Lincoln Electric IM524 User Manual

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IM524-D

October, 2001

For use with machines having Code Numbers: 10365 10511

10366 10512 10433 10520 10434 10607 10449 10610

INVERTEC POWER WAVE 450

OPERATOR’S MANUAL

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.

• 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

• World's Leader in Welding and Cutting Products •

Date of Purchase: Serial Number: Code Number: Model: Where Purchased:

RETURN TO MAIN MENU

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, co vers and

devices in position and in good repair.Keep hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan.Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

SAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following saf ety highlights.F or additional saf ety inf ormation, it is strongly recommended that you purchase a copy of “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.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition.Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES can be dangerous.

5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

5.c. 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.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

FOR ELECTRICALLY powered equipment.

8.a.Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even

though

they have been “cleaned”. For information, purchase “Recommended Safe Practices for the

Preparation

for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding.They may explode.

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.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

SAFETY

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 suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a.Utiliser un bon masque avec un v erre filtr ant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b.Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar.‘93

Thank You

for selecting a QUALITY product by Lincoln Electric.We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton

and Equipment For

Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below f or future reference.This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

TABLE OF CONTENTS

vi vi

POWER W AVE 450

Page

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

Wire Feeder Connections.....................................................................................................A-4

Operation...............................................................................................................................Section B

Safety Instructions......................................................................................................................B-1

Quick Start Reference for Process Selection Overlay................................................................B-2

General Description....................................................................................................................B-3

Synergic Welding..................................................................................................................B-3

Recommended Processes...................................................................................................B-3

Operational Features and Controls......................................................................................B-3

Design Features and Advantages........................................................................................B-3

Welding Capability................................................................................................................B-3

Limitations............................................................................................................................B-3

Controls and Settings.................................................................................................................B-4

Case Front Controls............................................................................................................ .B-4

Operating Overlays.....................................................................................................................B-5

Overview...............................................................................................................................B-5

Installing an Overlay.......................................................................................................... ...B-5

Overlay Types.......................................................................................................................B-6

Pulse, GMAW, FCAW, Stick Overlay....................................................................................B-7

Weld from Memory Overlay................................................................................................B-10

vii vii

POWER W AVE 450

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

Options/Accessories...................................................................................................................C-1

Wire Feeder Setup...............................................................................................................C-1

Guns and Cables .................................................................................................................C-1

Water Cooler Usage.............................................................................................................C-2

Undercarriages.....................................................................................................................C-2

Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-1

Routine and Periodic Maintenance ............................................................................................D-1

Input Filter Capacitor Discharge Procedure ...............................................................................D-1

Resistor Locations ...............................................................................................................D-2

Discharge Label....................................................................................................................D-3

Resistors with Leads............................................................................................................D-3

Preventive Maintenance .............................................................................................................D-4

Recommended Tools for Installation or Service of Cooler.........................................................D-5

G3503-[ ] Installation or Service Tool Usage..............................................................................D-5

Removing and Installing the G3503-[ ] Cooler...........................................................................D-5

G3503-[ ] Cooler Periodic Maintenance.....................................................................................D-6

G3503-[ ] Cooler Service............................................................................................................D-6

General Component Locations...................................................................................................D-7

Troubleshooting and Repair ................................................................................................Section E

How To Use Troubleshooting Guide...........................................................................................E-1

Troubleshooting Guide................................................................................................................E-2

Electrical Diagrams ..............................................................................................................Section F

Parts Manual....................................................................................................................P-261 Series

POWER W AVE 450

TECHNICAL SPECIFICATIONS - POWER WAVE 450

INPUT - THREE PHASE 50/60 HZ. ONLY

Input Voltages: 200 230 400 460 575

Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28

RATED OUTPUT

Duty Cycle Amps

Volts at Rated Amperes

200 - 60% Duty Cycle 500 40 VDC

230/400/460 - 60% Duty Cycle 500 40 VDC

460/575 - 60% Duty Cycle 500 40 VDC

200 - 100% Duty Cycle 450 38 VDC

230/400/460 - 100% Duty Cycle 450 38 VDC

460/575 - 100% Duty Cycle 450 38 VDC

OUTPUT

Constant Open Continuous Process

Cir

cuit Volta

ge Current Range

Current Ranges

75 Volts 5-540 Amps GMAW 50-540 Amps

FCAW 40-540 Amps STICK 30-540 Amps

Pulse Pulse Pulse and Background Pulse

Current Range Voltage Range Time Range Frequency

5-750 Amps 5-55 Volts 100 Microsec - 3.3 Sec 0.15 - 1000 Hz

RECOMMENDED INPUT WIRE AND FUSE SIZES

Type 75°C Type 75°C Type 75°C

Input Duty Input Ampere Copper Wire in Ground Wire in (Super Lag)

Voltage/ Cyc

le Rating on Conduit Conduit or Breaker

Freqenc

y Nameplate AWG[IEC] AWG[IEC] Siz

e (Amps)

Sizes (MM2) Sizes (MM2)

200/50-60 60% 87 4 (25) 8 (10) 120 230/50-60 60% 76 4 (25) 8 (10) 100 400/50-60 60% 44 8 (10) 10 (6) 50 460/50-60 60% 38 8 (10) 10 (6) 50 575/50-60 60% 32 8 (10) 10 (6) 50

200/50-60 100% 75 4 (25) 8 (10) 100 230/50-60 100% 65 4 (25) 8 (10) 100 400/50-60 100% 38 8 (10) 10 (6) 50 460/50-60 100% 32 8 (10) 10 (6) 50 575/50-60 100% 28 8 (10) 10 (6) 40

PHYSICAL DIMENSIONS

Height Width Depth Weight

905 mm 515 mm 1010 mm 138 kg

35.6 in. 20.3 in. 39.8 in. 304 lbs.

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° to 40°C -50° to 85°C

INSTALLATION

A-1 A-1

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

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.

• Do not touch electrically hot parts.

• Always connect the Power Wave grounding terminal (located inside the reconnect input access doors).

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can circulate in through the rear louvers and out through the side and front louvers. 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. Do not use such filters. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

The Power Wave may be used outdoors. Power W ave power sources carry an IP23 enclosure rating. They are rated for use in damp, dirty environments subject to occasional falling water such as rain. However, the best practice is to keep the machine in a dry , shelter ed area, since a wet environment speeds corrosion of parts. Do not place the machine in puddles or otherwise submerge parts of the machine in water. This may cause improper operation and is a possible safety hazard.

STACKING

Power Wave machines cannot be stacked.

TILTING

Each machine must be placed on a secure, level surface. The machine may topple over if this procedure is not followed.

LIFTING

Lift the machine by the lift bail only. Do not attempt to lift the machine by the push handle.

HIGH FREQUENCY PRECAUTIONS

If possible, 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.

INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the rear of the machine. See Figure A.1 for the location of the rating plate.

INSTALLATION

A-2 A-2

POWER W AVE 450

WARNING

1. RATING PLATE

2. RECONNECT/INPUT ACCESS DOOR

3. INPUT CORD ACCESS HOLE

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.

Use a three-phase supply line. The Power Wave has a 1.375” (35 mm) access hole for the input cord, but the input cord is not supplied.

WARNING

FIGURE A.1 - RATING PLATE LOCATION

Failure to follow these instructions can cause immediate 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 grounding methods. See example Figure A.2 for the location of the reconnect/input access door and your specific connection diagram.

INPUT POWER CONNECTIONS

Connect L1, L2, L3 according to the Input Supply Connection Diagram decal located on your reconnect/input access door. See example Figure A.2.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and

wire sizes. Fuse the input circuit with the recommended super lag fuses or delay type circuit breakers. Choose an input and grounding wire size according to local or national electrical codes. Using 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 VOLT A GE RECONNECT PROCEDURE

Only a qualified electrician should connect the input leads to the Pow er Wav e .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.

------------------------------------------------------------------------

Welders are shipped connected for the highest input voltage listed on the rating plate. To change this connection for a different input voltage, refer to reconnect instructions which follow and to the reconnect diagram supplied with your machine, located inside your reconnect access door. See example Figure A.2.

INSTALLATION

A-3 A-3

POWER W AVE 450

FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR

Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the magnitude of the current increases.

NOTE: Turn main input power to mthe machine OFF before performing reconnect procedure. Failure to do so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON.

CAUTION

WARNING

SAMPLE

ONL

REFER TO

OUR

SPECIFIC DIAGRAM

INSTALLATION

A-4 A-4

POWER W AVE 450

FIGURE A.3 – FRONTPANEL/BACK PANEL

(OUT)

(IN)

1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE

4 WATER COOLING FITTINGS (ON ACCESS PANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL) 6 ELECTRODE TERMINAL

To reconnect your machine for the proper input voltage, 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 voltage, and the labels near the switch.

2. Move the auxiliary “A” lead to the appropriate terminal, according to your input voltage and the labels near the terminals.

OUTPUT CONNECTIONS

See Figure A.3 for the location of the work terminal, electrode terminal, remote control amphenol receptacle, water cooler fittings and wire feeder connections.

WORK AND ELECTRODE CABLE CONNECTIONS

Size

Use the largest welding (electrode and ground) cables possible — at least 70mm2(#2/0) copper wire — even if the output current does not require it. When pulsing, the pulse current often exceeds 650 amps with the Power Wave 450. Voltage drops can become excessive if undersized welding cables are used.

Routing

To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly. Avoid excessive lengths, bundle the electrode and ground cables together where practical, and do not coil excess cable.

WATER COOLER CONNECTIONS

The water cooler fittings are a quick-connect type. Refer to the Accessories and Maintenance sections of this manual for water cooler operation and recommended coolants.

WIRE FEEDER CONNECTIONS

Refer to the Accessories section for Wire Feeder Connections.

Refer to Setup overlay in Operation section for Wire Feeder Configuration.

OPERATION

B-1 B-1

POWER W AVE 450

OPERATING INSTRUCTIONS

Read and understand this entire section of operating instructions before operating the machine.

SAFETY INSTRUCTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection. Observe additional Safety Guidelines

detailed in the beginning of this manual.

HOT COOLANT can burn skin

• Always be sure coolant is not hot before doing any work on cooler parts.

WARNING

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.

Step 1: Select your process information:

a. Install the desired PROCESS OVERLAY. b. Tur n the machine ON. c. Select the desired welding

PROCESS1.

d. Select ELECTRODE CLASS.

e. Select ELECTRODE SIZE.

f. Select ELECTRODE/GAS TYPE.

g. Press the WAVE CONTROL

UP or DOWN keys to see the present setting. Press the WAVE CONTROL UP or WAVE CONTROL DOWN keys to adjust

Step 2: Adjust the wire feed to speed “WFS” and voltage “V” or arc length “T” (if necessary).

a. Press the DISPLAY RECALL key to

view additional procedure information.

b. Adjust wire feed speed and voltage or arc

length trim through the controls on your wire feeder. The new values appear on both the wire feeder and the Power Wave display.

Step 3: Save process information (if desired).

a. Press the SAVE TO MEMORY key . b. Press one of the MEMORY LOCATION keys

(1-8).

You can recall your procedure later by pressing the RECALL FROM MEMORY key and the appropriate MEMORY LOCATION key.

The electrode class, electrode size, and electrode/ gas type you can select for your process will be limited to the machine’s programmed recommendations. Therefore, selecting certain options may limit other option selections.

The wave control scale displayed shows the default setting. (The higher the setting, the softer the arc.) If you change the setting, your new setting will be displayed.

OPERATION

B-2 B-2

POWER W AVE 450

SAVE

RECALL

GENERAL DESCRIPTION

The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform 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.

SYNERGIC WELDING

The Power Wave system is designed primarily as a synergic welding system. The word “synergic” comes from the word “synergism,” which means “two or mor e things working together to achieve an effect which neither can achieve individually.”

The Power Wave and wire feeder operate as a team. Each “knows” what the other is doing at all times. They each also know what process, wire type, wire size, and gas combination are being used. In a synergic system, the wire feeder and power source must “talk” together . This means that only certain wir e feeders can work in a synergic setup. A synergic feeder has special circuitry to “talk” with and “listen” to the Power Wave power source.

Welding experts have preprogrammed the system for the best range of process settings according to wire type, wire size, and gas combination. When the wire feed speed is changed, the system automatically adjusts the current and voltage waveforms to give the best weld characteristics. This improves the soundness, appearance, and repeatability of welds.

Refer to the Accessories section of this manual for available wire feeders.

RECOMMENDED PROCESSES

The Power Wave is designed to be used as a multiple process machine. It comes preprogrammed with GMAW pulse, GMAW (short arc and spray) FCAW (Innershield™ and Outershield™), and stick procedures.

OPERATIONAL FEATURES AND CONTROLS

The Power Wave, through use of a keypad overlay system, provides various options and controls such as Multiple Process/Procedure Selection; Memory Storage of Procedures; Weld from Memory Only operation; Dual Process/Dual Feeder capability.

