repair possible machine malfunctions. Simply follow the three-
step procedure listed below.
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.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local Lincoln
Authorized Field Service Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-1
USING THE STATUS LED TO TROUBLESHOOT

SYSTEM PROBLEMS
Not all of the POWER WAVE® R450 errors will be displayed on the
user interface (if it is installed). There are two status lights that
display error codes. If a problem occurs it is important to note the
condition of the status lights. Therefore, prior to cycling power to
the system, check the power source status light for error
sequences as noted below.
There is one externally mounted status light located on the case
front of the machine. This status light corresponds to the main
control board and input control board’s status.
Included in this section is information about the Status Lights and
some basic troubleshooting charts for both machine and weld
performance.
The status light for the main control board and input control board
are dual-color LED’s. Normal operation for each is steady green.
Error conditions are indicated in the following chart Table E.1.
TABLE E.1
Light Meaning
Condition Main control board status light and Input control board
Steady Green System OK. Power source is operational, and is communicating normally with all healthy peripheral equipment connected to its
ArcLink network.
Blinking Green
Occurs during power up or a system reset, and indicates the POWER WAVE® R450 is mapping (identifying) each component in
the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.
Indicates Auto-mapping has failed

Fast Blinking Green
Alternating Green and Red Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are present. Read the
error code(s) before the machine is turned off.
Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in
red with a long pause between digits. If more than one code is present, the codes will be separated by a green light. Only active
error conditions will be accessible through the Status Light.
Error codes can also be retrieved with the Power Wave Manager Utility available at
www.powerwavesoftware.com). This is the preferred method, since it can access historical information contained in the
error logs.
To clear the active error(s), turn power source off, and back on to reset.
Steady Red Not applicable.
Blinking Red Not applicable.
Status LED off Not applicable.
E-2
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWER WAVE® R450

The following is a partial list of possible error codes for the POWER WAVE® R450. For a complete listing consult the Power Wave
Manager “Lookup Error”.
MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code # Indication
36 Thermal error Indicates over temperature. Usually accompanied by Thermal LED. Check fan
operation. Be sure process does not exceed duty cycle limit of the machine
The long term average secondary (weld) current limit has been exceeded.
54 Secondary (Output) over current error
NOTE: The long term average secondary current limit is 325A (1 Phase) or
575A (3 Phase).
56 Chopper communication error Indicates communication link between main control board and chopper has
errors. If cycling the input power on the machine does not clear the error, contact
the Service Department.
58 Primary Fault error Review error code from input board status light or status beeper. Most likely
caused by an over power condition which caused an under voltage on the prima-
ry bus. If cycling the input power on the machine does not clear the error, contact
the Service Department.
71 Secondary (Output) over power error The long term secondary (Weld) power limit has been exceeded.
NOTE: The long term average secondary current limit is 25kw (3 Phase), 14kw (1
Phase).
Other Error codes that contain three or four digits are defined as fatal errors. These
codes generally indicate internal errors on the Power Source Control Board. If
cycling the input power on the machine does not clear the error, contact the
Service Department.
E-3
INPUT CONTROL BOARD

Error Code # Indication Type
Instantaneous input current limit has been exceeded. Typically indicates short
331 Instantaneous Input Current Limit term power overload. If problem persists contact Service Department. Persistent
Input current limit was exceeded during machine power-up. If problem per-
334 Startup Current Check Failure sists contact Service Department. Persistent
Input voltage was too high or too low during machine power-up. Verify that
335 Startup Voltage Check Failure the input voltage is between 200V and 650V. Temporary
Thermostat on primary module tripped. Typically caused by a fan malfunction
336 Thermal Fault or blocked air vent. Temporary
The DC bus voltage was not charged to a certain level at end of precharge. If
337 Precharge Timeout problem persists contact Service Department. Persistent
The input power drawn by the machine exceeded a safe level. If problem per-
338 Input Power Limit sists, contact the Service Department. Persistent
The input voltage momentarily dropped out. Check connections and verify
341 Input Voltage Dropout quality of input power. Temporary
Transformer current too high. Typically indicates short-term power overload. If
346 Transformer Primary Overcurrent problem persists, contact the Serivce Department. Persistent
Average input current limit has been exceeded. Typically indicates short term
347 Average Input Current Limit power overload. If problem persists contact Service Department. Persistent
The DC bus voltage dropped below the allowable limit. If problem persists,
349 Bus Undervoltage contact the Service Department. Temporary
Persistent errors require power to be cycled for the error to clear.
Temporary faults will go away on their own if the error condition is removed.
WIRE DRIVE MODULE

Error Code # Indication
81 Motor Overload Long term average motor current limit has been exceeded. Typically indicates
mechanical overload of system. If problem continues consider higher torque gear
ratio (lower speed range).
82 Motor Overcurrent Absolute maximum motor current level has been exceeded. This is a short term
average to protect drive circuitry.
83 Shutdown #1 Is Open 1.This refers to the ‘green’ I/O connector on the bottom of the controller.
If not being externally accessed, verify the integrity of the connector and jumper.
If accessed through a remote circuit, verify the integrity of that circuit.
84 Shutdown #2 Is Open 1.This refers to the ‘green’ I/O connector on the bottom of the controller.
If not being externally accessed, verify the integrity of the connector and jumper.
If accessed through a remote circuit, verify the integrity of that circuit.
E-4
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Basic Machine Problems
Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly sized. See
installation section of this manual for
recommended sizes.
2. Improper Weld Procedure requiring out- 2. Reduce output current, duty cycle, or
put levels in excess of machine rating. both.
3. Major physical or electrical damage is 3. Contact your local authorized Lincoln

evident when the covers are removed. Electric Field Service facility for techni-
cal assistance.
Machine will not power up (no lights) 1. Make sure input supply disconnect has
1. No Input Power been turned ON. Check input fuses.
Make certain that the Power Switch
(SW1) on the power source is in the
“ON” position.
2. Make certain that input voltage is cor-

