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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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR
THIS
EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS
CONTAINED
THROUGHOUT.
And,
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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:
most
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
IM524-D
TM
10365
10511
10366
10512
10433
10520
10434
10607
10449
10610
Copyright © 2001 Lincoln Global Inc.
October, 2001
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Related Manuals for Lincoln Electric INVERTEC POWER WAVE 450 IM524-D
Summary of Contents for Lincoln Electric INVERTEC POWER WAVE 450 IM524-D
- 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 thought- ful operation on your part.
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Page 2: Safety
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. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- 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 1. Protegez-vous contre la secousse électrique: a.
- 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 ...A-2 Stacking...A-2 Tilting ...A-2 Lifting ...A-2 High Frequency Precautions...A-2 Input Connections...A-2 Ground Connections...A-3 Input Power Connections ...A-3 Input Fuse and Supply Wire Connections ...A-3 Input Voltage Reconnect Procedure ...A-3 Output Connections...A-4 Work and Electrode Cable Connections ...A-4 Water Cooler Connections ...A-4... - Page 8 Weld from Memory, Dual Procedure Overlay...B-11 Dual Wire Feeders, Dual Procedure Overlay...B-13 Limits Overlay...B-14 Setup Overlay...B-16 Wire Feeder Setup Description ...B-17 Overview of Welding Procedures ...B-19 FCAW and GMAW...B-19 Pulse Procedures ...B-19 Stick/TIG Procedures ...B-19 Wave Control...B-19 Pulse Welding...B-21 Overload Protection...B-21 Thermal Protection ...B-21 Over Current Protection ...B-21 Accessories...Section C...
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Page 9: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE 50/60 HZ. ONLY Input Voltages: Input Currents @ 500A/40 VDC @ 450A/38 VDC Duty Cycle 200 - 60% Duty Cycle 230/400/460 - 60% Duty Cycle 460/575 - 60% Duty Cycle 200 - 100% Duty Cycle 230/400/460 - 100% Duty Cycle 460/575 - 100% Duty Cycle... -
Page 10: Safety Precautions
Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Using filters on the air intake to prevent dirt from building up restricts air flow. -
Page 11: Ground Connections
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 12: Output Connections
FIGURE A.3 – FRONTPANEL/BACK PANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To reconnect your machine for the proper input volt- age, see the reconnect instructions on your input access door and: 1. Move the large input voltage switch to the proper position according to your input volt- age, and the labels near the switch. -
Page 13: 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 14 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.
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Page 15: General Description
GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. 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. -
Page 16: 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 17: 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 18: Overlay Types
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 19 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...
- Page 20 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 21 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.
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Page 22: Weld From Memory Overlay
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: Weld From Memory, Dual Procedure Overlay
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 24 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.
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Page 25: Dual Wire Feeders, Dual Procedure Overlay
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 26: Limits Overlay
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 27 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.
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Page 28: Setup Overlay
OPERATION FIGURE B.9 – SETUP OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9660 SETUP OVERLAY 5 WIRE FEEDER 1+/- POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY 3. -
Page 29: Wire Feeder Setup Description
When the “WATER COOLER PRESSURE” light turns on, release the key. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polari- ty of wire feeder 1. The present polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY”... - Page 30 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 31: Overview Of Welding Procedures
OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage is preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average volt- age for the procedure at the given wire feed speed. If the wire feed speed is changed on the wire feeder, the voltage automatically changes with it. - Page 32 In Pulse processes: The wave control adjustment allows the frequency setting to vary. Increasing the wave control allows the frequency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet trans-fer and allows fine-tuning for different welding positions.
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Page 33: Pulse Welding
PULSE WELDING Some people have trouble getting used to the behavior of the pulsing arc. The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appearance. There are, however, a few things to keep in mind when pulse welding. -
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) • Internal water cooler • Undercarriages (Single [K961-1]or Dual [K962-1]Gas Cylinders) • Remote control (stick welding) K941-1 • Amptrols (Hand K963-1 or -2, Foot K870) •... -
Page 35: Priming The Cooler
There are two water connections on the rear of the Power Wave. See Figure C.1. Connect the water lines between these connectors and those on the wire feed- er. The water is fed through the feeder into the gun. When a water cooler is used, the water cooler must be enabled by using the Setup Overlay. -
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: Resistor Locations
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: Discharge Label
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. -
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: Recommended Tools For Installation Or Service Of Cooler
RECOMMENDED TOOLS FOR INSTAL- LATION OR SERVICE OF COOLER: • absorbent towels • alcohol wipe • 3 mm allen wrench (G3503 only) • socket wrench • 4 inch long minimum socket extension • 1/4, 5/16, and 3/8 hex standard depth sockets •... -
Page 41: G3503-[ ] Cooler Periodic Maintenance
• Do not discard old pump. Remove both fittings, Keep v-clamp, Seal old pump in a waterproof bag, Package into protective container, and Return to nearest Lincoln Electric FSS center. g. Install new pump and v-band clamp: • Do not apply any lubricant to pump’s drive coupling. -
Page 42: 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 43: How To Use Troubleshooting Guide
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 44: Troubleshooting Guide
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 – 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 46 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 47 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 48 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...
- Page 49 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 50 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...
- Page 51 |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. AMERICAN EXPRESS MasterCard AMERICAN EXPRESS 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)
- Page 52 ● 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 53 ● ● 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 ●...
- Page 54 • 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...