LIFTING

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

LIMIT ON STACKING

FALLING EQUIPMENT can cause injury.
• Do not lift this machine using lift
bale if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when lifting.
• Do not stack more than three high.
• Do not stack the CV-400 on top of any other
machine.
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MACHINE GROUNDING
The frame of the welder must be grounded. A ground
terminal marked with the symbol is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave away from radio controlled
machinery.
The normal operation of the Power Wave may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.
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INPUT CONNECTION
Only a qualified electrician should
connect the input leads to the Power
Wave. Connections should be made
in accordance with all local and
national electrical codes and the
connection diagram located on the inside of the
reconnect/input access door of the machine.
Failure to do so may result in bodily injury or
death.
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Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1
on the following page.
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
ELECTRIC SHOCK can kill.
• Only qualified personnel should per-
form this installation.
• Turn the input power OFF at the
disconnect switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding system
at the disconnect switch or fuse box before work-
ing on the equipment.
• Do not touch electrically hot parts.
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door)
to a proper safety (Earth) ground.
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SELECT SUITABLE LOCATION
Do not use Power Waves in outdoor environments. The Power
Wave power source should not be subjected to falling water, nor
should any parts of it be submerged in water. Doing so may
cause improper operation as well as pose a safety hazard. The
best practice is to keep the machine in a dry, sheltered area.
Do not mount the Power Wave 455/STT over combustible sur-
faces. Where there is a combustible surface directly under sta-
tionary or fixed electrical equipment, that surface shall be cov-
ered with a steel plate atleast .060" (1.6mm) thick, which shall
extend not less than 5.90" (150mm) beyond the equipment on
all sides.
Place the welder where clean cooling air can freely circulate in
through the rear louvers and out through the case sides and bot-
tom. Dirt, dust, or any foreign material that can be drawn into the
welder should be kept at a minimum. Do not use air filters on the
air intake because the air flow will be restricted. Failure to
observe these precautions can result in excessive operating tem-
peratures and nuisance shutdowns.
Machines above code 10500 are equipped with F.A.N. (fan as
needed) circuitry. The fan runs whenever the output is enabled,
whether under loaded or open circuit conditions. The fan also
runs for a period of time (approximately 5 minutes) after the out-
put is disabled, to ensure all components are properly cooled.
If desired, the F.A.N. feature can be disabled (causing the fan to
run whenever the power source is on). To disable F.A.N., con-
nect leads 444 and X3A together at the output of the solid state
fan control relay, located on the back of the Control PC board
enclosure. (See Wiring Diagram)

A-2

INSTALLATION
POWER WAVE 455/STT

A-2

WARNING
WARNING
CAUTION
CAUTION