2. Input voltage is too low or too high.
rect, according to the Rating Plate locat-
ed on the rear of the machine.
Machine won’t weld, can’t get any output. 1. Input voltage is too low or too high. 1. Make certain that input voltage is cor-
rect, according to the Rating Plate locat-
ed on the rear of the machine.
2. Thermal Error. 2. See “Thermal LED is ON”�section.

This problem will normally be accompa-
nied by an error code. See “Status Light”
section of this document for additional 3. Secondary current limit has been 3. Possible short in output circuit. If con-
information. exceeded. (see error 54) dition persists, contact an authorized
3a. Input control board fault (see input Lincoln Electric Field Service facility.
control board error status).
E-5
Thermal LED is ON Improper
Basic fan operation
Machine Problems (Continued)
Thermal LED is ON 1. Improper fan operation. 1. Check for proper fan operation. Fan
should run in a low speed setting when
the machine is idle and increase in
speed as the machine temperature
increases. Check for material blocking
intake or exhaust louvers, or for exces-
sive dirt clogging cooling channels in
machine.
2. Open thermostat circuit. 2. Check for broken wires, open connec-

tions or faulty thermostats in the ther-
mostat circuit.
“Real Time Clock” no longer functioning 1. Control PC Board Battery. 1. Replace the battery (Type: BS2032)
Weld and Arc Quality Problems

General degradation of weld performance 1. Wire feed problem. 1. Check for feeding problems.
2. Cabling problems. 2. Check for bad connections, excessive

loops in cable, etc.
NOTE: The presence of heat in the exter-

nal welding circuit indicates poor connec-
tions or undersized cables.
3. Loss of, or improper Shielding Gas. 3. Verify gas flow and type are correct.
4. Verify weld mode is correct for process. 4.Select the correct weld mode for the
application.
5. Machine calibration. 5. The power source may require calibra-

tion. (current, voltage, WFS).
E-6
Weld and Arc Quality Problems (Continued)
Wire burns back to tip at the end of the 1. Burnback Time 1. Reduce burnback time and/or work point.
weld.
Machine output shuts down during a weld. 1. Secondary current limit has been exceed- 1. Adjust procedure or reduce load to lower
ed, and the machine shuts down to pro- current draw from the machine.
tect itself.
2. System Fault 2. A non-recoverable fault will interrupt

welding. This condition will also result in
a status light blinking. See the Status
Light section for more information.
Machine won’t produce full output. 1. Input voltage may be too low, limiting 1. Make certain that the input voltage is
output capability of the power source. proper, according to the Rating Plate
located on the rear of the machine.
2. The input may be single phase. 2. Verify all 3 phases are present.
3. Machine calibration. 3. Calibrate secondary current and voltage.
Excessively long and erratic arc. 1. Wire feed problem. 1. Check for feeding problems. Make sure
proper gear ratio has been selected.
2. Loss of, or improper Shielding Gas 2. Verify gas flow and type are correct
3. Machine calibration. 3. Calibrate secondary current and voltage.
E-7
Ethernet
Cannot Connect 1. Physical connection. 1. Verify that the correct patch cable or
cross over cable is being used (refer to
local IT department for assistance).
1a. Verify the cables are fully inserted into

the bulk head connector.
1b. The LED under the PC board ethernet

connector will be lit when the machine
is connected to another network device.
2. IP address information. 2. Use the appropriate PC utility to verify the

correct IP address information has been
entered.
2a. Verify no duplicate IP addresses exist on

the network.
3. Ethernet Speed 3. Verify that the network device connected

to the Power Wave is either a 10-baseT
device or a 10/100-baseT device.
10-baseT is recommended
Connection Drops while welding 1. Cable Location

1. Verify Network cable is not located next
to current carrying conductors. This
would include input power cables and
welding output cables.
E-8
MANUFACTURER: No
POWER WAVE R450 Codes (12644, 12645, 12847, 13386, 13887)