DESIGN FEATURES AND ADVANTAGES

• Designed to NEMA Standards.

• Multiple process output ranges 5 - 540 amps.

• 2-line LCD display.

• Easy access for input connections. Connections are simple strip and clamp (no lugs required).

• Modular construction for easy servicing.

• Thermostatically protected.

• Electronic overcurrent protection.

• Overvoltage protection.

• Digital signal processor and microprocessor control.

• RS232 interface for future welding application updates.

• Simple, reliable reconnection for various input voltages.

• New accessories and wire feeders communicate using a digital current loop to transfer information.

• Auto device recognition simplifies accessory cable connections.

• Direct support of two wire feeders.

• Auto-configurable for either metric or English mode.

• Multiprocess control: Stick, short arc, GMAW spray, GMAW pulse, and flux cored arc welding (FCAW).

• Simple control through use of overlays that limit access to only those keys required for a given application.

WELDING CAPABILITY

The Power Wave 450 is rated at 500 amps, 40 volts at 60% duty cycle based on a ten minute time period. It is capable of higher duty cycles at lower output currents. If the duty cycles are exceeded, a thermostat will shut off the output until the machine cools to a reasonable operating temperature.

LIMITATIONS

• The Power Wave is not recommended for processes other than those specified by available overlays.

• The Power Wave is not recommended for pipe thawing.

OPERATION

B-3 B-3

POWER W AVE 450

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations.

FIGURE B.1 – CASE FRONT CONTROLS

CASE FRONT CONTROLS

Refer to Figure B.1 for the location of the following controls:

1. LCD DISPLAY: Provides welding procedure infor-

mation and parameters such as wire type, gas type, WFS, trim, etc.

2. POWER SWITCH: Controls input power to the

Power Wave. When the switch is turned to the ON position, the connected wire feeder meters light up and the LCD display on the Power Wave shows the following:

LINCOLN ELECTRIC

Version X.X

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.

3. HIGH TEMPERATURE LIGHT (thermal overload): A

yellow light that comes on when an over temperature situation occurs. Output is disabled until the machine cools down. At that point the light goes out and output is enabled again.

4. REMOTE CONTROL AMPHENOL RECEPTACLE:

Allows remote current control during stick welding via a hand or foot Amptrol accessory.

5. 5 AMP CIRCUIT BREAKER: Protects two auxiliary

power circuits: the 24V supply used by the trigger circuits and the 42V supply used by the internal machine circuits and the wire feeders.

6. LCD DISPLAY ADJUSTMENT: Use a small flat

blade screw driver to adjust the viewing angle of the LCD display.

OPERATION

B-4 B-4

POWER W AVE 450

1 LCD DISPLAY 2 POWER SWITCH 3 HIGH TEMPERATURE LIGHT 4 REMOTE CONTROL AMPHENOL RECEPTACLE 5 5 AMP CIRCUIT BREAKER 6 LCD DISPLAY ADJUSTMENT

OPERATING OVERLAYS

OVERVIEW

The Power Wave is controlled by a panel of keys (keypad) located on the front of the machine. The operator can access controls by placing an overlay over the keys.

An OVERLAY is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other. See Figure B.2. The printed keys allow the operator to communicate with the machine for a specific set of functions. The bar code allows the machine to identify the overlay.

FIGURE B.2 – TYPICAL POWER WAVE OVERLAY

Before the Power Wave is turned ON, the operator selects the desired overlay and mounts it in the overlay frame on the front of the machine. Then, when the machine is turned ON, it reads the overlay bar code and configures the machine accordingly, allowing the operator to access only certain keys. The machine

must be powered up each time an overlay is changed.

INSTALLING AN OVERLAY

1. Open the ACCESS DOOR by grasping the provid-

ed indent on the door and pulling the door forward. See Figure B.3 for door location.

FIGURE B.3 – OVERLAY ACCESS DOOR

2. Select the desired overlay from the storage com-

partment located behind the access door.

3. Remove any overlay already in the overlay frame

and place it in the storage compartment.

4. Slide the new overlay into the overlay frame. Align

the overlay with the two tracks on the sides of the frame. Be sure the overlay is seated in the bottom lip of the frame and on the top two locating pins. Close the access door securely.

OPERATION

B-5 B-5

POWER W AVE 450

HIGH TEMP.

DISPLAY

1M2

3M4

5M6

7M8

PROGRAM LIST

WARNING

RECALL

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9361-2 WELD FROM MEMORY

MEMORYRECALL

INVERTEC POWER WAVE 3 50

1 OVERLAY ACCESS DOOR 2 OVERLAY FRAME 3 ACCESS DOOR INDENT 4 TRACKS 5 LOCATING PINS

™

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 procedures by selecting and adjusting the various welding settings that have been programmed into the Power Wave at the factory.

2. Weld From Memory Overlays. These overlays (also called Shop Overlays) provide a simple way for operators to recall and use any of the welding procedures that have been stored in the memory of the Power Wave.

3. Setup Overlays. These overlays provide specific machine setup information, such as operating limits for the welding procedures stored in memory.

4. Special Purpose Overlays. These are custom overlays for specific customer applications.

Detailed information on how to use currently available Power Wave overlays follows.

Overlay Overlay Figure

Type Name No.

1 PULSE, GMAW,

FCAW, STICK PROCESS SELECTION OVERLAY B.4

2 WELD FROM MEMORY

OVERLAY B.5

2 WELD FROM MEMORY, DUAL

PROCEDURE OVERLAY B.6

2 *DUAL WIRE FEEDERS, DUAL

PROCEDURES OVERLAY B.7

2 *DUAL FEEDER, DUAL

PROCEDURE, MEMORY SELECTION OVERLAY --

3 *LIMITS OVERLAY B.8 3 SETUP OVERLAY B.9 4 *TEST & CALIB. OVERLAY --

*These overlays are optional. See Accessories Section for Order Numbers.

OPERATION

B-6 B-6

POWER W AVE 450

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

NUMBER = 1

A welding procedure is made up of seven components: process, material type, wire diameter, program, wire feed speed, voltage or arc length trim, and wave control. A new welding procedure is created by selecting a combination of these components from the ones that have been programmed into the Power Wave. See Figure B.4 for key locations.

NOTE: The following four selections should always be performed in this order: process, electrode class, electrode size, electrode/gas type. Selecting a setting for one component narrows your choice of available settings in remaining components. This is why the order of performing the steps is important. However, if you make component selections out of order, the machine will prompt you to make a new selection for any settings that do not apply.

2. PROCESS SELECT KEY: Use the PROCESS SELECT key to select from the processes available in the machine. Press the PROCESS SELECT key until the light by the desired process is lit.

OPERATION

B-7 B-7

POWER W AVE 450

345 7

FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY

1 LCD DISPLAY WINDOW 2 PROCESS SELECT KEY 3 ELECTRODE CLASS UP/DOWN KEYS 4 ELECTRODE SIZE UP/DOWN KEYS 5 ELECTRODE/GAS TYPE UP/DOWN KEYS 6 WAVE CONTROL UP/DOWN KEYS

7 DISPLAY RECALL KEY 8 SAVE TO MEMORY KEY

9 MEMORY LOCATION NUMBER KEYS 10 RECALL FROM MEMORY KEY 11 HIGH TEMPERATURE LIGHT

PULSE, GMAW, FCAW, AND STICK/TIG PROCESS SELECTION OVERLAY

An operator can use this overlay to create a new welding procedure, save a newly created welding procedure, view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See Figure B.4. The steps for performing each of these functions are given below.

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 displayed.

4. ELECTRODE SIZE UP/DOWN: Use the ELEC- TRODE SIZE UP or DOWN keys to select from the wire diameters available for the selected process and material type. Press the ELECTRODE SIZE UP or DOWN key until the desired wire diameter is displayed.

5. ELECTRODE/GAS TYPE UP/DOWN KEYS: Use the ELECTRODE/GAS TYPE UP or DOWN keys to select from the programs available for the selected process, material type, and wire diameter. Press the ELECTRODE/GAS TYPE UP or DOWN Key until the desired program is displayed.

6. WA VE CONTROL UP/DOWN KEYS: Press one of the two WAVE CONTROL keys to display the present wave control. This is shown on a scale from LO to HI. Use the WAVE CONTROL UP or WAVE CONTROL DOWN key to change the wave control to the desired level. When this scale is shown, the WAVE CONTROL setting can also be changed while welding (on the fly). Press the DISPLAY RECALL key to exit the wave control function. For a description of how the wave control setting affects the welding procedure, refer to the Overview of Welding Procedures sub-section of the Operation section of this manual.

The wire feed speed and voltage or arc length trim desired for the new procedure can be changed from the wire feeder.

7. DISPLAY RECALL KEY : Since not all the informa- tion about the procedure can be seen on the 2-line LCD display window at the same time, use the DISPLAY RECALL key to display and verify all of the selected procedure information. The normal default display window shows the Procedure Description, WFS, and preset voltage or arc length trim values. Press and hold the DISPLAY RECALL key, and the window shows the procedure description and gas type for as long as the key is held depressed. Release the DISPLAY RECALL key, and the window shows wire size, material type, and process description. After a few seconds, the window changes back to the default display.

8. SAVE TO MEMORY KEY : This key is used to save a newly created welding procedure. The Power Wave has eight memory locations which can be used to store all the settings of up to eight welding procedures. Once stored in a memory location, a procedure can be recalled for later use with the RECALL FROM MEMORY key. To save a newly created welding procedure:

Press the SAVE TO MEMORY key and then one of the MEMORY LOCATION NUMBER keys. Keep a record of this number for future reference.

Any previously created welding procedure stored in that location will be erased.

If you press the SAVE TO MEMORY key but decide not to save the procedure, you can exit this function by pressing the DISPLAY RECALL key.

9. MEMORY LOCATION NUMBER KEYS: To view information about any stored welding procedure, simply press its MEMORY LOCATION NUMBER key.

As you hold down the selected key, the procedure description and gas type of the procedure appear in the display window. The process type is shown by the indicating light opposite the appropriate process symbol.

When you release the selected key, the wire size, material type and process description appear for a few seconds.

This function does not display the wire feed speed and voltage or arc length trim settings. To view these, you must recall the procedure from memory with the RECALL FROM MEMORY key.

OPERATION

B-8 B-8

POWER W AVE 450

SAVE

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. Simply press the RECALL FROM MEMORY key and then the appropriate MEMORY LOCATION NUMBER key.

If you press the RECALL FROM MEMORY key and then change your mind, you can exit this function by pressing the DISPLAY RECALL key. If the memory location you select does not contain a stored welding procedure, this will be indicated in the display window. Select another memory location. It is not necessary to save a procedure back to memory after it is recalled from memory. When a procedure is saved into a memory location, it can be recalled from there until another procedure is stored in that location or the location is cleared.

The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location.

Press the SAVE TO MEMORY key and then the RECALL FROM MEMORY key . (Do not press both keys at the same time.) A message in the display window will ask you to press the MEMORY LOCATION NUMBER key of the memory location you want to clear.

If you press the SAVE TO MEMORY and RECALL FROM MEMORY keys and then change your mind, you can exit this function by pressing the DISPLAY RECALL key.

11. HIGH TEMPERATURE LIGHT: The high tempera- ture light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out.

OPERATION

B-9 B-9

POWER W AVE 450

RECALL

SAVE

RECALL

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 = 2

This message is then replaced by the following message:

SELECT A MEMORY

LOCATION

2. MEMORY RECALL NUMBERS: Select the mem- ory location of the desired welding procedure by pressing the appropriate MEMORY RECALL NUMBER key.

If no procedure was saved in the selected memory location, the following message appears:

MEMORY LOCATION

# IS EMPTY Select another memory location. When a welding procedure is recalled from mem-

ory, the display window will show the procedure description, wire feed speed, and arc length trim or preset voltage.

With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values will replace the previous values and become a permanent part of the procedure.

If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedure, these limits will be active when this overlay is in place. They cannot be overridden from this overlay.

3. PROGRAM LIST: The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory. A “Dry Erase” marker should be used for this purpose.

4. DISPLA Y RECALL KEY: To view other information about the selected procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the selected procedure for as long as the key is held depressed. When the key is released, material type, wire size, and process descriptions will be displayed for a few seconds.

5. HIGH TEMPERATURE LIGHT: The high tempera- ture light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out.

6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory is active at any given time.

OPERATION

B-10 B-10

POWER W AVE 450

WELD FROM MEMORY OVERLAY

The Weld Fr om Memory Overlay lets an operator recall and use any welding pr ocedur e stored in one of eight memory locations. See Figure B.5.

