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INVERTEC POWER WAVE 450
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you
act and be careful.
World's Leader in Welding and Cutting Products
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
For use with machines having Code Numbers:
OPERATOR'S MANUAL
TM
10391
10392
10405
10406
Premier Manufacturer of Industrial Motors
IM579
April, 1999
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric INVERTEC POWER WAVE 450 IM579
Summary of Contents for Lincoln Electric INVERTEC POWER WAVE 450 IM579
- Page 1 INVERTEC POWER WAVE 450 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part.
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Page 2: Safety
“Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. - Page 3 WELDING SPARKS can cause fire or explosion. 4.a. Remove fire hazards from the weld- ing area. If this is not possible, cover them to prevent the welding sparks from Remember that sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 4 FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 7.c. Do not add the fuel near an open flame welding arc or when the engine is run- ning.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc Protegez-vous contre la secousse électrique: Les circuits à...
- Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
TABLE OF CONTENTS Safety...i-iv Installation ...Section A Technical Specifications ...A-1 Safety Precautions...A-2 Select Suitable Location (Stacking, Tilting, Lifting) ...A-2 High Frequency Precautions...A-2 Input Connections...A-2 Output Connections...A-4 Operation...Section B Safety Instructions ...B-1 Quick Start Reference ...B-2 General Description ...B-3 Controls and Settings ...B-4 Operating Overlays ...B-5 Overview of Welding Procedures ...B-19 Overload Protection...B-22... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE ONLY Input Voltages: Input Currents @ 500A/40 VDC @ 450A/38 VDC Duty Cycle 230/400/460 - 60% Duty Cycle 230/400/460 - 100% Duty Cycle Constant Open Circuit Voltage 75 Volts Pulse Current Range Voltage Range 5-750 Amps... -
Page 9: Safety Precautions
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. •... -
Page 10: Ground Connections
CAUTION Failure to follow these instructions can cause immedi- ate failure of components within the welder. GROUND CONNECTIONS 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 ground- ing methods. -
Page 11: Output Connections
FIGURE A.3 – FRONTPANEL/BACK PANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To operate at 208-230 VAC: 1. Open the reconnect/input access door. 2. Move the input voltage switch to voltage = 208- 230V position. 3. Move “A” lead to the 208-230V terminal. To operate at 440-460 VAC: No setup required. -
Page 12: Operation
OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. •... -
Page 13: Quick Start Reference
QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave. NOTE: Selection of certain options may limit the selection of subsequent options. -
Page 14: General Description
It uses three-phase input power only. The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder. SYNERGIC WELDING The Power Wave system is designed primarily as a synergic welding system. -
Page 15: Controls And Settings
LCD display on the Power Wave shows the following: LINCOLN ELECTRIC This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine. At this point, the machine is ready for operation. -
Page 16: Operating Overlays
The bar code allows the machine to identify the overlay. FIGURE B.2 – TYPICAL POWER WAVE OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9361-2 WELD FROM MEMORY INVERTEC POWER WAVE 350 WARNING... - Page 17 OVERLAY TYPES Four types of overlays can be used with the Power Wave. 1. Process Overlays. These overlays are used to create, save and recall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power Wave at the factory.
- Page 18 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLAY ID...
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Page 19: Overview Of Welding Procedures
3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4. - Page 20 10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations. RECALL FROM MEMORY key appropriate MEMORY LOCATION NUMBER key.
- Page 21 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
- Page 22 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
- Page 23 When a pair of welding procedures are recalled from memory, the display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the LAST pro- cedure welded with. With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder.
- Page 24 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLAY ID NUMBER = 9 2.
- Page 25 1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
- Page 26 Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be dis- played. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.
- Page 27 The present status of the water cooler is indicated by the “WATER COOLER ON” light. OPERATION FIGURE B.9 – SETUP OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9660 SETUP OVERLAY +POLARITY ELECTRODE SENSE LEAD ENABLED...
- Page 28 When the “WATER COOLER PRESSURE” light turns on, release the key. If this key has been pressed for 30 seconds and the ‘WATER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polari- ty of wire feeder 1.
- Page 29 Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage reference. The work sense (21) lead is used only in rare circum- stances. For most installations, use the WORK SENSE LEAD KEY to select the + output terminal for the negative voltage reference.
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Page 30: Overview Of Welding Procedures
OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage has been preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed. - Page 31 TABLE B.3 – RELATIONSHIP BETWEEN VOLTAGE TRIM AND PRESET VOLTAGE Voltage Trim Relationship to Preset Voltage 60% of preset voltage 80% of preset voltage no change to preset voltage 120% of preset voltage 140% of preset voltage Explanation of Table B.3: If, for example, the minimum voltage trim is set to 0.8 and the maximum voltage trim is set to 1.4, this means that the voltage for a given wire feed speed...
- Page 32 In Pulse processes: The wave control adjustment allows the frequency set- ting to vary. Increasing the wave control allows the fre- quency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet transfer and allows fine-tuning for different welding positions.
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Page 33: Overload Protection
OVERLOAD PROTECTION THERMAL PROTECTION The Power Wave has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power source is subjected to any of these conditions or any of the con- ditions mentioned above, a thermostat will open. The yellow high temperature light on the case front comes on. -
Page 34: Accessories
OPTIONS/ACCESSORIES • Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed • MAGNUM 400 gun (K471-2) or 550 gun (K598) • Remote control (stick welding) K941-1 • Limits Overlay (K946-4) • Dual Wire Feeders, Dual Procedures Overlay (K946-9) WIRE FEEDER SETUP The Power Wave must be used with wire feeders list- ed above. -
Page 35: Water Cooler Usage
WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler. We recommend using the water cooler when welding above 300 amps with argon blends on a regular basis. The gun heating from pulsing above 300 amps average current is often excessive and leads to reduced consumable life, reduced gun life, and opera- tor discomfort. -
Page 36: Maintenance
MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least... - Page 37 MAINTENANCE FIGURE D.1 – RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine.
- Page 38 6. Locate the #9 and #12 terminals, identified by the “Discharge” labels, on each of the four Switch Boards. See Figure D.2. 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor.
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Page 39: Preventive Maintenance
PREVENTIVE MAINTENANCE Perform the following preventive maintenance proce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance record; a record tag attached to the machine works best. 1. Remove the hex head screws from the sides and top of the machine. -
Page 40: General Component Locations
MAINTENANCE FIGURE D.4 – GENERAL COMPONENT LOCATIONS 1 DISPLAY BOARD (BACK OF PANEL) 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 6 HEAT SINK FINS 7 OUTPUT TERMINALS 8 OVERLAY BAR CODE SENSORS 9 TERMINAL STRIP (LOCATION) POWER WAVE 450... -
Page 41: Troubleshooting
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance. WARNING Step 3. CONSULT LOCAL AUTHORIZED FIELD... - Page 42 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 43 – fans run – circuit breaker (5-amp) repeatedly trips. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 44 The fans run and the display is on. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 45 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING...
- Page 46 NOT INITIALIZED” on power-up. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
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Page 47: Troubleshooting Guide
The machine beeps without the keys being pressed. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF... - Page 48 Machine often “noodle welds” with a particular procedure. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
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Page 49: Wiring Diagrams
WIRING DIAGRAMS WIRING DIAGRAM 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. POWER WAVE 450... - Page 50 MasterCard ® ® |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45) Educational Video Information (ED-93) James F.
- Page 51 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO 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.
- Page 52 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- Desconectar el cable de ali- piración. mentación de poder de la máquina Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
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Page 53: Limited Warranty
Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer. All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.