Table of Contents
Advertisement
Quick Links
Operator's Manual
POWER WAVE R450
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10421
| Issue D ate July-17
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12644, 12645, 12712, 12713,
12714, 12715
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
Advertisement
Table of Contents
Related Manuals for Lincoln Electric POWER WAVE R450
Summary of Contents for Lincoln Electric POWER WAVE R450
- Page 1 Operator’s Manual POWER WAVE R450 For use with machines having Code Numbers: 12644, 12645, 12712, 12713, 12714, 12715 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator...
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. 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...
- Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
-
Page 4: Electric Shock Can Kill
S FETY 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”... - Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
- Page 6 POWER WAVE R450 SAFETY REGULATORY STATEMENTS Industry Canada IC: 22017-LEWB0000111 FCC ID: 2AJY8-LEWB0000111 This device complies with Industry Canada license-exempt This equipment has been tested and found to comply with the RSS standard(s). Operation is subject to the following two...
-
Page 7: Welding Cables
EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric methods of reduCIng emIssIons equipment. It is designed for industrial and professional use. -
Page 8: Table Of Contents
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 FCC REGULATORY STATEMENT..........................A-5 INPUT CONNECTION..............................A-6 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS.....................A-6 INPUT VOLTAGE SELECTION............................ - Page 9 POWER WAVE R450 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE R450 ® POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Rated Output 40% rating 208/230/400*460/575 80/73/41/37/29 K3451-1 50/60 Hz 500 Watts Max.
- Page 10 POWER WAVE R450 INSTALLATION TECHNICAL SPECIFICATIONS - Power Wave R450 CE POWER SOURCE-INPUT VOLTAGE AND CURRENT 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.
- Page 11 POWER WAVE R450 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE R450 CCC ® POWER SOURCE-INPUT VOLTAGE AND CURRENT 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.
- Page 12 POWER WAVE R450 INSTALLATION TECHNICAL SPECIFICATIONS - ALL MODELS WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U Mean Peak GMAW 40-550A GMAW-Pulse FCAW GTAW-DC 5-550A SMAW PHYSICAL DIMENSIONS WEIGHT MODEL HEIGHT WIDTH DEPTH K3451-1, K3451-2, 24.80in ( 630mm) 150 lbs (68 kg) 14.00in ( 356 mm)
-
Page 13: Installation
POWER WAVE R450 INSTALLATION 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. -
Page 14: Input Connection
POWER WAVE R450 INSTALLATION 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. - Page 15 POWER WAVE R450 INSTALLATION 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...
- Page 16 POWER WAVE R450 INSTALLATION 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 Ethernet Electrode Cable Control Cable Water Work Cable...
-
Page 17: Recommended Work Cable Sizes For Arc Welding
POWER WAVE R450 INSTALLATION rECOMMEndEd WOrk CaBLE sIZEs FOr arC gEnEraL guIdELInEs WELdIng • Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive voltage drops caused by Connect the electrode and work cables between the appropriate ®... -
Page 18: Cable Inductance And Its Effects On Welding
POWER WAVE R450 INSTALLATION CAUTION CaBLE InduCtanCE and Its EFFECts On WELdIng If the auto sense lead feature is disabled and remote Excessive cable inductance will cause the welding performance to voltage sensing is enabled but the sense leads are degrade. - Page 19 POWER WAVE R450 INSTALLATION 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...
-
Page 20: Voltage Sensing Considerations For Multiple Arc Systems
POWER WAVE R450 INSTALLATION 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. - Page 21 POWER WAVE R450 INSTALLATION • 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.