TB
GENERAL INFORMATION
U CAVITY NUMBERING SEQUENCE
L3 L3 4 358A ELECTRICAL SYMBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
33
32
33A
32A
GND5
3 356A
J30
TO V WI-FI BOARD 2 54E LEAD COLOR CODING
1
2
3
4
5
6
6
7
8
1 415
4 417
5 418
2 416
3 GND4
851 1 1 2 1 3
L2 J1 (OPTIONAL) 1 53E B - BLACK J10A1, J2, J5, J11, 1 J9, J13, J16,
SUPPLY L2 852 2 J10B1, J31, J46, J26, J27, J62,
G8814 853 3 R - RED J811, 2 J51, J111, 3 4 6
414 7 4 J112, J83, J1
J63
B5
J62
xxxxxxx
W 317 L17 854 4 N- BROWN J2 J82, J81
413 2
L1 L1 412 6 J61 115 VAC 855 5 J8, J24, J28, 1 4 1 5
B6 318 V - VIOLET J3, J4,
411 1 INVERTER PCB 856 6 J29, J43, J47,
xxxxxxx
(ASSEMBLY G6571) G - GREEN J45, J61
OPTIONAL 857 7 J63, J84 10
5 8 J86 6
115V SUPPLY DEVICENET 858 8 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
859 9 1 8
(OPTIONAL) ALIGNS WITH WHITE LEAD OF LED SOCKET. 1 6
8510 10 J6, J7,
S24842-12 (SOLDER END)
J12, J23,
65A 1 8511 11 J41, J85
16
358
371
372
416
373
553
J25, J42
356
9
374
54
53
6 12 J87
343
347
345
341
348
344
357
349
352
354
342
346
2 8512 12
POWER WAVE® R450
892
893
891
894
3 J46
66 12 11 10 9 8 7
33A 4 6 5 4 3 2 1
33
1
2
3
4
5
6
7
8
9
10
S7
1
2
3
4
5
6
7
8
5
9
2
3
4
1
10
11
12
1
2
3
4
CB1
2
1
4
3
10A 1 51A I/O RECEPTACLE S7
2 A
32 (LOCATED ON REAR A J
3
J4
DC BUS E 3 F B
J2
4 52 K
J11
32A
J13
34 PANEL) 2 4
J12
BOARD J47 A I C
5 51 D B L
L15732 1
N
DIGITAL CONTROL BOARD 6 1 5 E
7 2 3 H
D
J15 B 4 M
G6682 8 52A C D C G
E
S12
021 N D)
F
GND5 - 7 3 (SO L D E R I NG E S18657 (INSERTION END)
J7
J8
J3 S12021-79 (INSERTION SIDE)
J6
J5
J9
S3 S2 S4 S5 S6
115V
2
4
3
2
1
9
8
7
6
5
4
3
RECEPTACLE
1
7
3
9
3
12
2
10
5
4
8
7
6
4
2
11
6
5
15
1
16
14
13
12
11
16
4
2
15
14
3
13
10
5
6
(Neutral Bonded)
INPUT
SWITCH
ETHERNET
CONNECTOR
67
410
364
409
365
J56
379
370
402
554
403
213
350
418
415
355
375
378
376
417
214
212
211
377
21F
367A
L8
366A
1
206F
202F
67F L1 T1
RJ 45 ETHERNET 206F 4 206E S2
TYPE
L18 L19 67C 67D
CABLE 202F 3 202B 2 VOLTAGE
67F 2 67E
21F 21 3
SENSE L2 T2
1
RECEPTACLE
65A .0141 MF P112 J16
CB2 4
10A 65 R/Y J56 371 8 52D
L3 T3
B1B 52C 6
B1C 379 7 67D
67C 5 67F
1 353B B1C 52C
373 6 51C 4 51D
FAN 207 THERMAL LED
TSTAT
TSTAT
3 351B J53 B1A 67C
370 5 54C 3 54D J51
S6 ROBOTIC 51C
372 4 2
2 359B 4 353 B1 B
INTERFACE B 351 200 54C
374 3 53C 1 53D 377
8 4
N/U OHM 2 CONTROL BD STATUS
368
W
361
RECEPTACLE 2 359 CHOPPER CONTROL 378 3
314A
316A
331A
307A
333A
328A
335A
336A
315A
313A
326A
338A
337A
332A
308A
334A
100 W 1 NOT USED RED/GREEN LED
1 353A BOARD G6786 376 2
R/Y J55 5 351A CURRENT
A SHIELDED 375 1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
539
16
14
15
13
10
12
W B
11
6 359A 8 348 206A TRANSDUCERS TWISTED
1 353C HEAT PAIR
7 347
B 541 FAN SINK
3 351C 6 346
C 521 2 359C 351A 10 5 345 214 4 BLACK UPPER
J41
B 66 9 4 344 211 3 WHITE LEM
J32
J33
D 522 N/U 351 8 3 343 213 2 BLUE
P52 359A 7 2 342 212 RED
B2 1 +
E B/G 359 6 1 341
R
G
1 367A J92
541
539
521
522
B/R
53E
53D
54E
51D
52D
847
B/G
54D
B2
B1
B3
B/W
NOT USED B13
J37
2 365 353A 5 J91
F 847 218 4 BLACK LOWER
3 GND 65 4
4
215 WHITE
4
3
1
4
4
2
3
5
B2
1
1
1
2
3
5
7
LEM
6
8
2
3
2
3
G W GND-B 4 366A 353 3
F-1
5 364 INPUT 217 2 BLUE
B16
350 2 216 RED
B11
H B/W 6 CHOKES 1 + J84 J83 J82 J81
1 L16139 1
355 1 216 2
I 2 217 3
J42
202C
315B
313B
336B
337B
331B
328B
333B
335B
314B
332B
316B
3 215 FEEDHEAD PCB 4

J 4 218
B5
553 5
B12
OUTPUT S28626 J86 6
R 316A 16
1
K
6
2
4
5
554
3
9
7
8
10
13
14
15
16
11
12
CHOKE 15 7
B8 8
L B/R L13270-4 314A 14
B7 9
M G B56 BL6 A 13
J85 10
B20 336A 12 J87
J23B
N 67G B2 POWER BOARD A2