FIGURE B.5 – WELD FROM MEMORY OVERLAY

1 6

1 LCD DISPLAY WINDOW 2 MEMORY RECALL KEYS 3 PROGRAM LIST 4 DISPLAY RECALL KEY 5 HIGH TEMPERATURE LIGHT 6 MEMORY LIGHTS

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 = 3

This message is then replaced by the following message:

SELECT A MEMORY

LOCATION

2. MEMORY RECALL KEYS: The following four memory pairs are available on this overlay: Memory 1 and Memory 2 Memory 3 and Memory 4 Memory 5 and Memory 6 Memory 7 and Memory 8

Select a memory location PAIR for the two desired welding procedures by pressing either of the two corresponding MEMORY RECALL NUMBER keys.

If no procedure was saved to one of the memory pair locations, the following message appears:

MEMORY LOCATION

# IS EMPTY In this case select another memory pair. Set the dual procedure switch or gun trigger to the

position for PROCEDURE A or PROCEDURE B. Position A activates the welding procedure from the odd numbered memory locations (1, 3, 5 or 7). Position B activates the welding procedure from the corresponding even numbered memory locations (2, 4, 6 or 8). For example, if memory location 3 was

selected, Position A activates the procedure from memory location 3; Position B activates the procedure from memory location 4.

OPERATION

B-11 B-11

POWER W AVE 450

WELD FROM MEMORY, DUAL PROCEDURE OVERLAY

The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position trigger. The switch or trigger selects which procedure will be active. See Figure B.6

1 6

1 LCD DISPLAY WINDOW 2 MEMORY RECALL KEYS 3 PROGRAM LIST

4 DISPLAY RECALL KEY 5 HIGH TEMPERATURE LIGHT 6 MEMORY LIGHTS

FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY

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.

If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedures, these limits will be active when this overlay is in place. They cannot be overridden from this overlay.

3. THE PROGRAM LIST: The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory. A “Dry Erase” marker should be used for this purpose.

4. DISPLAY RECALL KEY : T o view other information about the active procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions display for a few seconds.

6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory location is active at any given time.

OPERATION

B-12 B-12

POWER W AVE 450

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. WIRE FEEDERS MEMORY CHART: The active welding procedure is determined by the active wire feeder and its gun switch position. The welding procedure recall from memory is as follows:

Active Gun Trigger Memory Location

Wire Feeder Position of Procedure

#1 A 1 #1 B 2 #2 A 3

#2 B 4 Pull the trigger on either wire feeder. Depending on the gun switch position, the corre-

sponding memory location is automatically recalled. The wire feeders memory chart has no keys; it is simply a chart.

The display window will show the procedure description, wire feed speed, and the preset voltage or arc length trim of the last active welding procedure.

With this overlay in place, the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder. The new values replace the previous values and become a permanent part of the procedure.

3. DISPLAY RECALL KEY:To view other information about the active welding procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions will be displayed for a few seconds.

4. HIGH TEMPERATURE LIGHT: The high tempera- ture light comes on when the internal machine temperature exceeds the allowed limit. Output is disabled until the machine cools down and the high temperature light goes out.

5. MEMORY LIGHTS: A memory light is on when its corresponding memory is slected. This tells you what memory location is active at any given time.

OPERATION

B-13 B-13

POWER W AVE 450

1 LCD DISPLAY WINDOW 2 WIRE FEEDERS MEMORY CHART 3 DISPLAY RECALL KEY 4 HIGH TEMPERATURE LIGHT 5 MEMORY LIGHTS

DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY (OPTIONAL)

The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feeders and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4 can be automatically recalled and used. See Figure B.7.

FIGURE B.7 – 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 = 4

This message is then replaced by the following message:

SELECT A MEMORY

LOCATION

2. RECALL FROM MEMORY KEY:

AND

3. MEMORY LOCATION NUMBERS: The RECALL FROM MEMORY key is used

to recall a welding procedure from memory.

Determine the memory location number of the welding procedure for which you want to set limits.Then press the RECALL FROM MEMORY key

followed by the MEMORY LOCATION NUM-

BER key for the selected procedure. If no procedure was saved in the selected memo-

ry location, the following message appears:

MEMORY LOCATION

# IS EMPTY

Select another memory location.

4. SET LIMIT KEY: AND

5. LIMIT UP / DOWN KEYS:

The SET LIMIT key and LIMIT UP / LIMIT DOWN keys are used to set the maximum and minimum allowed wire feed speed, and voltage trim or arc length trim values of the procedure that was recalled from memory.

OPERATION

B-14 B-14

POWER W AVE 450

1 LCD DISPLAY WINDOW 2 RECALL FROM MEMORY KEY 3 MEMORY LOCATION NUMBER KEYS 4 SET LIMIT KEY

5 LIMIT UP/DOWN KEYS 6 SAVE TO MEMORY KEY 7 DISPLAY RECALL KEY 8 MEMORY LIGHTS

LIMITS OVERLAY (OPTIONAL)

The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length trim for any welding procedure stored in memory. See Figure B.8.

FIGURE B.8 – LIMITS OVERLAY

RECALL

1 8 2 6

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 displayed.

Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.

Press the SET LIMIT key. The present maximum and minimum voltage trim or arc length trim will be displayed. (Refer to Table B.3 to see how voltage trim affects preset voltage. Refer to Table B.6 to see how arc length trim affects preset arc length.)

Use the LIMIT UP and LIMIT DOWN keys to change the maximum value. The maximum for either type is 1.5.

Press the SET LIMIT key. The new maximum and old minimum voltage trim or arc length trim will be displayed.

Use the LIMIT UP and LIMIT DOWN keys to change the minimum value. The minimum for either type is 0.5.

6. SAVE TO MEMORY KEY: The SAVE TO MEMO- RY KEY is used to save the procedure with the newly set limits to memory. Press the SAVE TO MEMORY key followed by the MEMORY LOCATION NUMBER key of the desired memory location. This does not have to be the original location from which the procedure was recalled.

Step 6 can be performed any time during the limitsetting process. You do not have to set all the available limits. When you have set all the desired limits, save the procedure to memory.

To clear any previously set limits, recall the procedure from memory and change the limits to the maximum range available. Then save the procedure to memory.

7. DISPLAY RECALL KEY : To view other information about the active welding procedure, press the DISPLAY RECALL key. The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed. When the key is released, the wire size, material type, and process descriptions will be displayed for a few seconds.

6. MEMORY LIGHTS: A memory light is on when its corresponding memory is selected. This tells you what memory is active at any given time.

OPERATION

B-15 B-15

POWER W AVE 450

SAVE

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 = 0

This message is then replaced by the following message:

POWER WAVE

SETUP

2. WATER COOLER ON/OFF KEY: Press this key to toggle the water cooler between being enabled and disabled. The present status of the water cooler is indicated by the “WATER COOLER ON” light.

3. WATER COOLER PRESSURE LIGHT: This light indicates whether or not the coolant flow rate is high enough for normal water cooler operation. If the water cooler loses the required flow rate it will shut down within a couple of seconds, the water cooler pressure light will turn off,and the machine sounds a buzzer.

4. PRIME WATER COOLER KEY: The water cooler may have to be primed if there is not enough coolant in the system for proper operation. Make sure that the water cooler has been turned on before it is primed. (The “WATER COOLER ON” light should be turned on.) Check reservoir for proper coolant level - See Water Cooler information in ACCESSORIES section. To prime the water cooler, hold the PRIME WATER COOLER key down. While this key is pressed, the display will show:

PRIME WATER

COOLER

OPERATION

B-16 B-16

POWER W AVE 450

1 LCD DISPLAY WINDOW 2 WATER COOLER ON/OFF KEY 3 WATER COOLER PRESSURE LIGHT 4 PRIME WATER COOLER KEY

5 WIRE FEEDER 1+/- POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY

SETUP OVERLAY

The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figur e B.9.

FIGURE B.9 – SETUP OVERLAY

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9660 SETUP OVERLAY

WARNING

+POLARITY

ELECTRODE

SENSE LEAD

WORK SENSE

LEAD ENABLED

+/ -

POLARITY

ELECTRODE

SENSE

LEAD

WORK SENSE

LEAD

WATER COOLER ENABLED

WATER COOLER PRESSURE

WATER

COOLER

ENABLE

PRIME WATER

COOLER

WATER COOLER CAN ONLY BE PRIMED WHEN IT IS ENABLED.

PRIME THE WATER COOLER UNTIL WATER COOLER PRESSURE LIGHT TURNS ON.

+POLARITY

ELECTRODE SENSE LEAD

ENABLED ENABLED

WORK SENSE

LEAD ENABLED

+/ -

POLARITY

ELECTRODE

SENSE

LEAD

WORK SENSE

LEAD

WIRE WIRE

FEEDER 2FEEDER 1

WATER COOLER SETUP

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 polarity of wire feeder 1. The present polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY” light. If wire feeder 1 is set for positive voltage sensing polarity, this light is turned on.

6. WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY: Press this key to enable or disable the electrode sense lead (lead #67) of wire feeder 1. When enabled, voltage sensing is done by the electrode sense lead. When disabled, voltage sensing is done at the Power Wave output terminal. When enabled, the “WIRE FEEDER 1 ELECTRODE SENSE LEAD ENABLED” light will be illuminated.

7. WIRE FEEDER 1 WORK SENSE LEAD KEY: Press this key to enable or disable the work sense lead (lead #21) of wire feeder 1. When enabled, voltage sensing is done by the work sense lead. When disabled, voltage sensing is done at the Power Wave output terminal. When enabled, the “WIRE FEEDER 1 WORK SENSE LEAD ENABLED” light will be illuminated.

WIRE FEEDER SETUP DESCRIPTION

The Power Wave may be set up for either positive or negative arc voltage sensing using any two of the following places:

1. the positive output terminal of the Power Wave

2. the negative output terminal of the Power Wave

3. the electrode sense lead (67) lead of the wire

feeder

4. a work sense (21) lead The SETUP Overlay allows you to select between

which two places arc voltage will be sensed. Once the selection is made it is not necessary to reconfirm the selection every time a new overlay is used or a wire feeder is replaced with another one. The selection will remain until it is changed with the SETUP Overlay.

When welding with a stick procedure, the arc voltage is automatically measured between the Power Wave’s output studs.

I. Select arc voltage sensing polarity first.

+/- POLARITY KEY A. Positive Polarity Voltage Sensing: In most welding applications the electrode cable is

connected to the + output terminal and the work cable is connected to the - output terminal of the power source. This is positive polarity voltage sensing illustrated by Figure B.10. When the Power Wave and the wire feeder(s) are connected in this manner, the arc voltage can be measured in one of four ways. These four ways are shown in Table B.1.

Table B.1: Positive Voltage Sensing Options

Positive Voltage Reference Negative Voltage Reference

+ Output Terminal - Output Terminal

+ Output Terminal Work Sense (21) Lead* Electrode Sense (67) Lead - Output Terminal Electrode Sense (67) Lead Work Sense (21) Lead*

*Consult the factory before using this option.

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 circumstances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for the negative voltage reference. Consult the factory if use of the work sense (21) lead is desired.

B. Negative Polarity Voltage Sensing: In some welding applications (such as Inner-

shield

) the electrode cable is connected to the output terminal and the work cable is connected to the + output terminal of the power source. This is negative polarity voltage sensing illustrated by Figure B.11. When the Power Wave and the wire feeder(s) are connected in this manner, the arc voltage can be measured in one of four ways. These four ways are shown in Table B.2.

Table B.2: Negative Voltage Sensing Options

Positive Voltage Reference Negative Voltage Reference

– Output Terminal + Output Terminal

– Output Terminal Work Sense (21)Lead* Electrode Sense (67) Lead + Output Terminal Electrode Sense (67) Lead Work Sense (21) Lead*

*Consult the factory before using this option

OPERATION

B-17 B-17

POWER W AVE 450

Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage reference.

The two wire feeders can only be connected in the same manner, either by the Positive Polarity or the Negative Polarity setup.

OPERATION

B-18 B-18

POWER W AVE 450

Power

Wave

Control Cable (includes 67 lead)

Electrode Sense Lead

Electrode

Cable

Work Cable

Wire Feeder

Block

POSITIVE VOLTAGE SENSING POLARITY

FIGURE 11B

Power

Wave

Electrode

Cable

Work Cable

Wire Feeder

Block

NEGATIVE VOLTAGE SENSING POLARITY

Control Cable (includes 67 lead)

Electrode Sense Lead

FIGURE B.10

FIGURE B.11

OVERVIEW OF WELDING PROCEDURES

FLUX CORED ARC WELDING (FCA W) 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 voltage 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.

In some cases, the operator may want to change the preprogrammed voltages; for example, to compensate for cable and fixture voltage drops.The preset voltages can be adjusted on the wire feeder’s Voltage display. When a change is made to the voltage at one wire feed speed, this change is applied to all other wire feed speed settings. For example, if the operator turns up the voltage by 10 percent, the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent. In the GMAW and FCAW process, the display shows The Procedure Description, WFS and Preset Voltage.The preset voltage which was pro-grammed at the factory, may be changed on the wire feeder voltage display. Note that if you change the default preset voltage up or down a respective “ ” or “ ” sign will be dis-played after the preset value.When the gun trigger is pulled note that the display changes to show WFS , Actual Arc Volt-age and Actual Arc Current. See Table B.4 for display summary.

