Lincoln Electric IM542 User Manual

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INVERTEC POWER WAVE

450 ROBOTIC

IM542-D

October, 2001

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. 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.

10344 10513 10611 10345 10514 10346 10515 10347 10516 10431 10608 10432 10609

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

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 Above For Diesel Engines

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 safety highlights. For additional safety information, 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.

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 Gasoline Engines

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 welding 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, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, 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.

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

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.

___________________________________________________

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.

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.

Mar ‘95

SAFETY

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.

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.

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

vapors

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

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.

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

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.

Mar ‘95

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.

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.

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 verre filtrant 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.

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!

Please Examine Carton

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 for 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.

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:

and Equipment For Damage Immediately

WARNING

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

CAUTION

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

vi vi

TABLE OF CONTENTS

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

Dimension Print...........................................................................................................................A-5

Component Diagram...................................................................................................................A-6

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

Robotic Interface, Weld from Memory, Dual Procedure Overlay .......................................B-10

vii vii

Limits Overlay.....................................................................................................................B-12

Setup Overlay.................................................................................................................. ...B-14

Wire Feeder Setup Description..........................................................................................B-15

Overview of Welding Procedures .............................................................................................B-16

FCAW and GMAW..............................................................................................................B-16

Pulse Procedures...............................................................................................................B-16

Wave Control......................................................................................................................B-16

Pulse Welding.....................................................................................................................B-18

Overload Protection ..................................................................................................................B-18

Thermal Protection.............................................................................................................B-18

Current Protection ..............................................................................................................B-18

Robotic Interface ..................................................................................................................Section C

1. INTERFACE DESCRIPTION..................................................................................................C-1

1.1 WELDING VOLTAGE......................................................................................................C-1

1.2 WIRE BURNBACK FUNCTION......................................................................................C-1

1.3 WIRE STICK RESET FUNCTION ...................................................................................C-1

1.4 COLD WIRE INCHING FUNCTION................................................................................C-1

2. ROBOT SIGNAL DESCRIPTIONS........................................................................................C-1

2.1 VOLTAGE COMMAND....................................................................................................C-1

2.2 WIRE FEED SPEED COMMAND ...................................................................................C-1

2.3 TOUCH SENSE SIGNAL................................................................................................C-2

2.4 ARC DETECT.................................................................................................................C-2

2.5 GAS FAULT ....................................................................................................................C-2

2.6 WIRE FAULT...................................................................................................................C-2

2.7 WATER FAULT................................................................................................................C-2

2.8 POWER FAULT ...............................................................................................................C-2

2.9 VOLTAGE FEEDBACK....................................................................................................C-2

2.10 CURRENT FEEDBACK ................................................................................................C-2

2.11 WELD START...............................................................................................................C-2

2.12 GAS START..................................................................................................................C-2

2.13 TOUCH SENSE COMMAND ........................................................................................C-2

2.14 WIRE+..........................................................................................................................C-2

2.15 WIRE-...........................................................................................................................C-2

2.16 WIRE STICK ALARM....................................................................................................C-2

2.17 DUAL PROCEDURE SWITCH COMMAND..................................................................C-3

2.18 WIRE STICK DETECT..................................................................................................C-3

3. INTERFACE CIRCUIT DESCRIPTIONS...............................................................................C-3

3.1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS .........................................C-3

3.1.1 DIGITAL OUTPUTS...............................................................................................C-3

3.1.2 DIGITAL INPUTS...................................................................................................C-3

3.1.3 ANALOG OUTPUTS..............................................................................................C-3

3.1.4 ANALOG INPUTS..................................................................................................C-3

viii viii

3.1.5 WIRE STICK DETECT...........................................................................................C-3

4. POWER WAVE CIRCUITS.....................................................................................................C-3

4.1 VOLTAGE COMMAND....................................................................................................C-3

4.2 WIRE SPEED COMAND.................................................................................................C-3

4.3 TOUCH SENSE SIGNAL................................................................................................C-3

4.4 ARC DETECT.................................................................................................................C-4

4.5 GAS FAULT ....................................................................................................................C-4

4.6 WATER FAULT................................................................................................................C-4

4.7 POWER FAULT ...............................................................................................................C-4

4.8 VOLTAGE FEEDBACK....................................................................................................C-4

4.9 CURRENT FEEDBACK ..................................................................................................C-4

4.10 WELD START...............................................................................................................C-4

4.11 GAS START..................................................................................................................C-4

4.12 TOUCH SENSE COMMAND ........................................................................................C-4

4.13 WIRE+ & WIRE- ...........................................................................................................C-4

4.14 DUAL PROCEDURE SWITCH COMMAND..................................................................C-4

4.15 WIRE STICK DETECT..................................................................................................C-4

5. ROBOT CONTROLLER SETUP ............................................................................................C-5

5.1 WELD SYSTEM SETUP.................................................................................................C-5

5.2 WELD EQUIPMENT SETUP ...........................................................................................C-5

5.3 SYSTEM VARIABLES.....................................................................................................C-5

5.4 TOUCH SENSING SETUP .............................................................................................C-5

6. CONNECTIONS.....................................................................................................................C-6