B6 BL5 337A 11
G6846 331A 10
8
7
9
3
5
4
2
6
8
B23
9
7
3
5
4
2
6
1
12
11
16
15
14
13
10
12
11
16
15
14
6
13
10
B18 BL4 A3 361

53A 51A 1 51F 328A 9
ARCLINK - A J23A 5
53B 52A 2 52F 315A 8
.0141 MF B28 BL3 A4 4 366
54A 67A 3 67 B17 7 J26 1
ARCLINK + B 3
852
1B
851
854
853
855
856
8511
1W
511A
8512
857
858
8510
512A
859
54B 54A 4 54F BL2 A5 313A 6 2

53A 5 53F 2
ELECTRODE 67A 5 3
C L6 51B 6 51C A6 4 1
B
SENSE 67B 332A 4
B4
W
BL1
B10
52B 7 52C CHOKES 5.0 MF
52A CAP. 333A 3 PFC CONTROL BOARD 5
+40VDC D L5 67B 8 67C T12218-37 B5 CHOPPER BOARD 335A 12 362 6
52B 2
54B 9 54C G6870 G6860 11 326A 7
51A B4 1
0 VDC E 53B 10 53C 318 8 10 B1A 8
51B 9 368 9 B W
B15
B9
L4 7 402 6
8 B1B 10
S3 ARCLINK 6 356A 5
J55 J22 7 206E 11
RECEPTACLE L3 317 5 358A 4 J25
J36 B29 6 367 + 12
4 403 3 512A 13 512 FEEDHEAD STATUS
326B
B44
B55
.0047 uF INPUT BOARD 356 2 5 WHITE LED
3 511A 14 511
M22489 358 1 4
10 362 206C 1W 15 B
2 3
B4 B5 9 1B 16 W
1 2 206D
A 8
J24
J1 1 369
J21
J50 4
B 7 J85A
3
250 OHM 25 W
6 366 J20 100
J35
J34
DIFF_1 HIGH C G
B3 T3 2 M20305-1
G 1 357 54 OHM
5 367
4
3
2
1
8
7
6
5
4
3
2
1
DIFF_1 LOW D B/G B/G 53

67F
1
512
511
2 354 100 W
67G
B2 T2 4
250 OHM 25 W
DIFF_2 HIGH E R R 3 352 3 369

B/R
4
4 349
1
1
2
3
5
2
.1047 MF
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
DIFF_2 LOW F B/R B1 T1 2
11
12
202A
10
13
15
14
16
1 202
52
338A
334B
334A
51
307A
54A
53A
307B
308A
308B
338B
S5 L7 J1 J2
WORK
SYNC/TANDEM
307B
331B
336B
334B
337B
308B
328B
335B
326B
338B
333B
332B
314B
315B
316B
313B
- VOLTAGE SENSE
CONNECTOR 202B SELECT PCB
202C .1047 MF M19540-2
1 GROUND BOND CIRCUIT
G
+24 VDC INPUT 2 894 S4 BASE TO EARTH GROUND PER THE
+24 VDC COMMON 3 893 DEVICENET GND1 VERTICAL PANEL
GND2 CASEBACK
DNET CAN_H 4 892 CONNECTOR
GND3 CASEFRONT
DNET CAN_L 5 891 (OPTIONAL) WI-FI MODULE C
G8901 PRINT
R
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure
panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DIAGRAMS
MANUFACTURER: No
POWER WAVE R450 CE Codes (12712, 12713, 12848)