PULSE PROCEDURES

In these procedures, the actual voltage greatly depends on the waveform used. The peak currents, background currents, rise times, fall times, and pulse times all affect the actual volt-age. The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known. In this case, it is not practical to preset an actual voltage for the pro-cedure. Instead, an arc length adjustment is provided. The machine “knows” what the best arc length is at the given wire feed speed but allows the operator to change it.

The arc length can be adjusted between 0.5 and 1.5 on the wire feeder’s Voltage display. An arc length trim of

1.0 means that no adjustments will be made to the preset arc lengths. An arc length trim greater than 1.0 increases the preset arc lengths. An arc length trim less than 1.0 decreases the pre-set arc lengths. The arc length adjustment is factored in at all wire feed speed settings.

Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length settings of the procedure by 10 percent. In the Pulse process, the display shows the Procedure Description, WFS and Arc Length Trim. Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder. When the tr igger is pulled, the WFS, Actual Arc Voltage and Actual Arc Current are dis-played.

Stick / TIG PROCEDURES

Stick welding can be performed with the Power Wave 450 by attaching a remote control kit to the 6-pin amphenol on the front of the machine. The K941-1 remote control kit is recom-mended. Select the Stick Process from either the Pulse, GMAW and FCAW, Stick process selection overlay, or recall it from a previously stored memory location with a Weld From Memory overlay. When this process is selected, the Power Wave 450 reads the current (amps) setting from the remote control kit. It also controls the output of the machine based on the position of the Output Terminals switch, which is also located on the remote control kit. When this switch is in the ON position, the output terminals of the Power Wave 450 are electrically hot. When the switch is in the OFF position, the output terminals of the Power Wave 450 are electrically cold and the machine cannot produce an output. In the Stick Pro-cess, the LCD display shows Procedure Description, and Pre-set Current (SET=). The Current Trim is always equal to 1 (T=1.00).When the trigger is pulled the Preset Current, Ac-tual Arc Voltage and Actual Arc Current are displayed.

See Tables B.3 and B.4 for a summary of the information discussed above.

WAVE CONTROL

The wave control settings of all procedures can be changed on the Power Wave 450 GMAW Pulse, GMAW and FCAW, Stick Process Selection Overlay. The wave control is a setup parameter that may be adjusted when the welding procedures are set. This feature pro-vides an easy way to change the arc behavior without creating a new procedure.The wave control setting of a procedure limits the speed at which the current waveform of that procedure can change. Typically, each procedure is programmed to have average wave con-trol (at the center of the scale).

OPERATION

B-19 B-19

POWER W AVE 450

OPERATION

B-20 B-20

POWER W AVE 450

Trigger

Position

GMAW GMAW STICK

Pulse GMAW

Pulse FCAW FCAW

WFS DISPLAY: WFS DISPLAY:

Wire Feed Speed Wire Feed Speed

WFS and WFS and Preset VOLTAGE VOLTAGE

Open Arc Length Trim Preset Voltage Current DISPLAY: DISPLAY:

Arc Length Trim Preset Voltage

WFS, WFS, WFS DISPLAY: WFS DISPLAY:

Actual Arc Actual Arc Preset Current, Wire Feed Speed Wire Feed Speed

Closed Voltage, Voltage, Actual Arc VOLTAGE VOLTAGE

Actual Arc Actual Arc Voltage, Actual DISPLAY: DISPLAY:

Current Current Arc Current Actual Arc Voltage Actual Arc Voltage

In Stick, trigger is on Remote Control Kit K941-1.

Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder.

Power Wave 450

Wire Feeder

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.

In GMA

W and FCAW processes:

The wave control adjusts the inductance. (Inductance is inversely proportional to pinch.) Increasing the wave control setting decreases the inductance, which results in the arc getting colder and pinched tighter. Decreasing the wave control setting increases the induc-tance, which results in the arc getting wider.

In Stick processes:

The wave control adjusts the arc force. Increasing the wave control setting increases the arc force, making the arc more harsh but less likely to stick.Decreasing the wave control setting decreases the arc force, making the arc softer and smoother.

Adjustable GMAW GMAW

Parameters Pulse FCAW Stick

Wire Feeder Wire Feed Wire Feed —

WFS Display Speed Speed

Wire Feeder Arc Length Preset —

Voltage Display Trim Voltage

Power Wave 450 Display

(with GMAW Pulse, Wave Wave Wave

GMAW FCAW, Stick Control Control Control

Process Selection Overlay) (Frequency) (Inductance) (Arc Force)

TABLE B.3 – ADJUSTBLE PARAMETERS

TABLE B.4 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS

FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS

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.

Spatter levels are often very low with the pulse welding process. Pulsing is often used to eliminate

cleaning operations necessary when using other welding processes.

Fume levels are sometimes lower with the pulsing process. Whether or not you will get lower fume levels

depends on the pulsing programs used. Cer tain waveform characteristics are necessary to get low fume levels. Unfortunately, low fume procedures are harder to weld with than procedures designed to optimize the welding process.

The pulsing process is not slower than other processes. The process is sometimes less forgiving when

the arc gets on or ahead of the puddle. More attention must be paid to the weld to avoid losing the puddle. Speed is a matter of deposition rate. All things being equal regarding the joint being welded, the speed will depend on the wire feed speed. The travel speed is maximized by maintaining a very short arc. Often the process is “trimmed” down until the arc “crackles.” The spatter increases slightly, but many of the advantages of pulsing are retained.When welding steel, the Power Wave is designed to run well in this region between pulse and short arc.

The pulsing process greatly affects the heat input to the workpiece. This can be a valuable tool for either

increasing or decreasing the heat input with a given process. For instance, it is possible to greatly increase the heat input when welding steel at high deposition rates. On the other hand, it is possible to reduce the heat input using the pulsing process.For example , heat input is reduced greatly with some of the low current stainless steel procedures using the processes programmed into the Power Wave.In all cases, the Power Wave procedures have been check ed for their ability to deliver a sound weld. However, the fusion of the weld metal into the workpiece may be affected. It is the responsibility of the user to determine if the welds produced are suitable and sound.

The Power Wave is optimized for use with a 0.75” (1.9 cm) stickout. The adaptive behavior is pro-

grammed to support a stickout range from 0.5”to 1.25” (1.3 to 3.2 cm).In the low and high end of the wire feed speed ranges of most processes, the adaptive behavior may be restricted. This is a physical restriction due to reaching the edge of the operating range for the process. It is possible to achieve adaptive behavior for longer stickout lengths.However, shielding gas is often lost when the stickout is too long.

A longer electrical stickout is often used with the puls-ing process at higher deposition rates. A long

stickout will increase the melt-off rate of the wire. In pulse welding, like other wire welding processes, the arc length is determined by the voltage setting. This voltage is programmed at the factory for each process and wire feed speed. It may be changed using the Voltage setting on the wire feeder.

When adaptive processes are used, the voltage will vary with stickout.The machine must change the v olt-

age to keep a stable arc. It is very impor tant to recognize this. “Actual” arc voltage when welding will vary because the stickout will seldom be held at the nominal

0.75” (1.9 cm) value.

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 the conditions mentioned above, a thermostat will open. The yellow high temperature light on the case front comes on. See Figure B.1 for location. Machine output is disabled, and welding is not possible until the machine is allowed to cool and the High Temperature Light goes out.

Current Protection

The Pow er W av e is limited to producing 750 amps peak current. If the average current exceeds 540 amps, the peak current will automatically be cut back to 100 amps until the average current decreases to 50 amps.

OPERATION

B-21 B-21

POWER W AVE 450

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)

• Limits Overlay K946-4

•

Dual Wire Feeders, Dual Procedures Overlay K946-9

•

Dual Feeder, Dual Procedure, Memory Selection Overlay K946-12

• Test and Calibration Overlay

WIRE FEEDER SETUP

The Power Wave must be used with wire feeders listed above. Mount the feeder in a location suitable to your needs.

For most applications, connect the electrode cable between the feeder and the positive (+) connection of the power source. When negative electrode polarity is required, such as in some Innershield™ applications, connect the electrode cable between the feeder and the negative (-) connection of the power source. See Figure C.1.

Connect the control cable between the feeder and power source. The cable has different connectors on each end and will fit in only one way. If only one feeder is used, it must be connected to the Feeder 1 Amphenol located on the back panel in the upper lefthand corner (as you view the machine from the back). If a second feeder is used, it must be plugged into the Feeder 2 Amphenol receptacle located just to the right of the Feeder 1 Amphenol receptacle.

Connect the work cable between the work and the negative (-) connection of the power source. When negative electrode polarity is required, such as in some Innershield™ applications, connect the work cable between the work and the positive (+) connection of the power source. See Figure C.1.

• Connect the feeder to a welding gas supply.

• Load the wire into the feeder and gun.

• Configure wire feeders (Refer to Setup overlay in operation section.

GUNS AND CABLES

Several MAGNUM guns are recommended for use with the Power Wave as shown in Table C.1.

Place the proper liner in the gun and connect the gun to the feeder. Consult the specific instructions supplied with the gun for detailed operating instructions.

Using a water-cooled gun is recommended to reduce the size of the gun and improve parts life. The Power Wave comes with a standard internal water cooler. However, an external cooler may also be used.

TABLE C.1 – RECOMMENDED GUNS FOR USE

WITH POWER WAVE 450

Gun Application Cooling Product No.

MAGNUM 400 GMAW Gas K471-2 MAGNUM 550 GMAW Gas K598

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 operator discomfort. Water cooling greatly increases the durability of the gun and parts at high current.

ACCESSORIES

C-1 C-1

POWER W AVE 450

FIGURE C.1 – WIRE FEEDER AND

WATER COOLER CONNECTIONS

1 WIRE FEEDER CONNECTIONS (LOCATION) 2 WATER COOLER LINE (IN) 3 WATER COOLER LINE (OUT) 4 CIRCUIT BREAKER (WATER COOLER) 5 FILL SPOUT (WATER COOLER)

Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operator’s Manual for available options.

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 feeder. 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.

The water cooler contains a flow switch, which is closed when there is adequate coolant circulating in the system. If this flow rate drops below the switch manufacturer’s set point, the flow switch opens.A cou- ple of seconds after the flow switch opens the water cooler shuts down. If the water cooler is enabled and the flow switch opens, the machine beeps loudly indicating that there is a problem with the water cooler operation.

RECOMMENDED COOLANTS

1. The following coolants have been determined to be

compatible with the wetted materials used in the G3503-[ ] cooler assembly:

• Distilled or deionized water

• Potable tap water

• Sediment-free mixtures containing a maxi-

mum of 50% ethylene glycol or automotivegrade antifreeze and the balance of distilled or deionized water.

2. Ethylene glycol mixtures should be selected if the

cooler may be exposed to a temperature below the freezing point of water.

3. Consult gun, torch, and wire feeder manuals for

coolant recommendations and select one from the above list.

4. Pure solutions and mixtures of, or materials (i.e.

towels) wetted with ethylene glycol are toxic to humans and animals.They must not be haphazardly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information.

5. The cooler’s reservoir has a nominal liquid capacity

of 1.6 gallons.

PRIMING THE COOLER

1. Select a recommended coolant and fill cooler to

specified level (see Fig.C.2).

2. Attach desired water-cooled accessory (gun and

wire feeder or TIG torch) to cooler’s QDs.

3. Pr ime the cooler : a. Install the Set-up overlay. b.Keep accessories’ hose lengths horizontal, either

coiled or straight, and no higher than 4 feet of the

specified coolant level. c. Switch on the Power Wave machine. d. Press the "WATER COOLER ENABLE" button so

that the "WATER COOLER ENABLED" light is illuminated.

e. Press the "PRIME WATER COOLER" button until

the "WATER COOLER PRESSURE" light is steadily illuminated.

4. Check coolant level. Add more if required.

Figure C.2

Do Not Use: Any prepacked welding industry coolant mixture, such as those offered by Miller, OKI, Bernhard, or Dynaflux. These coolants contain substances which attack plastic components and may shorten the life of the system. Once added, these substances are virtually impossible to purge from the system. DO NOT USE OIL-BASED COOLANTS OF ANY TYPE.

K961-1 Single Cylinder Undercarriage -

Designed for quick installation in the field. Consists of a front caster assembly, a rear platform assembly, a handle, and an upper cylinder support.

K962-1 Dual Cylinder Undercarriage -

Designed for quick installation in the field. Consists of a front caster assembly, a dual bottle rear platform assembly, a handle, and a dual bottle upper cylinder support.

