Lincoln Electric IM579 User Manual
OPERATOR’S MANUAL
IM579
April, 1999
For use with machines having Code Numbers: 10391
10392
10405
10406
INVERTEC POWER WAVE 450
TM
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 Premier Manufacturer of Industrial Motors
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SAFETY
i i
POWER W AVE 450
WARNING
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.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can kill.
1.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.
1.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 Reduce Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
1.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.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition.
Replace damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.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.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see items 4.c. and 6.
ARC RAYS can burn.
2.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
Z87.1 standards.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from the
arc rays.
2..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.
3.a. Welding may produce flames 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.
3.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.
3.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.
3.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.
3.e. Also see item 7b.
SAFETY
ii ii
POWER W AVE 450
WELDING SPARKS can
cause fire or explosion.
4.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.
4.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.
4.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.
4.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).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
4.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
eat plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
4.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.
4.h. Also see item 7c.
CYLINDER may explode
if damaged.
5.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.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.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.
5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for use.
5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-I,
“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.
6.a. Tur n off input power using the disconnect switch at the fuse box
before working on the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
SAFETY
iii iii
POWER W AVE 450
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
7.c.Do not add the fuel near an open flame
welding arc or when the engine is 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.
7.d. Keep all equipment safety guards, covers
and devices in position and in good
repair. Keep hands, air, clothing and
tools away from V-belts, gears, fans and
all other moving parts when starting,
operating, or repairing equipment.
7.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.
7.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.
7.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.
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine
is hot.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current cr eates EMF fields around welding cables and welding
machines.
8.b. EMF fields may interfere with some pacemakers, and welders
have a pacemaker should consult their physician before
welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together -
Secure them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.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.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
SAFETY
iv iv
POWER W AVE 450
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lir e 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 ten-
sion 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.
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
enroule 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 rayonnementde
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 laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es 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 ttout risque d’incendie dû 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 la 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 atres 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 fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations 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 roxique) ou autres produits irritants.
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, l’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 dispostifis de sûreté à leur
place.
POWER W AVE 450
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.
vv
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 (Stacking, Tilting, Lifting)....................................................................A-2
High Frequency Precautions.......................................................................................................A-2
Input Connections.......................................................................................................................A-2
Output Connections....................................................................................................................A-4
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-1
Quick Start Reference ................................................................................................................B-2
General Description....................................................................................................................B-3
Controls and Settings.................................................................................................................B-4
Operating Overlays.....................................................................................................................B-5
Overview of Welding Procedures .............................................................................................B-19
Overload Protection ..................................................................................................................B-22
Accessories...........................................................................................................................Section C
Wire Feeder Setup......................................................................................................................C-1
Guns and Cables........................................................................................................................C-1
Water Cooler Usage...................................................................................................................C-2
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-1
Routine and Periodic Maintenance ............................................................................................D-1
Input Filter Capacitor Discharge Procedure ...............................................................................D-1
Preventive Maintenance ......................................................................................................... ....D-4
General Component Locations...................................................................................................D-5
Troubleshooting and Repair ................................................................................................Section E
Electrical Diagrams ..............................................................................................................Section F
Parts Manual..........................................................................................................................Appendix
TECHNICAL SPECIFICATIONS - POWER WAVE 450
Input Voltages: 230 460
Input Currents
@ 500A/40 VDC 76 38
@ 450A/38 VDC 65 32
Duty Cyc
le Amps Volts at Rated Amperes
230/400/460 - 60% Duty Cycle 450 38 VDC
230/400/460 - 100% Duty Cycle 400 38 VDC
Constant Open Continuous Process
Cir
cuit Voltage Current Range Current Ranges
75 Volts 5-520 Amps GMAW 50-520 Amps
FCAW 40-520 Amps
STICK 30-520 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
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
Freqency Nameplate AWG[IEC] AWG[IEC] Size (Amps)
Sizes (MM2) Sizes (MM2)
230/50-60 60% 76 4 (25) 8 (10) 80
460/50-60 60% 38 8 (10) 10 (6) 45
230/50-60 100% 65 4 (25) 8 (10) 80
460/50-60 100% 32 8 (10) 10 (6) 45
Height
Width Depth Weight
905 mm 515 mm 1010 mm 137.9 kg
35.6 in. 20.3 in. 39.8 in. 303.5 lbs.