GND
L3 GENERAL INFORMATION
WI-FI BOARD
CAVITY NUMBERING SEQUENCE
(OPTIONAL)
L4 L6 3 356A
L1 L16084-1
J30
TO G8814 2 54E LEAD COLOR CODING
1 415
4 417
5 418
2 416
3 GND4
CE FILTER 851 1 1 2 1 3
L2 NOT USED J1 1 53E B - BLACK J10A1, J2, J5, J11, 1 J9, J13, J16,
SUPPLY L2 PCB 852 2 J10B1, J31, J46, J26, J27, J62,
853 3 R - RED J811, 2 J51, J111, 3 4 6
L5 4 J112, J83, J1
J62
L7 854 4 N- BROWN J2 J82, J81
L1 L1 855 5 J8, J24, J28, 1 4 1 5
V - VIOLET J3, J4,
856 6 J29, J43, J47,
G - GREEN J45, J61
OPTIONAL 857 7 J63, J84 10
5 8 J86 6
GND DEVICENET 858 8 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
P52 L2 859 9 1 8
ALIGNS WITH WHITE LEAD OF LED SOCKET. 1 6
8510 10 J6, J7,
1 367A S24842-12 (SOLDER END)
J12, J23,
65A 1 8511 11 J41, J85
16
358
371
372
416
373
553
J25, J42
356
9
374
54
53
2 365 6 12 J87
343
347
345
341
348
344
357
349
352
354
342
346
2 8512 12
892
893
891
894
3 GND J46
POWER WAVE® R450
66 3 12 11 10 9 8 7
4 366A 4 6 5 4 3 2 1
5 364
1
2
3
4
5
6
7
8
9
10
S7
1
2
3
4
5
6
7
8
5
9
2
3
4
1
6
10
11
12
1
2
3
4
2
1
4
3
1 51A I/O RECEPTACLE S7
2 A
P54 3 (LOCATED ON REAR A J
J4
DC BUS E 3 F B
J2
4 52 K
J11
J13
PANEL) 2 4
J12
1 T1A BOARD J47 A I C
5 51 D B L
2 L15732 1
N
7 J56 2 3 H
3 D
J15 B 4 M
4 G6682 8 52A C D C G
E
5 206F 4 206E S12
021 N D)
F
- 7 3 (SO L D E R I NG E S18657 (INSERTION END)
J7
J8
J3 202F 3 202B S12021-79 (INSERTION SIDE)
J6
6
J5
J9
7 67F 2 67E S3 S2 S4 S6
S5
8 T2A 21F 1 21
2
4
3
2
1
9
8
7
6
5
4
3
8
1
7
3
9
3
12
2
10
5
4
8
7
6
4
2
11
6
5
15
1
16
14
13
12
11
16
4
2
15
14
3
13
10
5
6
THERMAL LED
INPUT
L11 SWITCH
ETHERNET J51
CONNECTOR B
L1 T1
67
410
364
409
365
379
370
402
554
403
L12
213
350
418
415
355
375
378
376
417
214
212
211
377
21F
377 4
367A
366A
206F
202F
L8 67F 1 2 3 4 378 3 W CONTROL BD STATUS
RJ 45 ETHERNET 376 RED/GREEN LED L2 T2
L9 L10 67C 67D 2
TYPE CABLE 375
L13
S2 1
W B
VOLTAGE
L3 T3
J16 SENSE
CB2 65A .0141 MF P112 J55A
RECEPTACLE 53A
10A 65 A ARCLINK -
R/Y J56 371 8 52C 6 52D 51E 1 51A 53B
B1B 54A
379 7 67D
67C 5 67F 52E 2 52A B ARCLINK +
1 353B B1C B1C 51D 67A 54B
207 52C
373 6 51C 4 67G 3
FAN L20 67A ELECTRODE
TSTAT
TSTAT
3 351B B1A 67C
370 5 54C 3 54D 54E 4 54A C
J53 67B SENSE
S6 ROBOTIC 51C
372 4 2 53E 5 53A L21 52A
2 359B 4 353 B1 D +40VDC
B 200 54C
374 3 53C 1 53D 51F 6 51B 52B
INTERFACE 8 351
N/U OHM 2 52F 7 52B 51A
E 0 VDC
368
361
RECEPTACLE 2 359 CHOPPER CONTROL
314A
316A
331A
307A
333A
328A
335A
336A
315A
313A
326A
338A
337A
332A
308A
334A
100 W 1 67H 8 67B 51B
1 353A BOARD G6786 NOT USED
R/Y J55 54F 9 54B L22 .0047MF
A 5 351A CURRENT 53B
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
539 53F 10
16
14
15
13
10
12
11
6 359A 8 348 206A TRANSDUCERS L23
1 353C HEAT SHIELDED
7 347 FRONT S3
B 541 FAN SINK TWISTED
3 351C 6 346 PAIR ARCLINK
C 521 2 359C 351A 10 5 345 214 4 BLACK UPPER RECEPTACLE
J41
B 66 9 4 344 211 3 WHITE LEM
J32
J33
D 522 N/U
553 351 8 3 343 213 BLUE
2
554 359A 7 B2 2 342 212 1 RED
E B/G 359 6 1 341
+
R
G
J92
541
539
521
522
B/R
53E
53D
54E
51D
52D
847
B/G
54D
B2
B1
B3
B/W
B13
J37
353A 5 J91
65 4
4
215 WHITE
4
3
1
4
4
2
3
5
B2
1
1
1
2
3
5
7
LEM
6
8
2
3
2
3
G W GND-B 353 3 217 2 BLUE
F-2
INPUT
B16
51G 1 51A 350 2 216 RED
B11
H B/W CHOKES 1 + J84 J83 J82 J81
52G 2 52A L16139 1
355 1 1 216
67J 3 67 2
I 54G 2 217 3
4 54A
J42
315B
313B
336B
337B
331B
328B
333B
335B
314B
332B
316B
53G 5 53A 3 215 202C FEEDHEAD PCB 4

J 4 218
B5
51F 6 51C 5
B12
52F 7 52C OUTPUT S28626 J86 6
R 316A 16
1
K
6
2
4
5
3
9
7
8
10
13
14
15
16
11
12
67H 8 67C CHOKE 7

54F B8 15
L B/R 9 54C L13270-4 8
53F B7 314A 14
10 53C A 9
M G B56 BL6 13
J85 10
B20 336A 12 J87
J23B
N 67G J55 B2 POWER BOARD A2

B6 BL5 337A 11
G6846 331A 10
8
7
9
3
5
4
2
6
8
B23
9
7
3
5
4
2
6
1
12
11
16
15
14
13
10
12
11
16
15
14
6
13
10
B18 BL4 A3 361

53A 328A 9
ARCLINK - A J23A 5
53B 51A 1 51G 315A 8
.0141 MF B28 BL3 A4 4 366
54A 52A 2 52G B17 7 J26 1
ARCLINK + B 3
852
1B
851
854
853
855
856
8511
1W
511A
8512
857
858
8510
512A
859
54B 67A 3 67J A5 313A 6 2