ACCESSORIES

C-2 C-2

POWER W AVE 450

Reservoir Screen

Rear Panel of Power Wave

Visible Coolant Level

0.25 to 0.50 inches

SAFETY PRECAUTIONS

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 once every six months.

Prior to performing preventive maintenance it is important to perform the following capacitor discharge procedure to avoid electric shock.

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

1. Turn off input power and disconnect input power lines.

2. Remove the hex head screws from the top and the sides of the machine. Remove the handle bar and the wrap-around machine cover.

3. Remove the two case sides. There are hex head screws on each side.

TO PREVENT DAMAGE TO MACHINE, AVOID UNNECESSARY MOVEMENT OF FRONT PANEL.

4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with the machine. Secure this resistor to a piece of insulating material such as a glastic board. See Figure D.3. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.

MAINTENANCE

D-1 D-1

POWER W AVE 450

WARNING

CAUTION

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. See Figure D.1. Do not touch the resistors or any other internal machine component. Using a DC voltmeter, check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground (20 measurements in all). If a voltage is present, be careful not to touch these resistors.

ELECTRIC SHOCK can kill.

• Proceed with caution being careful not to touch any internal machine components during the discharge procedure.

MAINTENANCE

D-2 D-2

POWER W AVE 450

5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND

FIGURE D.1 – RESISTOR LOCATIONS

WARNING

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.

8. Carefully connect the needle nose end of one of the jumper leads to terminal #9. See Figure D.3. Connect the needle nose end of the other jumper lead to terminal #12. Terminals #9 and #12 are indicated by the “Discharge” label. Leave resistor connected for 10 seconds. DO NOT TOUCH TERMINALS, RESISTORS, OR ANY INTERNAL MACHINE COMPONENT DURING THIS PROCEDURE!

FIGURE D.3 – RESISTORS WITH LEADS

CONNECTED

9. Check voltage across terminals (9 and 12) with a DC voltmeter. Terminal 9 has positive polarity and terminal 12 has negative polarity. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.

10. Repeat discharge procedure (steps 7, 8 and 9) for each of the other three Switch Boards.

MAINTENANCE

D-3 D-3

POWER W AVE 450

I S C H A R

D I S C H A R G E

FIGURE D.2 – DISCHARGE LABEL

PREVENTIVE MAINTENANCE

Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a r ecor d tag attached to the machine works best.

1. Remove the hex head screws from the sides and top of the machine. Remove the handle bar and the machine wrap-around cover. Remove the two case sides. There are hex head screws on each side.

2. Perform the input filter capacitor discharge procedure described at the beginning of the Maintenance Section.

3. Disconnect the shunt from the negative (-) output terminal. Failure to do this could cause damage to the shunt circuitry.

4. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following components thoroughly (Refer to Figure D.4):

• Display, Snubber, and Shunt printed circuit

boards

• Power Switch

• Main Transformer

• Auxiliary Transformers

• Input Rectifier

• Heat Sink Fins

• Input Filter Capacitors

• Output Terminals

• Terminal Strip

5. Examine the capacitors for leakage or oozing. Replace if needed.

6. Examine the wrap-around and side covers for dents and breakage. Repair them as needed. The covers must be kept in good condition to assure that high voltage parts are protected and that correct spacings are maintained.

7. Remove welding cables and check the electrical ground continuity. Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case. The meter reading should be 500,000 ohms or more. If the meter reading is less than 500,000 ohms, check for electrical components that are not properly insulated from the case. Correct component insulation, if needed.

8. Reconnect the shunt and wire #467 to the negative (-) output terminal. Make sure the connection is tight.

9. Replace and secure the machine covers and handle bar.

10. Remove the overlay from the front panel of the machine. Clean the plastic case with a low pressure airstream. Wipe the sensors (Fig D.4 Item 8) with a clean, soft cloth. Make sure the sensors are not scratched in the process.

11. Check the back of the overlays. If the bar code (black square(s)) on the back of the overlay is scratched, apply a dull black spray finish to the scratched-off areas only. If a large area of the bar code is scratched off, the machine either will not recognize the overlay or will mistake the overlay for another one.

12. Inspect gun and cables for good condition.

MAINTENANCE

D-4 D-4

POWER W AVE 450

MAINTENANCE

D-5 D-5

POWER W AVE 450

RECOMMENDED TOOLS FOR INSTALLATION 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

• 5/32 allen socket

• medium blade slotted screwdriver

• large blade slotted screwdriver, 8 inches long

minimum

• two 7/16 open or box end wrenches

• one 7/8 open or box end wrench

• needlenose pliers

• two 10 inch long adjustable wrenches

• wire cutter

• molex pin removal tools

• tape measure

• small mechanic’s mirror

• flashlight

• dental pick

• digital multimeter (DMM)

G3503-[ ] INSTALLATION OR SER-

VICE TOOL USAGE

Fastener Usage Qty. Tool

Shroud to cooler base 4 all use 5/16 hex screw and 3/8 hex Quick Disconnect (QD) bracket 2 nut. Relay may require large blade Heat exchanger to cooler base 2 slotted screwdriver 8 in.long min. Relay to cooler base 2

Screw to 4 3 mm allen wrench (G3503 only) fasten reservoir to cooler base 5/16 Hex Socket (G3503-1 only)

Hose Clamp 10 1/4 hex or medium slotted screwdriver Fan set screw 1 5/32 allen socket with wrench and 4

in. min. extension Pump carbonator clamp screw 1 5/16 hex socket with ratchet wrench Motor mounting bolts 4 two 7/16 open or box end wrenches Motor access door 2 1/4 hex socket with wrench Motor harness ground at motor 1 1/4 hex socket with wrench

terminals 2 needlenose pliers relay terminals 1 and 2 2 large blade slotted screwdriver 8 in.

minimum long. relay terminals 3 and 4 2 medium slotted screwdriver All plumbing components N/R two 10 inch adjustable wrenches

REMOVING AND INSTALLING THE G3503-[ ] COOLER

1. Preparation:

• Always switch off the Power Wave machine power.

• Always disconnect the Power Wave machine from service input power.

2. Remove cooler assembly G3503-[ ]: a. remove gas cylinder(s) from tray. b.remove cooler access panel. c. Remove both fasteners from base that hold cool-

er in place. Remove ground lead, if present. Carefully pull cooler assembly rearward, until cooler’s Molex connectors are visible.

d. disconnect cooler’s connectors from the P3 and

P4 harnesses. Continue pulling the cooler out of the Power Wave.

3. If necessar y, perform per iodic maintenance or ser-

vice on the cooler.

4. Reinstall cooler by reversing tasks in step 2.Be sure

to reattach ground lead, if previously removed.

5. If necessary , fill cooler with selected coolant to spec-

ified level (see Fig.1).

6. Attach desired water-cooled accessory (gun and

wire feeder or TIG torch) to cooler’s QDs.

7. Reconnect service input power to the Power Wave:

• verify that the reconnect panel setting and lead placement match the service voltage.

8. Prime the cooler: a. Install the Set-up overlay. b.Keep accessories’ hose lengths horizontal,

either coiled or straight, and no higher than 4

feet of the specified coolant level (Fig. 1). c. Switch on the Power Wave machine. d. Press the "WATER COOLER ENABLE" button

so that the "WATER COOLER ENABLED" light is illuminated .

e. Press the "PRIME WATER COOLER" button

until the "WATER COOLER PRESSURE" light is steadily illuminated.

9. Check coolant level. Add more if required.

MAINTENANCE

D-6 D-6

G3503-[ ] COOLER PERIODIC MAINTENANCE

1. Preparation:

• Always switch off the Power Wave machine power.

• Always disconnect the Power Wave machine from

service input power.

• Do not remove the pump relief valve’s 3/4 in. acorn hex nut or attempt to adjust the relief valve setting.

2. Remove the G3503-[ ] cooler from the Power Wave machine.

3. Clean the pump’s inlet strainer:

• Drain the reservoir of coolant and dispose of it in an environmentally responsible manner (see Recommended Coolants).

• Place absorbent towels underneath pump head.

• Hold pump head to apply countertorque when loos-

ening strainer’s 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head.

• Gently rinse strainer under running water to thoroughly clean it.

• Use the mirror to inspect inside of pump for contamination. Carefully remove hardened debris with dental pick if necessary, without scratching inside of the pump.

• Reinstall strainer and acorn nut, tightening with 75±15 in.-lbs.of torque.Wipe dry all areas wetted by coolant. Dispose of towels in an environmentally responsible manner (see Recommended Coolants).

4. Gently rinse the reservoir’s strainer under running water to thoroughly clean it.

5. Remove fan shroud and inspect hoses and electrical harnesses for kinking or damage (cut, abrasion, swelling, etc.). Replace if necessar y.

6. Remove accumulated dust from cooler, especially from the motor and heat exchanger, by blowing it off with shop air or vacuuming it out.

• The heat exchanger fins are sharp but can be easily bent. Treat them with care to avoid personal injury and damaging them.

• Remove the cooler from the machine for a more thorough cleaning job.

7. Motor lubrication is recommended once a year:

• Remove plug over lube port at top of motor near fan end.

• Add 20 drops of electric motor or SAE 10 oil then reinstall plug.

8. Flush coolant from the system and replace with fresh, recommended coolant at least once a year. More frequent flushing may be necessary, depending upon a user’s particular system or its usage.

NOTE: Never run the pump dry. Always use a recommended

coolant, otherwise pump damage may result.

9. Reinstall the G3503-[ ] cooler into the Power Wave machine.

G3503-[ ] COOLER SERVICE

1. Preparation:

• Always switch off the Power Wave machine power.

• Always disconnect the Power Wave machine from

service input power.

• Do not remove the pump relief valve’s 3/4 in. acorn hex nut or attempt to adjust the relief valve setting.

2. Remove the G3503-[ ] cooler from the Power Wave machine whenever:

• replacing major cooler components (i.e. pump, motor, heat exchanger, etc.).

• replacing hoses and electrical harnesses that are kinked or damaged (cut, abraded, deteriorated or swollen, etc.).

• investigating suspect coolant leakage.

3. Pump replacement: a. Drain the reservoir of coolant and dispose of it in an

environmentally responsible manner (see

Recommended Coolants). b.Remove fan shroud. c. Place absorbent towels underneath pump head and

wherever coolant system is opened. d. Carefully pull pump inlet hose and its elbow from

reservoir (bottom). e. Loosen pump outlet hose clamp at QD then carefully

remove from fitting. f.Disconnect v-band clamp from motor and remove

pump:

• Do not drop or lose drive coupling between pump and motor.

• 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.

• Pump body is properly oriented with its strainer at

the 6:00 position.

• Tighten v-clamp with 15 to 30 in-lbs.of torque.

h. Attach coolant lines to QD and reser voir. i.Wipe dry all areas wetted by coolant. Dispose of tow-

els in an environmentally responsible manner (see Recommended Coolants).

j. Reinstall cooler into machine.

4. Motor removal or replacement:

• Do not reuse the 4 internal-tooth star washers. Replace with new parts..

5. Installing the fan:

• Slide onto motor shaft until the fan is located between 0.25 to 0.50 inches from the heat exchanger.

• Tighten set screw with 65 to 75 in-lbs of torque against motor shaft’s flat.

• Fan rotation is counterclockwise, as viewed from fan-end of motor’s shaft.

• Fan pulls air through the heat exchanger, blows it over the motor, then exhausts it through the reservoir.

MAINTENANCE

D-7 D-7

POWER W AVE 450

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)

TROUBLESHOOTING

E-1 E-1

POWER W AVE 450

HOW TO USE TROUBLESHOOTING GUIDE

This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.

CAUTION

WARNING

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 Ser vice Facility for technical assistance.

This Troubleshooting Guide is provided to help you lo-cate and correct possible machine misadjustments. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM)

Look under the column labeled “PROBLEM (SYMP-TOMS).” This column describes possible symptoms that your machine may e xhibit.Find the listing that best describes the symptom that your machine is exhibiting.

Step 2. PERFORM EXTERNAL RECOMMENDED TESTS

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external pos-sibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In gen-eral, these tests can be conducted without removing the case wraparound cover.

Step 3. CONSULT LOCAL AUTHORIZED FIELD SERVICE FACILITY

If you have exhausted all of the recommended tests in step 2, consult your local Authorized Field Service Facility.

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

Machine is dead – no output – no fans – no displays.

Machine has no output – fans are running – display is on – a “clicking” sound is heard coming from the machine.

1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.

1. Make certain that the input power switch (S1) is in the “ON” position.

2. Check for proper input voltage – must match the rating on the machine nameplate.

3. Make certain the reconnect panel is configured properly for the applied voltage.

4. Check fuse (F1) in the reconnect panel. If faulty, replace with 5-amp slow-blow fuse.

1. Turn power OFF immediately.

2. Check for proper input voltage (per machine nameplate).

3. Make certain the reconnect panel is configured properly for the applied voltage.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-2 E-2

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Machine has no output – no fans – no display. Main input fuses are open, indicating excessive input current draw.