-
Page 22: Control Cable Connections
POWER WAVE R450 INSTALLATION 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. -
Page 23: Operation
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 before operating the machine. WARNING OR WARNING CAUTION DANGEROUS ELECTRIC SHOCK can kill. VOLTAGE •... -
Page 24: Product Description
Powerwavesoftware.com. The Ethernet communication also gives the POWER WAVE ® R450 the ability to run Production The Power Wave R450’s are not compatible with the S-Series user Monitoring™ 2. A Devicenet option allows the POWER WAVE ® Interface Kit. R450 to be used in a wide range of configurations and the POWER WAVE ®... -
Page 25: Case Front Controls
(See Troubleshooting Section for operational functions.) NOTE: The Power Wave R450 status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up. -
Page 26: Case Back Controls
POWER WAVE R450 OPERATION FIGURE B.2 CasE BaCk COntrOLs (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 or K2912-1 Advanced Module. -
Page 27: Common Welding Procedures
If a special weld mode is desired, contact the For a more complete description of the weld modes programmed local Lincoln Electric sales representative. into the POWER WAVE ®... -
Page 28: Smaw (Stick) Welding
POWER WAVE R450 OPERATION COnstant VOLtagE WELdIng Synergic CV sMaW (stICk) WELdIng The welding current and Arc Force settings can be set through a Power Feed™ 84 or Power Feed™ 25M wire feeder. Alternatively For each wire feed speed, a corresponding voltage is prepro-... - Page 29 POWER WAVE R450 OPERATION 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.
-
Page 30: Navigating The User Configuration Menu
POWER WAVE R450 OPERATION naVIgatIng thE usEr COnFIguratIOn MEnu COnnECtIVIty MOduLE Simultaneously press the Left BUTTON and the Right BUTTON to If the Power Wave ® is equipped with a K4352-1 connectivity enter the User Configuration menu. Use the Selection KNOB to... -
Page 31: Configuring An Additional Display
POWER WAVE R450 OPERATION To display wire feeder motor current, select MOTR CURR from the ALT DISP menu. COnFIgurIng an addItIOnaL dIsPLay Every five seconds while welding, the display will show motor By default, the display will show welding amperage and voltage current in amperes on the Left DISPLAY with AMPS on the Right during welding. -
Page 32: Front Ethernet Port Settings
POWER WAVE R450 OPERATION FrOnt EthErnEt POrt sEttIngs The following can be choosen: WIFI ON/OFF/CONF - Enable or disable Wi-Fi, or place the Wi-Fi in To view the IP address of the Ethernet port on the front of the configuration mode. -
Page 33: Bluetooth Settings
POWER WAVE R450 OPERATION BLuEtOOth sEttIngs WI-FI status IndICatOr LIght To view or change the settings for the Power Wave ® Bluetooth The green Wi-Fi STATUS INDICATOR light indicates the connection connection, use the Selection KNOB to select BLUT OOTH from the type and uses the three “bars”... -
Page 34: Options / Accessories
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. -
Page 35: Maintenance
POWER WAVE R450 MAINTENANCE MAINTENANCE WARNING Safety Precautions 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. -
Page 36: Troubleshooting
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. - Page 37 POWER WAVE R450 TROUBLESHOOTING 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.
- Page 38 POWER WAVE R450 TROUBLESHOOTING 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”.
- Page 39 POWER WAVE R450 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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.
- Page 40 (see error 54) dition persists, contact an authorized Lincoln Electric Field Service facility. 3a. Input control board fault (see input control board error status). 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.
- Page 41 POWER WAVE R450 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Thermal LED is ON Improper fan operation Basic Machine Problems (Continued) Thermal LED is ON 1. Improper fan operation. 1. Check for proper fan operation. Fan...
- Page 42 POWER WAVE R450 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 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.
- Page 43 POWER WAVE R450 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 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).
-
Page 44: Diagrams
POWER WAVE R450 DIAGRAMS xxxxxxx xxxxxxx xxxxxxx xxxxxxx... - Page 45 POWER WAVE R450 DIAGRAMS...
- Page 46 NOTES xxxxxxx xxxxxxx xxxxxxx xxxxxxx...
- Page 47 NOTES...
- Page 48 NOTES...
- Page 50 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 51 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
- Page 52 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.