BL2 2
54A 4 54G 5 3
ELECTRODE 67A 1
C 53A
L17
5 53G A6 4
B
SENSE 67B 332A 4
B4
W
BL1
B10
51B 6 51E CHOKES 5.0 MF
+40VDC D L16 52B 7 52E T12218-37 B5 CHOPPER BOARD 12 362 6
52B 335A 2
67B 8 67G G6870 G6860 11 326A 7
51A 54B 9 54E B4 1
0 VDC E 8 10 B1A 8
51B 53B 10 53E 9 368 9 B W
B15
B9
L15 7 402 6
S3 ARCLINK 6
L19 8 B1B 10
356A 5 J22 7 206E 11
RECEPTACLE L14 J55B 5 358A 4 J25
J36 B29 6 367 + 12
(REAR) 4 403 3 512A 13 512 FEEDHEAD STATUS
326B
B44
B55
3 511A 14 511
M22489 358 1 4
10 362 206C 1W 15 B
2 3
B4 B5 9 1B 16 W
1 2 206D
A 8
J24
J1 1 369
J21
J35
J34
J50 4
B 7 J85A
3
250 OHM 25 W
DIFF_1 HIGH C B3 T3 6 366 J20 100

G G 1 357 54 2 M20305-1
5 367 OHM
4
3
2
1
8
7
6
5
4
3
2
1
DIFF_1 LOW D B/G B/G 53

67F
1
512
511
2 354 100 W
67G
B2 T2 4
250 OHM 25 W
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
11
12
R
10
13
352
15
14
16
DIFF_2 HIGH E R 3 T2A 3 369
B/R
4
4 349
1
1
.1047 MF
2
3
5
2
DIFF_2 LOW F B/R B1 T1 2 202A

T1A 1 202
52
338A
334B
334A
51
307A
54A
53A
307B
308A
308B
338B
J1
307B
331B
337B
335B
333B
332B
336B
334B
308B
328B
326B
338B
314B
315B
316B
J2
313B
S5 L18 WORK
SYNC/TANDEM VOLTAGE SENSE
-
202C .1047 MF M19540-2
G
GND2 CASEBACK
GND3 CASEFRONT
DNET CAN_L 5 891 (OPTIONAL) WI-FI MODULE D
G8901-1 PRINT
R
DIAGRAMS
MANUFACTURER: No
POWER WAVE R450 CCC Codes (12714, 12849)

TB
GENERAL INFORMATION
U CAVITY NUMBERING SEQUENCE
33
32
33A
32A
GND5
3 356A
J30 54E
TO V WI-FI BOARD 2 LEAD COLOR CODING
1
2
3
4
5
6
6
7
8
1 415
4 417
5 418
2 416
3 GND4
851 1 1 2 1 3
L2 J1 (OPTIONAL) 1 53E B - BLACK J10A1, J2, J5, J11, 1 J9, J13, J16,
SUPPLY L2 852 2 J10B1, J31, J46, J26, J27, J62,
G8814 853 3 R - RED J811, 2 J51, J111, 3 4 6
414 7 4 J112, J83, J1
J63
B5
J62
xxxxxxx
W 317 L17 854 4 N- BROWN J2 J82, J81
413 2
L1 L1 412 6 J61 115 VAC 855 5 J8, J24, J28, 1 4 1 5
B6 318 V - VIOLET J3, J4,
411 1 INVERTER PCB 856 6 J29, J43, J47,
xxxxxxx
(ASSEMBLY G6571) G - GREEN J45, J61
OPTIONAL 857 7 J63, J84 10
5 8 J86 6
115V SUPPLY DEVICENET 858 8 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
859 9 1 8
(OPTIONAL) ALIGNS WITH WHITE LEAD OF LED SOCKET. 1 6
8510 10 J6, J7,
S24842-12 (SOLDER END)
J12, J23,
65A 1 8511 11 J41, J85
16
358
371
372
416
373
553
J25, J42
356
9
374
54
53
6 12 J87
343
347
345
341
348
344
357
349
352
354
342
346
2 8512 12
892
893
891
894
J46
POWER WAVE® R450
66 3 12 11 10 9 8 7
33A 4 6 5 4 3 2 1
33
1
2
3
4
5
6
7
8
9
10
S7
1
2
3
4
5
6
7
8
5
9
2
3
4
1
10
11
12
1
2
3
4
CB1
2
1
4
3
10A 1 51A I/O RECEPTACLE S7
2 A
32 (LOCATED ON REAR A J
3
J4
DC BUS E 3 F B
J2
4 52 K
J11
32A
J13
34 PANEL) 2 4
J12
BOARD J47 A I C
5 51 D B L
L15732 1
N
7 2 3 H
D
J15 B 4 M
G6682 8 52A C D C G
E
S12
021 N D)
F
GND5 - 7 3 (SO L D E R I NG E S18657 (INSERTION END)
J7
J8
J3 S12021-79 (INSERTION SIDE)
J6
J5
J9
S3 S2 S4 S5 S6
115V
2
4
3
2
1
9
8
7
6
5
4
3
RECEPTACLE
1
7
3
9
3
12
2
10
5
4
8
7
6
4
2
11
6
5
15
1
16
14
13
12
11
16
4
2
15
14
3
13
10
5
6
(Neutral Bonded)
INPUT
SWITCH
ETHERNET
CONNECTOR
67
410
364
409
365
J56
379
370
402
554
403
213
350
418
415
355
375
378
376
417
214
212
211
377
21F
367A
L8
366A
1
206F
202F
67F L1 T1
RJ 45 L1 T1
ETHERNET L18 L19 206F 4 206E S2
TYPE CABLE 67C 67D 202F 3 202B 2 VOLTAGE
67F 2 67E
21F 21 3
SENSE L2 T2
1 L2 T2
.0141 MF RECEPTACLE
65A P112 J16
CB2 4
10A 65 R/Y J56 371 8 52D
L3 T3
B1B 52C 6 L3 T3
B1C 379 7 67C
67D 5 67F
1 353B B1C 52C
373 6 51C 4 51D
FAN 207 THERMAL LED
TSTAT
TSTAT
3 351B J53 B1A 67C
370 5 54C 3 54D J51
S6 ROBOTIC 51C
372 4 2
2 359B 4 353 B1 B
INTERFACE B 351 200 54C
374 3 53C 1 53D 377
8 4
N/U OHM 2 CONTROL BD STATUS
368
W
361
RECEPTACLE 2 359 CHOPPER CONTROL 378 3
314A
316A
331A
307A
333A
328A
335A
336A
315A
313A
326A
338A
337A
332A
308A
334A
100 W 1 NOT USED RED/GREEN LED
1 353A BOARD G6786 376 2
R/Y J55 5 351A CURRENT
A SHIELDED 375 1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
539
16
14
15
13
10
12
W B
11
6 359A 8 348 206A TRANSDUCERS TWISTED
1 353C HEAT PAIR
7 347
B 541 FAN SINK
3 351C 6 346
C 521 2 359C 351A 10 5 345 214 4 BLACK UPPER
J41
B 66 9 4 344 211 3 WHITE LEM
J32
J33
D 522 N/U 351 8 3 343 213 2 BLUE
P52 359A 7 2 342 212 RED
B2 1 +
E B/G 359 6 1 341
R
G
1 367A J92
541
539
521
522
B/R
53E
53D
54E
51D
52D
847
B/G
54D
B2
B1
B3
B/W
NOT USED B13
J37
2 365 353A 5 J91
3 GND 65 4
4
215 WHITE
4
3
1
4
4
2
3
5
B2
1
1
1
2
3
5
7
LEM
6
8
2
3
2
3
G W GND-B 4 366A 353 3