Machine has no output – no display – fans run.

Machine has no output – no display – fans run – circuit breaker (5-amp) repeatedly trips.

1. Check for proper input voltage connections.

2. Make certain the reconnect panel is configured properly for the applied voltage.

3. Replace the input fuses with proper size and ratings.If the fuses fail again, contact your local Lincoln Authorized Field Service Facility.

1. Check circuit breaker (5-amp) located on the front panel. Reset if necessary.

1. Remove the feeder control cable from the machine. If symptoms disappear, feeder or control cable is faulty.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-3 E-3

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Machine has no output – fans run – display is on.

Machine regularly overheats – yellow light (LED) on the front panel glows, indicating a thermal overload. The fans run and the display is on.

1. Make sure that the machine was powered up with a properly installed overlay. (With no overlay on the machine or an invalid overlay, the machine will have no output.)

2. Check to see if the Limits or Setup overlay is installed on the front panel. These two overlays can not be used for welding.

3. Check for proper input voltage (per machine nameplate).

4. Make certain the reconnect panel is configured properly.

5. Check that when the trigger is pulled on the wire feeder, the wire feeder’s voltage display changes to indicate arc voltage. If this does not happen, feeder may be faulty.

6. Check feeder control cable for loose or faulty connections.

7. If the machine is connected for 380 VAC or higher and has not been used for a long period of time, the capacitors may require “conditioning.” Let the machine run at an idle state (no load) for 30 minutes.

1. Welding application may exceed recommended duty cycle.

2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maintenance Section of this manual.

3. Air intake and exhaust louvers may be blocked due to inadequate clearance around machine.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-4 E-4

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The voltage and/or wire feed speed will not adjust to user satisfaction.

The voltage and/or wire feed speed can be adjusted on the wire feeder but the changes are not shown on the Power Wave.

The Dual Procedure overlay is installed.The user cannot change from procedure “A” to procedure “B, ”or vice versa.

The display can not be seen clearly or can not be seen at all.

1. Certain limits may have been imposed on the welding parameters. Refer to the Limits Overlay section in the Operations section of this manual to change the set limits.

1.When the Limits Overlay or the Setup Overlay is placed on the machine, the Power Wave’s and feeder’s displays do not match. These overlays can not be used for welding.

2. If two wire feeders are connected to the Power Wave, only one of the feeder’s settings can be dis- played on the Power Wave at one time. Pull the tr ig-ger of the wire feeder whose settings you want displayed on the Power Wave.

1. Check for proper installation of the Dual Procedure overlay.

2. Check the Dual Procedure Gun Trigger or separate Dual Procedure switch.

1. Adjust the viewing angle of the display. Follow the instructions provided in the Operation Section of this manual. (Look under the “LCD DISPLAY ADJUSTMENT” in the “CONTROLS AND SETTINGS” sub-section of the Operation section.)

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-5 E-5

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Machine does not respond to keys being pressed, or the machine has improper displays.

Machine display reads “Error Invalid Overlay,” or it displays an incorrect overlay ID number on power-up.

Machine displays “ERROR: S.L. NOT INITIALIZED” on power-up.

1. Each time an overlay is changed make certain that the machine is powered-up with the new overlay in place.

2. Make certain that the correct overlay ID number is displayed on power-up.Refer to the Operation Section of this manual.

3. In some cases, some of the keys on the overlay may be locked out. Refer to the Operation Section of this manual for the overlay descriptions.

1. Make certain the overlay is installed properly.

2. Inspect the overlay bar code sensors on the front panel (Fig 17 Item 8). If they are dirty, blow them out with low pressure air and clean with soft cloth.

3. Inspect for damage to the Bar Code(s) on the back of the overlay.

1. Contact your local Lincoln authorized Field Service Facility for Technical assistance.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-6 E-6

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

The Beeper (Piezoelectric Buzzer) cannot be heard – machine operating normally.

The welding parameters that were saved in memory are different when recalled.

The water cooler does not turn on.

The machine beeps without the

keys being pressed.

1. Background noise may be too loud for user to hear beeper.

1. Make certain that a remote control unit is not connected.When a remote control unit is used, the weld parameters are set by the remote control potentiometers.

1. Make sure that the water cooler has been enabled. Refer to the Setup Overlay description in the Operation Section of this manual.

2.The cooler’s circuit breaker may have tripped.

3. If the water cooler is enabled but generates insufficient coolant flow rate, the machine will beep loudly and the water cooler will shut down. In this case, prime the water cooler. Refer to the Setup Overlay description in the Operation Section of this manual.

If the water cooler is enabled and the flow switch inside the water cooler opens (due to inadequate coolant flow rate), the machine indicates this by beeping.This happens regardless of the overlay placed on the machine. In this case do the following:

1.Turn the machine off and on a couple of times and see if the beeping continues. If the flow rate dropped momentarily then turning the machine off and on eliminates the beeping. A momentary drop in flow rate could be due to someone stepping on the water cooler hose, for example.

2 Check the water cooler and accessory hoses for kinks, internal obstructions or blockage, or ruptures. If such problems were found then correct them and turn the machine off and on to check if the beeping has been eliminated.

3. Check the water cooler fluid level. Low coolant level could cause the flow rate to drop.

4. Prime the water cooler.Refer to the Setup Overlay section of this manual for instructions.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-7 E-7

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Machine loses output while welding. Fans and display are functioning properly.

For no apparent reason the weld characteristics have changed.

Machine often “noodle welds” with a particular procedure.

1. Check for proper input voltages (per machine nameplate).

2. Check for balanced three-phase input supply voltage.

3. Check electrode and work cables for loose or poor connections.

1. Check for proper wire feed speed setting. In the MIG/ MAG and FCAW Modes, check for proper voltage settings.In the MIG/MAG Pulse Modes, check the arc length trim setting.These controls are on the wire feeder.

2. Check for proper shielding gas and gas flow.

3. Check for loose or faulty welding cables.

1.The machine may be trying to deliver too much power.When the average output current exceeds a maximum limit, the peak current is drastically cut back. Lower the welding parameter settings and/or increase the stickout length to eliminate this problem.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-8 E-8

POWER W AVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

WIRING DIAGRAMS

F-1 F-1

POWER W AVE 450

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.

WIRING DIAGRAM - CODE 10607 (200/230/400/460 V)

(TOP)

LOAD

LINE

SW1

POWER

LCD

DISPLAY

N.E.

KEYPAD

FRONT OF MACHINE

TO J62

467

WORK

FOOT AMPTROL/ REMOTE CONTROL RECEPTACLE

5A CIRCUIT BREAKER

MAIN CHOKE

ELECTRODE

DISPLAY BOARD CONTROL BOARD PROTECTION BOARD

J10

TO FUSE

321B

321A

TO J30

H1B

H1 TO

TO CR1

TERM STRIP

L3A

L1A

J11

J12

N.D.

J13

J14

TO J19

J15

J16

J17

TO J18

J18

J19

BUS BAR #1

400A

SHUNT

177A

176A

175A 105B

D E

102C

TO J15

TO J33

32A

TO P70

PROTECTION BD (SQUARE WAVE)

499

TO J60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

1 2 3 4

1 2 3 4 5 6

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TO OUTPUT

RECTIFIER

TO J93

750

277

76 291 292 276 275 294

453

454

455 456

371

374

372

373

261 262 264 266 265 263

300 301

448 443 442

444 449 445 446 447

302

303

306 307

SHUNT AMPLIFIER

300

301

TO S3, S4 CONNECTION

BOARD

213

23415

J50

TO P82 P83 J92

TO J37

J26

TO PIEZO

BUZZER

J44

P81

KEYPAD

LCD

PIEZO

BUZZER

201

202

203

3 4

J20

5 6 7 8

1 2 3 4

J21

7 8

1 2 3 4 5 6

J22

7 8

9 10 11 12

J23

5 6

J24

9 10 11 12 13 14

J25

9 10

J26

J27

J28

204 205 206 207 208

211 212 213

215

221

5W 5R

226 227

223 224 225

232 233 234 235 236

PLANE #1 PLANE #2

J61

J30

TO J36 J50

TO J42 J44

TO J39

RECT. THERM

SWITCH THERM

J31

J32

J33

J34

261 262

263

J14

264 265 266

111A

P83

112A

117A

P82

118A

J35

J36

J37

J38

J39

TO F3,F4,

205

56789

J61

291 292 293 294

296

177A 176A 175A 102C

105B

R11, WORK

J20

461

201

462

202

207

203

206

2341567

TO J10,J38

TO P1

J21

TO J62

TO P82, P83,

ELECTRODE

499

204

221A

167A

121314

SNUBBER BD

208

234

1 2 3 4 5 6

1 2 3 4 5 6 7 8

121A

234

567

J60

462

R11 40

100W

TO J62

464

J92

J93

212

PROTECTION BD (SQUARE WAVE)

HXB

COOLER CIRCUIT BREAKER

HXA

WATER COOLER

TERM STRIP

H1A

GND

234

WATER COOLER

N.D.

321A

1 2 3 4 5

H1B

6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6

1 2 3 4

464

467

GROUND

SW1

CR1

12K

RECONNECT

SWITCH

12J

321

323

CR1

324

P71

326

32A

333

C. BREAKER

334

P70

336

31C

42C

102D

32D

32E

106A

P82

31B

P83

42B

102B

32B 32C

105A

351

J43

356

361 362

211

J21

215

371 372

J12

373

J13

374

293 296

J92

234 232

J23

233

12E 12L

J62

401

12F

N.D.

TO J11

453

454

455

456

HXB

345

456A

455A

454A

453A

234

403

P3P4

POWER BOARD

J40

J41

J42

J43

J44

9E 9L

402

404

2 3 4 5

7 8

9 10 11 12 13 14 15 16

5 6

9 10 11 12 13 14 15 16

5 6

9 10 11 12

TO R9

R2 25 25W

TO SWITCH BD #2

R4 25 25W

TO SWITCH BD #2

GROUNDGROUND

TO SWITCH BD #1 TO SWITCH BD #1

TO R9

25W

TO SWITCH BD #1 TO SWITCH BD #1

TO SWITCH BD #2

R3 25 25W

TO SWITCH BD #2

SWITCH

4R 3W

BDS

3 & 4

1W 1R

SWITCH

2R 1W

BDS

1 & 2

J22

J35

J16

J22

BUS

BAR #1

SHUNT

9L TO R2

12L TO R1

N.B.

OUTPUT

RECTIFIER

7.5K 25W

2W 2R

221 226

227 223 224 225

356

351

442

443 5W 5R

444

445

446

447

448

449

12M TO R10

R5 25 25W

405

TO SWITCH BD #3 TO SWITCH BD #3

TO SWITCH BD #4 TO SWITCH BD #4

12H

R7 25 25W

TO SWITCH BD #4 TO SWITCH BD #4

407

C12

R12

C13

R13

10 2W.0047/400V

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

F3,F4 CONN.

CONNECTION FOR

S3,S4

CONN.

D7-D10 LEAD 461 TO CHOKE

CONNECTION FOR F3,F4 D1-D6

S1,S2 CONN.

CONNECTION FOR S1,S2 D11-D14

CONNECTION FOR

F1,F2

CONN.

D15-D20

C16

C15

12M

TO SWITCH THERM

R16

R15

10 2W.0047/400V

TO R6

R10

7.5K 25W

TO R5

237

235

TO J23

- TO J62

TO SWITCH BD #312G TO SWITCH BD #3

TO R10

R6 25 25W

406

R8 25 25W

408

RECT.

THERM

LEFT SIDE OF MACHINE

THIS AREA VIEWED FROM LEFT SIDE OF MACHINE

(MACHINE SHOWN CONNECTED FOR 440-460V)

H2 TO TERM STRIP

H3 TO TERM STRIP

H4 TO TERM STRIP

H5 TO TERM STRIP

9A TO SWITCH BD #1 9B TO SWITCH BD #2 9K TO J31 POS TO INPUT RECT. POS TO INPUT RECT.

12J TO J31

12A TO SWITCH BD #1 12B TO SWITCH BD #2

RECONNECT SWITCH

MAIN TRANSFORMER LEFT SIDE

SECONDARY

(TOP)

SECONDARY

(BOTTOM)

SECONDARY

(TOP)

SECONDARY

(BOTTOM)

PRIMARY

(TOP)

PRIMARY (BOTTOM)

PRIMARY

(TOP)

PRIMARY (BOTTOM)

RIGHT SIDE

'A'

ON OFFOFF

TO SWITCH BD #3

TO SWITCH BD #4

CURRENT

TRANSFORMER

4T 4B 1T 1B

(TO SWITCH BDS)

4T 4B 1T 1B

(FROM TRANSFORMER)

TO SWITCH BD #1

TO SWITCH BD #2

200-208V 220-230V 380-415V 440-460V

VOLTAGE=380-460VVOLTAGE=200-230V

TO CT

TO SW1

321B

F1 5A SLOW BLOW FUSE

9C TO SWITCH BD #3 9D TO SWITCH BD #4

9J TO J31

12C TO SWITCH BD #3 12D TO SWITCH BD #4 12K TO J31 NEG TO INPUT RECT. NEG TO INPUT RECT.