6.1 POWER WAVE INTERFACE BOARD.............................................................................C-6

6.2 ARCTOOL WELDING INPUTS AND OUTPUTS.............................................................C-6

6.3 MISCELLANEOUS CONNECTIONS..............................................................................C-6

Accessories...........................................................................................................................Section D

Water Cooler Usage...................................................................................................................D-1

Recommended Coolants ............................................................................................................D-1

Priming the Cooler ......................................................................................................................D-1

Wire Feed Unit Dimension Print.................................................................................................D-2

Mounting the Wire Feed Unit......................................................................................................D-3

Connecting Wire Feed Unit to Power Source............................................................................D-3

Electrode Routing.......................................................................................................................D-3

Drive Roll and Guide Tube Kits ..................................................................................................D-4

Procedure to Install Drive Roll & Guide Tubes ...........................................................................D-4

Idle Roll Pressure Setting..................................................................................................... ......D-5

K659-1 Gas Guard Regulator .....................................................................................................D-5

Wire Reel Loading ......................................................................................................................D-5

Routine Maintenance of Wire Feed Unit ....................................................................................D-8

Gun Cable Connector Requirements.........................................................................................D-9

ix ix

Maintenance..........................................................................................................................Section E

Safety Precautions......................................................................................................................E-1

Routine and Periodic Maintenance.............................................................................................E-1

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

Resistor Locations ................................................................................................................E-2

Discharge Label ....................................................................................................................E-3

Resistors with Leads............................................................................................................E-3

Preventive Maintenance..............................................................................................................E-4

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

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

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

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

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

General Component Locations...................................................................................................E-7

Troubleshooting and Repair.................................................................................................Section F

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

Troubleshooting Guide................................................................................................................F-2

Electrical Diagrams..............................................................................................................Section G

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

A-1 A-1

INSTALLATION

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

75 Volts 5-540 Amps GMAW 50-540 Amps

ge Current Range Current Ranges

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/ Cycle Rating on Conduit Conduit or Breaker

Freqency Nameplate AWG[IEC] AWG[IEC] Size (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

POWER WAVE 450

A-2 A-2

INSTALLATION

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• 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.

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.

FIGURE A.1 - RATING PLATE LOCATION

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.

1. RATING PLATE

2. RECONNECT/INPUT ACCESS DOOR

3. INPUT CORD ACCESS HOLE

WARNING

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.

POWER WAVE 450

A-3 A-3

INSTALLATION

CAUTION

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 VOLTAGE RECONNECT PROCEDURE

WARNING

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

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.

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

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.

Note:The above connection diagram is a sample of what may be found on the reconnect/input door. If it is not the correct diagram for your machine use the one on the reconnect/input access door. See the written connection instructions in this section.

SPECIFIC

SAMPLE

REFER

DIAGRAM

ONL

YOUR

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.

POWER WAVE 450

A-4 A-4

(OUT)

(IN)

INSTALLATION

FIGURE A.3 – FRONTPANEL/BACK PANEL

1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE

To reconnect your machine for the proper input 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.

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

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.

POWER WAVE 450

A-5 A-5

18.76

19.50

15.50

35.82

16.08

29.49

32.26

35.00

38.82

M17793

INSTALLATION

POWER WAVE 450 ROBOTIC DIMENSIONS

POWER WAVE 450

A-6 A-6

POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT

COMPONENTS DIAGRAM

K680 K681 CONTROL TO WIRE DRIVE CABLES

CUSTOMER MUST PROVIDE WIRE DEREELING METHOD

SYNERGIC 7F WIRE DRIVE

K679-1 (LOW SPEED) K679-2 (HIGH SPEED)

DRIVE ROLLS CONSULT IM559 FOR LATEST INFORMATION

POWER WAVE 450 ROBOTIC

K1447-1 (W/O WATER COOLER)

K1447-2 (W/ WATER COOLER)

TO WORK

TO ROBOT CONTROLLER

REQUIRED:

• APPROPRIATE WORK CABLE SIZE AND LENGTH

• APPROPRIATE MAGNUM GUN AND CABLE ASSEMBLY

AND ADAPTER IF REQUIRED.

• WIRE FEEDER CONTROLS ARE LOCATED WITHIN THE POWER WAVE 450 ROBOTIC POWER SOURCE.

CONSULT IM559 FOR LATEST INFORMATION

INSTALLATION

POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT

COMPONENTS DIAGRAM

POWER WAVE 450

B-1 B-1

OPERATION

OPERATING INSTRUCTIONS

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

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

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

POWER WAVE 450

B-2 B-2

SAVE

RECALL

OPERATION

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. Turn the machine ON. c. Select the desired welding

PROCESS

d. Select ELECTRODE CLASS.

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.

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

POWER WAVE 450

B-3 B-3

OPERATION

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.

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 contr ol.

• 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.

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.

POWER WAVE 450

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.

B-4 B-4

OPERATION

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

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

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.

POWER WAVE 450

B-5 B-5

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 350

OPERATION

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

™

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

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

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

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.

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.

POWER WAVE 450

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