5 364 INPUT 217 2 BLUE
F-3
B16
350 2 216 RED
B11
H B/W 6 CHOKES 1 + J84 J83 J82 J81
1 L16139 1
355 1 216 2
I 2 217 3
J42
202C
315B
313B
336B
337B
331B
328B
333B
335B
314B
332B
316B
3 215 FEEDHEAD PCB 4

J 4 218
B5
553 5
B12
OUTPUT S28626 J86 6
R 316A 16
1
K
6
2
4
5
554
3
9
7
8
10
13
14
15
16
11
12
CHOKE 15 7
B8 8
L B/R L13270-4 314A 14
B7 9
M G BL6 A 13
B56 J85 10
B20 336A 12 J87
J23B
N 67G B2 POWER BOARD A2

B6 BL5 337A 11
G6846 331A 10
8
7
9
3
5
4
2
6
8
B23
9
7
3
5
4
2
6
1
12
11
16
15
14
13
10
12
11
16
15
14
6
13
10
B18 BL4 A3 361

53A 51A 1 51F 328A 9
ARCLINK - A J23A 5
53B 52A 2 52F 315A 8
.0141 MF B28 BL3 A4 4 366
54A 67A 3 67 B17 7 J26 1
ARCLINK + B 3
852
1B
851
854
853
855
856
8511
1W
511A
8512
857
858
8510
512A
859
54B 54A 4 54F BL2 A5 313A 6 2

53A 5 53F 2
ELECTRODE 67A 5 3
C L6 51B 6 51C A6 4 1
B
SENSE 67B 332A 4
B4
W
BL1
B10
52B 7 52C CHOKES 5.0 MF
+40VDC D L5 67B 8 67C T12218-37 B5 CHOPPER BOARD 335A 12 362 6
52B 2
54B 9 54C G6870 G6860 11 326A 7
51A B4 1
0 VDC E 53B 10 53C 318 8 10 B1A 8
51B 9 368 9 B W
B15
B9
L4 7 402 6
6 8 B1B 10
S3 ARCLINK J55 356A 5 J22
317 7 206E 11
RECEPTACLE L3 5 358A 4 J25
J36 B29 6 367 + 12
4 403 3 512A 13 512 FEEDHEAD STATUS
326B
B44
B55
3 511A 14 511
M22489 358 1 4
206C 1W 15 B
2 10 362 3 1B 16 W
1 B4 B5 9 2 206D
A
J24
8 1 369
J21
J50 J1 4 J85A
B 7 3
250 OHM 25 W
J20 100
J35
J34
DIFF_1 HIGH C G B3 T3 6 366 54 2 M20305-1
G 1 357 OHM
4
3
2
1
8
7
6
5
4
3
2
1
DIFF_1 LOW D B/G B/G 5 367 53