J40

TO R6

TO PRIMARY

TO REC. SWITCH

TO R5

TO REC. SWITCH

TO R6

TO CT

TO R5

J40

TO R8

TO PRIMARY

TO REC. SWITCH

TO R7

TO REC. SWITCH

TO R8

TO CT

TO R7

J40

TO J36

361

362

J41

TO R1

TO PRIMARY

TO REC. SWITCH

TO R2

TO REC. SWITCH

TO R1

TO CT

TO R2

J41

TO R3

TO PRIMARY

TO REC. SWITCH

TO R4

TO REC. SWITCH

TO R3

TO CT

TO R4

J41

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED

CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.

D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET. D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.

N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.

N.D. THESE ITEMS ARE ONLY USED ON A 450 MACHINE

WITH A WATER COOLER.

N.E. TOROID DOES NOT APPEAR ON EARLIER MODELS.

TO SW1

TO J30

406

3T 12C 12G

405

408

3B 12D 12H

407

401

9E 12A 12E

402

403

9F 12B 12F

404

L1A

3W 3R

4R 4W

3W 3R

1R 1W

2W 2R

TP4

TP5

AC1 AC3

POS

LEFT TOP

406

12C

405

4R 4W

SWITCH BOARD #3

LEFT BOTTOM

408

12D

407

SWITCH BOARD #4

RIGHT TOP

401

12A

402

SWITCH BOARD #1

RIGHT BOTTOM

403

12B

404

SWITCH BOARD #2

RIGHT SIDE OF MACHINE

TO SW1

L3A

T2 T3

TP6

AC2

NEG NEG

TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE.

CR1

INPUT

RECTIFIER

NEGPOS

N.C.

SWITCH

THERM

TO J23

TO RECT. THERM 237

N.C.

J12,J13,J15 J27,J28,J36 J37,J38,J39 J43

123413

J16,J22,J42,J44 J24,J31,J34 J10,J19,J30,J40,J41,J60

TO J17

TO J32

324

TO J32

236

326

J10

J28

J34

J60

J10

J27

J34

J60

BOTTOM FAN

TO REC. SWITCH

BOTTOM FAN

TO REC. SWITCH

AUXILIARY TRANSFORMER

334

333

336

P70

J3,J4 J14,J23,J26

J11,J20,J21

J32,J33,J35 J50,J92 J62,J93

J33

C. BREAKER

CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

ELECTRICAL SYMBOLS PER E1537

TO TERM STRIP

TOP FAN

TO SW1

TOP FAN

(24V)

(42V)

(115V)

117A (R) 118A (W)

111A (R) 112A (W)

302 306

303 307

CONNECTOR

32D

102D

106A

277

276

275

221A

32E

31C

42C

K L M N

167A

WIRE FEEDER

RECEPTACLE #2

32B

102B

105A

121A

32C

31B

42B

L M N

WIRE FEEDER

RECEPTACLE #1

ELECTRODE+

TERMINAL STRIP

(24V)

(440-460)

(380-415)

(220-230)

(200-208)

J17,J18,J25,J61

610

1 2 3 4 5 6 7 8

N.D.

RS232

TO P73

TO P4

TO P73

TO P4

TO P73

P71

P73

BOTTOM

H1A

HXA

P81

P82

P83

TOP FAN

FAN

321

323

8-28-98B

G3617-1

REAR OF MACHINE

J32

TO TERM STRIP

WIRING DIAGRAMS

F-2 F-2

POWER W AVE 450

WIRING DIAGRAM - CODE 10610 (460/575V)

Enhanced Diagram

(TOP)

LOAD

LINE

SW1

POWER

LCD

DISPLAY

KEYPAD

FRONT OF MACHINE

TO J62

467

WORK

FOOT AMPTROL/ REMOTE CONTROL RECEPTACLE

5A CIRCUIT BREAKER

MAIN CHOKE

ELECTRODE

DISPLAY BOARD CONTROL BOARD PROTECTION BOARD

J10

TO FUSE

321B

321A

TO J30

H1B

TO CR1

TERM STRIP

L3A

L1A

J11

J12

N.D.

J13

J14

TO J19

J15

J16

J17

TO J18

J18

J19

BUS BAR #1

400A

SHUNT

177A

176A

175A 105B

D E

102C

TO J15

TO J33

32A

TO P70

PROTECTION BD (SQUARE WAVE)

499

TO J60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

1 2 3 4

1 2 3 4 5 6

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TO OUTPUT RECTIFIER

TO J93

300

301

750

277

76 291 292 276 275 294

453

454

455 456

371

374

372

373

261 262 264 266 265 263

300 301

BUZZER

448 443 442

444 449 445 446 447

302

303

306 307

KEYPAD

23415

J50

SHUNT AMPLIFIER

BOARD

TO S3, S4 CONNECTION

TO P82 P83

J92

J37

J26

TO PIEZO

J44

P81

LCD

TO J21

PIEZO BUZZER

201

202

203

3 4

J20

5 6 7 8

1 2 3 4

J21

5 6 7 8

1 2 3 4 5 6

J22

7 8 9 10 11 12

1 2 3

J23

4 5 6

1 2 3 4 5 6 7

J24

8 9 10 11 12 13 14

1 2 3 4 5

J25

6 7 8 9 10

1 2 3

J26

4 5 6

1 2

J27

3 4

1 2

J28

3 4

204 205 206 207 208

211 212 213

215

221

5W 5R

226 227

223 224 225

232 233 234 235 236

PLANE #1 PLANE #2

J61

J30

TO J36 J50

TO J42 J44

TO J39

RECT. THERM

SWITCH THERM

J31

J32

J33

J34

261 262

263

J14

264 265 266

111A

P83

112A

117A

P82

118A

J35

J36

J37

J38

J39

TO F3,F4,

R11, WORK

J20

212

TO P82, P83,

213

ELECTRODE

TO J62

499

204

221A

167A

121314

SNUBBER BD

HXB

COOLER CIRCUIT

BREAKER

1 2 3 4 5 6

1 2 3 4 5 6 7 8

HXA

208

234

WATER COOLER

121A

234

567

J60

462

R11 40

100W

TO J62

464

J92

J93

PROTECTION BD (SQUARE WAVE)

N.D.

205

56789

J61

291 292 293 294

296

177A 176A 175A 102C

105B

TERM

STRIP

201

202

207

461

462

203

206

2341567

TO J10,J38

TO P1

H1A

GND

234

WATER COOLER

321A

1 2 3 4 5

H1B

6 7 8

9 10 11 12 13 14 15 16

9 10 11 12 13 14

464

467

GROUND

SW1

CR1

12K

RECONNECT

SWITCH

12J

321

323

CR1

324

P71

326

32A

333

C. BREAKER

334

P70

336

31C

42C

102D

32D

32E

106A

P82

31B

P83

42B

102B

32B 32C

105A

351

J43

356

361 362

211

J21

215

371 372

J12

373

J13

374

293 296

J92

234 232

J23

233

12E 12L

J62

401

12F

N.D.

TO J11

453

454

455

456

HXB

345

456A

455A

454A

453A

234

403

POWER BOARD

J40

J41

J42

J43

J44

9E 9L

402

404

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12

9 10 11 12

TO R9

R2 25

25W

TO SWITCH BD #2

R4 25 25W

TO SWITCH BD #2

GROUNDGROUND

TO SWITCH BD #1 TO SWITCH BD #1

TO R9

R1 25 25W

TO SWITCH BD #1 TO SWITCH BD #1

TO SWITCH BD #2

R3 25 25W

TO SWITCH BD #2

SWITCH

4R 3W

BDS

3 & 4

1W 1R

SWITCH

2R 1W

BDS

1 & 2

J22

J35

J16

J22

BUS

BAR #1

SHUNT

9L TO R2

12L TO R1

N.B.

OUTPUT

RECTIFIER

7.5K

25W

2W 2R

221 226

227 223 224 225

356

351

442

443 5W 5R

444

445

446

447

448

449

12M TO R10

R5 25

25W

TO SWITCH BD #3 TO SWITCH BD #3

405

TO SWITCH BD #4 TO SWITCH BD #4

12H

R7 25

25W

TO SWITCH BD #4 TO SWITCH BD #4

407

C12

R12

C13

R13

10 2W.0047/400V

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

F3,F4 CONN.

CONNECTION FOR

S3,S4

CONN.

D7-D10

LEAD 461

TO CHOKE

CONNECTION FOR F3,F4 D1-D6

S1,S2 CONN.

CONNECTION FOR S1,S2

D11-D14

CONNECTION FOR

F1,F2

CONN.

D15-D20

C16

C15

12M

TO SWITCH THERM

R16

R15

10 2W.0047/400V

TO R6

R10

7.5K 25W

TO R5

237

235

TO J23

- TO J62

TO SWITCH BD #312G TO SWITCH BD #3

TO R10

R6 25 25W

406

R8 25 25W

408

RECT.

THERM

LEFT SIDE OF MACHINE

THIS AREA VIEWED FROM LEFT SIDE OF MACHINE

(MACHINE SHOWN CONNECTED FOR 575V)

H3 TO TERM STRIP

H4 TO TERM STRIP

RECONNECT SWITCH

AIS TO PRI. TOP

BIS TO PRI. BOTTOM

AIS TO PRI. TOP

BIS TO PRI. BOTTOM

CIS TO PRI. BOTTOM

DIS TO PRI. TOP

CIS TO PRI. BOTTOM

DIS TO PRI. TOP

VOLTAGE=460V VOLTAGE=575V

MAIN TRANSFORMER LEFT SIDE

SECONDARY

(BOTTOM)

(TOP)

PRIMARY

(TOP)

PRIMARY

(BOTTOM)

(BOTTOM)(BOTTOM)

PRIMARY

(TOP)

PRIMARY

(BOTTOM)

RIGHT SIDE

'A'

OFF

TO SWITCH BD #3

TO SWITCH BD #4

CURRENT

TRANSFORMER

4T 4B 1T 1B

(TO SWITCH BDS)

4T 4B 1T 1B

(FROM TRANSFORMER)

TO SWITCH BD #1

TO SWITCH BD #2

460V 575V

AOT TO PRI. TOP

BOT TO PRI. BOTTOM

AOF TO PRI. TOP

BOF TO PRI. BOTTOM

COT TO PRI. BOTTOM

DOT TO PRI. TOP

COF TO PRI. BOTTOM

DOF TO PRI. TOP

AOT

AOF

AIS

TO CT

BOT

BOF

BIS

TO CT

TO J36

TO CT

DOT

DOF

DIS

TO CT

COT

COF

TO REC. SWITCH

CIS

TO SW1

321B

F1 5A SLOW BLOW FUSE

12J

J31

12A

SW.BD.#1

12B

SW.BD.#2

SW.BD.#3

TO PRIMARY

TO CT

TO R6

TO R5

SW.BD.#4

J40

REC.

SWITCH

TO INPUT RECT.

TO BOLT CONN.

REC.

SWITCH

TO R8

TO PRIMARY

TO INPUT RECT.

TO R7

TO BOLT CONN.

TO R8

TO CT

TO R7

J40

361

362

J41

TO R1

TO PRIMARY

TO INPUT RECT.

TO R2

TO BOLT CONN.

TO R1

TO CT

TO R2

J41

REC.

SWITCH

TO R3

TO PRIMARY

TO INPUT RECT.

TO R4

TO BOLT CONN.

TO R3

TO CT

TO R4

J41

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED

CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.

D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET. D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.

N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.

N.D. THESE ITEMS ARE ONLY USED ON A 450 MACHINE

WITH A WATER COOLER.

TO SW1

406

12C 12G

405

408

12D 12H

407

401

12A 12E

402

403

12B 12F

404

TO J30

9C 9G

9D 9H

9A 9E

L1A

3W 3R

4R 4W

3W 3R

1R 1W

2W 2R

TP4

TP5

AC1 AC3

POS NEG NEG

J31

SW.BD.#1 SW.BD.#2

LEFT TOP

406

12C

405

4R 4W

SWITCH BOARD #3

LEFT BOTTOM

408

12D

407

SWITCH BOARD #4

RIGHT TOP

401

12A

402

SWITCH BOARD #1

RIGHT BOTTOM

403

12B

404

SWITCH BOARD #2

RIGHT SIDE OF MACHINE

TO SW1

L3A

T2 T3

TP6

AC2

TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE.

TO J32

324

CR1

326

TO J32

INPUT

RECTIFIER

12D

J31

12C

12K

SW.BD.#3 SW.BD.#4

N.C.