0° to 40°C -50° to 85°C
INSTALLATION
A-1 A-1
POWER W AVE 450
INPUT - THREE PHASE ONLY
RATED OUTPUT
RATED OUTPUT
RECOMMENDED INPUT WIRE AND FUSE SIZES
PHYSICAL DIMENSIONS
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
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 35 mm access hole for the input cord, but the input
cord is not supplied.
WARNING
FIGURE A.1 - RATING PLATE LOCATION
1
2
3
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 Figure A.2 for the location of the
reconnect/input access door and related connection
diagram.
INPUT POWER CONNECTIONS
Connect L1, L2, L3 according to the Input Supply
Connection Diagram decal located on the reconnect/input access door. See 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 VOLTA GE RECONNECT
PROCEDURE
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 in Figure A.2 and proceed according to
the steps that follow for the appropriate voltage.
INSTALLATION
A-3 A-3
POWER W AVE 450
FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR
VOLTAGE=208-230V
4. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
3. CONNECT LEAD "A" TO DESIRED INPUT VOLTAGE RANGE.
2. CONNECT LEAD MARKED
1. CONNECT L1, L2, & L3 INPUT
INPUT SUPPLY CONNECTION DIAGRAM
NOTE:
MACHINES ARE SHIPPED FROM FACTORY
CONNECTED FOR 440 (OR 460) VOLTS
TO GROUND PER NATIONAL
SUPPLY LINES TO THE INPUT
ELECTRICAL CODE.
SIDE OF CR1 CONTACTOR AS
SHOWN.
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH A 5 AMP SLOW BLOW ONLY.
Disconnect input power before inspecting
or servicing machine.
Do not operate with covers removed.
Do not touch electrically live parts.
Only qualified persons should install, use
or service this equipment.
208-230V
380-415V
440-460V
208-230V
380-415V
440-460V
208-230V
380-415V
440-460V
"A" "A" "A"
VOLTAGE=380-415V VOLTAGE=440-460V
WARNING
ELECTRIC
SHOCK
CAN KILL
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
INSTALLATION
A-4 A-4
POWER W AVE 450
FIGURE A.3 – FRONTPANEL/BACK PANEL
1 WORK TERMINAL
2 ELECTRODE TERMINAL
3 REMOTE CONTROL AMPHENOL RECEPTACLE
4 WATER COOLING FITTINGS (ON BACK PANEL)
5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)
6 ELECTRODE TERMINAL
To operate at 208-230 VAC:
1. Open the reconnect/input access door.
2. Move the input voltage switch to voltage = 208230V position.
3. Move “A” lead to the 208-230V terminal.
T
o operate at 440-460 VAC: No setup required. The
machine is factory-connected to operate at 440 volts.
To verify, do the following:
1. Open the reconnect/input access door.
2. Check that the input voltage switch is set to
Voltage = 440-460V position.
3. Check that the “A” lead is at the 440-460V.
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 section of this manual for
water cooler operation and antifreeze mixtures.
WIRE FEEDER CONNECTIONS
Refer to the Accessories section for Wire Feeder Connections.
Refer to Setup overlay in Operation section for Wire
Feeder Configuration.
4
(OUT)
(IN)
6
5
31
2
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.
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. Turn 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
2
.
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.
1
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.
2
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 450 amps, 38 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 TEMPERA TURE 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
6
1 LCD DISPLAY
2 POWER SWITCH
3 HIGH TEMPERATURE LIGHT
4 REMOTE CONTROL AMPHENOL RECEPTACLE
5 5 AMP CIRCUIT BREAKER
6 LCD DISPLAY ADJUSTMENT
1
2
4
5
3
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
M
1M2
M
3M4
M
5M6
M
7M8
PROGRAM LIST
7
5
3
12
4
6
8
WARNING
RECALL
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
C COPYRIGHT 1994
L9361-2 WELD FROM MEMORY
R
MEMORYRECALL
INVERTEC POWER WAVE 350
TM
1
4
35
2
1 OVERLAY ACCESS DOOR
2 OVERLAY FRAME
3 ACCESS DOOR INDENT
4 TRACKS
5 LOCATING PINS
™
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