67F
1
512
511
2 354 100 W
67G
250 OHM 25 W
R 352 B2 T2 4
DIFF_2 HIGH E R 3
B/R 3 369 .1047 MF
4
4 349
1
1
2
3
5
2
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
DIFF_2 LOW F B/R
11
12
202A
10
13
15
14
16
B1 T1 2
1 202
52
338A
334B
334A
51
307A
54A
53A
307B
308A
308B
338B
S5 L7 WORK J1 J2
SYNC/TANDEM
307B
331B
336B
334B
337B
308B
328B
335B
326B
338B
333B
332B
314B
315B
316B
313B
- VOLTAGE SENSE
202C .1047 MF M19540-2
G
GND2 CASEBACK
GND3 CASEFRONT
DNET CAN_L 5 891 (OPTIONAL) WI-FI MODULE C
G8901-2 PRINT
R
DIAGRAMS
27.43
13.94
F-4
22.45
6.00
18.35
24.76
A.01
NOTES
L16215
NOTES
F-5
WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
electrode with skin or wet clothing.
l Insulate yourself from work and
AVISO DE
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
PRECAuCION
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
l Aislese del trabajo y de la tierra.
French
ATTENTION
l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
German
WARNuNG
l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
ATENÇÃO
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
AVISO DE
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o
PRECAuCION
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French
ATTENTION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
de travail.
German
WARNuNG
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
ATENÇÃO
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos
l Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CUSTOMER ASSISTANCE POLICY WELD FUME CONTROL EQUIPMENT
The business of Lincoln Electric is manufacturing and selling The operation of welding fume control equipment is affected by
high quality welding equipment, automated welding systems, various factors including proper use and positioning of the
consumables, and cutting equipment. Our challenge is to meet equipment, maintenance of the equipment and the specific
the needs of our customers, who are experts in their fields, and to welding procedure and application involved. Worker exposure
exceed their expectations. On occasion, purchasers may ask level should be checked upon installation and periodically
Lincoln Electric for information or technical information about their thereafter to be certain it is within applicable OSHA PEL and ACGIH
use of our products. Our employees respond to inquiries to the TLV limits.
best of their ability based on information and specifications
provided to them by the customers and the knowledge they may
have concerning the application. Our employees, however, are not
in a position to verify the information provided or to evaluate the
engineering requirements for the particular weldment, or to
provide engineering advice in relation to a specific situation or
application. Accordingly, Lincoln Electric does not warrant or
guarantee or assume any liability with respect to such information
or communications. Moreover, the provision of such information or
technical information does not create, expand, or alter any
warranty on our products. Any express or implied warranty that
might arise from the information or technical information,
including any implied warranty of merchantability or any warranty
of fitness for any customers’ particular purpose or any other
equivalent or similar warranty is specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the definition of
specifications, and 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
these types of fabrication methods and service requirements.

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What safety precautions should be followed when welding?

What safety precautions should be followed when welding?

What personal protective equipment should be worn when welding?

What personal protective equipment should be worn when welding?

Operator’s Manual

Power Wave R450 ®

For use with machines having Code Numbers:

Register your machine: Need Help? Call 1.888.935.3877

For Service outside the USA:

Serial: (ex: U1060512345)

IM10421-C | Issue Date May-22

WARNINGS 1.d. Keep all equipment safety guards, covers

1.l. Only use OUTSIDE and far away from

ELECTRIC SHOCK ARC RAYS CAN BURN.

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

Efficiency w hen m ax pow er

Idle state, follow instructions to test idle mode:

Typical gas usage for MIG/MAG equipment:

ECO design information 1 ECO design information

Item Component Material for recovery CRM Selective treatment

Reference: P-1258-A, code 12848

ECO design information 2 ECO design information

Parts List .........................................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice.

TECHNICAL SPECIFICATIONS - POWER WAVE® R450

Idle power is less than 50 watts when in Hibernation mode4

TECHNICAL SPECIFICATIONS - Power Wave® R450 CE

RECOMMENDED INPUT WIRE AND FUSE SIZES 1

INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

230/3/50/60 73A, 40% 4 (21) 90

Idle power is less than 50 watts when in Hibernation mode5

TECHNICAL SPECIFICATIONS - POWER WAVE® R450 CCC

RECOMMENDED INPUT WIRE AND FUSE SIZES 1

INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

380-415/3/50/60 41A, 40% 8 (10) 60

Idle power is less than 50 watts when in Hibernation mode4

TECHNICAL SPECIFICATIONS - ALL MODELS

IP23 155º(F) Insulation Class

* Weight does not include input cord.

WARNING INPUT AND GROUND CONNECTIONS

SELECT SUITABLE LOCATION MACHINE GROUNDING

Use a three-phrase supply line. A 1.40 inch diameter access hole

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

INPUT VOLTAGE SELECTION

FIGURE A.1 - for K3455-1 & K3455-2

CONNECT EACH PHASE OF A

On some models, toroids are on the power cord. When replacing

FIGURE A.1 for K3451-1, K3451-2, K3456-1

INPUT CORD STRAIN RELIEF

GMAW (MIG) WELDING

Work Piece Avoid excessive lengths and

Remote Sense Lead

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

200 100 2 2 2 1 1/0

If the auto sense lead feature is disabled and remote

Electrode Voltage Sensing

Work Voltage Sensing

Negative Electrode Polarity

VOLTAGE SENSING CONSIDERATIONS FOR

• For circumferential applications, connect all work