SWITCH

THERM

TO J23

236

TO RECT. THERM 237

N.C.

J33

C. BREAKER

J12,J13,J15 J27,J28,J36 J37,J38,J39 J43

123413

J16,J22,J42,J44 J24,J31,J34 J10,J19,J30,J40,J41,J60

302

306

TO J17

303 307

32D

102D 106A

277 276

J10

275

J28

221A

32E

J34

31C

J60

42C 117A (R) 118A (W)

167A

32B

102B

105A

J10

J27

J34

121A

32C

J60

31B

42B 111A (R) 112A (W)

TO TERM STRIP

TERMINAL STRIP

TOP FAN

BOTTOM FAN

TO SW1

TOP FAN

BOTTOM FAN

TO REC. SWITCH

AUXILIARY TRANSFORMER

334

(24V)

333

(42V)

336

(115V)

P70

J3,J4 J14,J23,J26

J11,J20,J21

J32,J33,J35 J50,J92 J62,J93

CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

ELECTRICAL SYMBOLS PER E1537

1 2 3 4 5 6 7 8

RS232

CONNECTOR

A B

C D E F G H I J K L M N

WIRE FEEDER

RECEPTACLE #2

A B

C D E F G H I J K L M N

WIRE FEEDER

RECEPTACLE #1

ELECTRODE+

TOP FAN

BOTTOM

FAN

TO P73

TO P4

H1A

N.D.

TO P73

TO P4

HXA

N.D.

TO P73

(24V)

P71

P73

J17,J18,J25,J61

610

P81

P82

P83

321

J32

323

(575)

TERM

STRIP

(460)

(230)

8-28-98B

G3617-4

REAR OF MACHINE

WIRING DIAGRAMS

F-3 F-3

POWER W AVE 450

WIRING DIAGRAM - CODE 10520 (Œ)

Enhanced Diagram

(TOP)

LOAD

LINE

SW1

POWER

LCD

DISPLAY

N.E.

KEYPAD

.05uF 600V

.0047uF 1400V

C10

.0047uF 1400V

C11

FRONT OF MACHINE

.0047uF 1400V

C12

TO J62

400A

J50

SHUNT AMPLIFIER

BOARD

A B C D

E F

.05uF 600V

.0047uF 1400V

SHUNT

1 2 3 4 5 6

WORK

FOOT AMPTROL/REMOTE CONTROL RECEPTACLE

5A CIRCUIT BREAKER

ELECTRODE

DISPLAY BOARD CONTROL BOARD PROTECTION BOARD

J10

TO FUSE

321B

321A

TO J30

H1B

TO CR1

TERM STRIP

L3A

L1A

J11

J12

N.D.

J13

J14

TO J19

J15

J16

J17

TO J18

J18

J19

467

216

213

J21

218

212

177A 176A

TO J93

175A 105B 102C

TO J33

32A

TO P70

499

TO J60

PROTECTION BD (SQUARE WAVE)

750

277

291

292

276

275

294

11 12 13 14 15 16

453

454

455

456

371 3 4

374

372

2 3

373

261

262

264

266

265

263

300 2

301 3 4

448 2

443 3

442 4 5 6

444 7

449 8

445 9

446

447 11

302

1 2 3

303

4 5 6

306

7 8

307 9

1 2 3 4 5 6 7 8 9

12 13 14 15 16

TO OUTPUT

BUS BAR #1

RECTIFIER

TO S3, S4 CONNECTION

MAIN

CHOKE

P82 P83 J92

PIEZO

BUZZER

KEYPAD

J20

J21

TO J3

J22

TO J37

J23

J37

J26

J24

J44

J25

J26

P81

J27

J28

LCD

300

TO J15

301

TO J62

462

R11 40

100W

TO J62

1 2 3 4 5 6 7 8

1 2 3 4 5

7 8

1 2 3 4 5 6 7 8

9 10 11 12

5 6

9 10 11 12 13 14

5 6

9 10

TO P82, P83,

ELECTRODE

464

201 202 203 204 205 206 207 208

211

212

213

215

216

218

221

5W 5R

226 227

223 224 225

232 233

RECT. THERM

234 235

SWITCH THERM

236

261 262 263 264 265 266

111A

112A

117A

118A

PIEZO BUZZER

499

121A

234

567

J60

J92

J93

PROTECTION BD (SQUARE WAVE)

321A

1 2

203

TO J10,J38

3 4 5

H1B

6 7 8

J30

9 10 11

C 12 13 14 15 16

12K 2 3 4 5 6 7

J31

8 9

9J 11 12

12J

321

1 2

323

J32

J33

J34

J35

J36

J37

J38

J39

TO F3,F4, R11, WORK

461

462

206

2341567

324

4 5

326

32A

333

334

4 5

336

31C 2 3

42C 4

102D

32D

5 6

32E 7

106A

31B 9

42B

102B

32B

32C

105A

351

1 2 3 4 5

356

361

362

211

215

371

372

373

374

1 2

293 3

296 4

234

232

233

464

467

GROUND

J62

TO P1

PLANE #1 PLANE #2

J61

TO J36 J50

TO J42 J44

TO J39

J14

P83

P82

J20

201

204

208

205

202

221A

167A

121314

SNUBBER BD

1 2 3 4 5 6

1 2 3 4 5 6 7 8

207

234

56789

J61

291 292 293 294

296

177A 176A 175A 102C

105B

N.D.

TO J11

H1A

453

454

455

456

H3A

234

WATER COOLER

234

WATER COOLER

TERM

STRIP

SW1

INPUT

RECTIFIER

RECONNECT

SWITCH

CR1

P71

C. BREAKER

P70

P82

P83

J43

J21

J12

J13

J92

J23

12E 12L TO R9

401

12F

403

SUBFRAME

FRONT

POWER BOARD

J40

J41

J42

J43

J44

BASE

9E 9L

402

404

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12

TO R9

R2 25 25W

TO SWITCH BD #2

R4 25 25W

TO SWITCH BD #2

SUBFRAME

STAND

GROUNDGROUND

TO SWITCH BD #1 TO SWITCH BD #1

25W

TO SWITCH BD #1 TO SWITCH BD #1

TO SWITCH BD #2

R3 25 25W

TO SWITCH BD #2

FRONT PANEL

4R 3W

1W 1R

2W 2R 1W 1R

2W 2R

5W 5R

SUBFRAME

221 226

227 223 224 225

356

351

442 443

444

445 446 447 448 449

REAR

SWITCH

BDS

3 & 4

SWITCH

BDS

1 & 2

J22

J35

J16

J22

BUS

BAR #1

SHUNT

9L TO R2

12L TO R1

REAR PANEL

N.B.

OUTPUT

RECTIFIER

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

7.5K 25W

C16

C15

LIFT BALE

12M TO R10

R5 25 25W

405

TO SWITCH BD #3 TO SWITCH BD #3

TO SWITCH BD #4 TO SWITCH BD #4

12H

R7 25 25W

TO SWITCH BD #4 TO SWITCH BD #4

407

C12

R12

C13

R13

10 2W.0047/400V

F3,F4 CONN.

S3,S4 CONN.

S1,S2 CONN.

F1,F2 CONN.

R16

R15

10 2W.0047/400V

TO R6

R10

7.5K 25W

12M

TO R5

RECONNECT

PANEL

CONNECTION FOR S3,S4 D7-D10 LEAD 461 TO CHOKE

CONNECTION FOR F3,F4 D1-D6

CONNECTION FOR S1,S2 D11-D14

CONNECTION FOR F1,F2 D15-D20

TO SWITCH THERM

237

235

TO J23

TRAY

- TO J62

TO SWITCH BD #312G TO SWITCH BD #3

TO R10

R6 25 25W

406

R8 25 25W

408

RECT.

THERM

LEFT SIDE OF MACHINE

THIS AREA VIEWED FROM LEFT SIDE OF MACHINE

(MACHINE SHOWN CONNECTED FOR 440V)

H2 TO TERM STRIP

H3 TO TERM STRIP

H4 TO TERM STRIP

H5 TO TERM STRIP

9A TO SWITCH BD #1 9B TO SWITCH BD #2 9K TO J31 POS TO INPUT RECT. POS TO INPUT RECT.

12J TO J31

12A TO SWITCH BD #1 12B TO SWITCH BD #2

RECONNECT SWITCH

MAIN TRANSFORMER LEFT SIDE

SECONDARY

(TOP)

SECONDARY

(BOTTOM)

SECONDARY

(TOP)

SECONDARY

(BOTTOM)

PRIMARY

(TOP)

PRIMARY (BOTTOM)

PRIMARY

(TOP)

PRIMARY (BOTTOM)

RIGHT SIDE

'A'

ON OFFOFF

TO SWITCH BD #3

TO SWITCH BD #4

CURRENT

TRANSFORMER

4T 4B 1T 1B

(TO SWITCH BDS)

4T 4B 1T 1B

(FROM TRANSFORMER)

TO SWITCH BD #1

TO SWITCH BD #2

200-208V

220-230V

380-415V

440V

VOLTAGE=380-440VVOLTAGE=200-230V

TO CT

TO SW1

321B

F1 5A SLOW BLOW FUSE

9C TO SWITCH BD #3 9D TO SWITCH BD #4

9J TO J31

12C TO SWITCH BD #3 12D TO SWITCH BD #4 12K TO J31 NEG TO INPUT RECT. NEG TO INPUT RECT.

TO R6

TO PRIMARY

TO REC. SWITCH

TO R5

TO REC. SWITCH

TO R6

TO CT

TO R5

TO R8

TO PRIMARY

TO REC. SWITCH

TO R7

TO REC. SWITCH

TO R8

TO CT

TO R7

361

TO J36

362

TO R1

TO PRIMARY

TO REC. SWITCH

TO R2

TO REC. SWITCH

TO R1

TO CT

TO R2

J41

TO R3

TO PRIMARY

TO REC. SWITCH

TO R4

TO REC. SWITCH

TO R3

TO CT

TO R4

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED

CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.

D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET. D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.

N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.

N.D. THESE ITEMS ARE NOT USED ON A 450 MACHINE

WITHOUT WATER COOLER.

N.E. TOROID DOES NOT APPEAR ON EARLIER MODELS.

TO SW1

L1A

UPPER

RECEPTACLE

.0047uF

C13

440V

TO J30

INPUT

RECTIFIER

J40

J41

406

12C 12G

12C

9C 9G

405

408

12D 12H

12D

9D 9H

407

401

12A

12E

402

403

12B

12F

404

RIGHT SIDE OF MACHINE

L3A

LOWER RECEPTACLE

.0047uF

C14

440V

L1B

INPUT LINE FILTER

TP4

TP5

AC1 AC3

POS

LEFT TOP

SWITCH BOARD #3

LEFT BOTTOM

SWITCH BOARD #4

RIGHT TOP

SWITCH BOARD #1

RIGHT BOTTOM

SWITCH BOARD #2

L3B

CR1

T2 T3

TP6

AC2

NEG NEG

NEG

N.C.

SWITCH

THERM

TO J23

236

TO RECT. THERM

237

N.C.

J33

C. BREAKER

J12,J13,J15 J27,J28,J36 J37,J38,J39 J43

123413

J16,J22,J42,J44 J24,J31,J34 J10,J19,J30,J40,J41,J60

TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE

TO J32

324

326

TO J32

TO J17

J10

J28

J34

J60

J10

J27

J34

J60

TO TERM STRIP

TOP FAN

BOTTOM FAN

TO SW1

TO REC. SWITCH

TOP FAN

BOTTOM FAN

TO REC. SWITCH

302 306

303 307

32D

102D 106A

277 276 275

221A

32E 31C

42C 117A (R) 118A (W)

167A

32B

102B 105A

77 76 75

121A

32C

31B

42B 111A (R) 112A (W)

TERMINAL STRIP

AUXILIARY TRANSFORMER #1

J3,J4 J14,J23,J26 J32,J33,J35 J50,J92 J62,J93

CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

ELECTRICAL SYMBOLS PER E1537

334

(24V)

333

(42V)

336

(115V)

P70

J11,J20,J21

1 2 3 4 5 6 7 8

RS232

CONNECTOR

A B

C D E F G H

I J K L M N

WIRE FEEDER

RECEPTACLE #2

A B

C D E F G H

I J K L M N

WIRE FEEDER

RECEPTACLE #1

ELECTRODE+

TOP FAN

BOTTOM

TO P73

TO P4

H1A

N.D.

TO P73

TO P4

H3A

N.D.

TO P73

(24V)

P71

(440-460)

(380-415)

(220-230)

(200-208)

P73

J17,J18,J25,J61

610

P81

P82

P83

FAN

321

J32

323

TERM

STRIP

8-8-97E

G3177-1

REAR OF MACHINE

NOTES

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WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● Do not operate with panel open or

guards off.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

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Lincoln Electric IM524 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual