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Lincoln Electric IM542-D User's Manual

1. egado del HAE AA AREY 3 lla Gada ve ue 8 gt WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR HORM PBMOX A NHRBEE lt RA ETIEMLT FEU tULTHHORAMEI ETF SU 8B ET ABL BE Rr de OE D AMEN Azo SEE oe nie HA ZARE AS gt SAIT BEHE Gud al Gail guet LINCOLN 8 e World s Leader in Welding and Cutting Products e 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
2. ke 87 Le ke 81 WIRE FEED DIRECTION CLEARANCE ENVELOPE OF QUICK RELEASE ARMS TOP VIEW L9777 POWER WAVE 450 LINCOLN amp D 3 D 3 ACCESSORIES MOUNTING THE WIRE FEED UNIT Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gear box See L9777 Dimension Print following to find the size and location of the mounting holes The gearbox assembly is electrically hot when the gun or nozzle is energized Therefore make certain the gearbox does not come in contact with the structure on which the unit is mounted The wire feed unit should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area Position the mechanism so it will point down at about a 45 angle so the wire feed gun cable will not be bent sharply as it comes from the unit CONNECTING WIRE FEED UNIT TO POWER SOURCE The Feeder to Control cable assemblies are available in two types K680 L Includes a control cable with 14 pin MS style connectors on each end and a 4 0 weld cable to route between the Wire Drive and the Control Box Available in lengths L og 16ft 4 9m and 25ft 7 6m K681 L Same as K680 but does not include weld cable Available in lengths 1 of12ft 3 6m 16ft 4 9m and 25ft
3. eene E 6 33503s Cooler S GrvICG ere erro eR ed RA rr eb tan P REPE LR E 6 General Component 5 2 3 ss E 7 Troubleshooting and Section F How To Use Troubleshooting Guide 4 F 1 Troubleshooting Guide ati tel a o F 2 Electrical Diagrams aniona a REO ORG D OO ARI E AR iaa Section G Parts Manual e epit er t ve ra Fee P 261 Series 1 1 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 450 INPUT THREE PHASE 50 60 HZ ONLY Input Voltages Input Currents 500A 40 VDC 450A 38 VDC RATED OUTPUT Duty Cycle Volts at Rated Amperes 200 60 Duty Cycle 40 VDC 230 400 460 60 Duty Cycle 40 VDC 460 575 60 Duty Cycle 40 VDC 200 100 Duty Cycle 38 VDC 230 400 460 100 Duty Cycle 38 VDC 460 575 100 Duty Cycle 38 VDC OUTPUT Constant Open Continuous Process Circuit Voltage Current Range Current Ranges 75 Volts 5 540 Amps GMAW 50 540 Amps FCAW 40 540 Amps STICK 30 540 Amps Pulse Pulse Pulse and Background Pulse Current Range Voltage Range Time Range Frequency 5 750 Amps 5 55 Volts 100 Microsec 3 3 Sec 0 15 1000 Hz RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 Input Input Ampere Copper Wire in Ground Wire in Super Lag Voltage Rating on Conduit Conduit or Breaker Freqency
4. Disconnect input power before inspecting or machine Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install use or service this equipment IF MACHINE CEASES TO OPERATE NO METER NO FAN AND THERE I NO OTHER KNOWN FAILURE CHECK FUSE REPLACE WITH A 5 AMP SLOW BLOW ONLY S 55 GENS EXO INPUT LINES GND 11213 NATIONAL 200 208V 200 2087 20 20 N gt de 2202907 e 380 415V 380 15V 380 415V g 440 460V 440460 440 460V VOLTAGE 220 230V VOLTAGE 380 415V VOLTAGE 440 460V 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 connec tion instructions in this section Also called inverse time or thermal magnetic circuit breakers These breakers have a delay in tripping action that decreases as the mag nitude of the current increases POWER WAVE 450 LINCOLN amp 4 4 INSTALLATION FIGURE A 3 FRONTPANEL BACK PANEL 1 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To r
5. Every six months check the motor brushes Replace them if they are less than 1 4 long POWER WAVE 450 LINCOLN B ACCESSORIES Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Units 749 19 0 1747 18 9 62 15 7 DIA 03 x 45 76 x 45 062R 1 5R Style A A DIA HOLE 295 7 49 ee 290 7 36 Connector must be 252 6 40 insulated in this area 260 6 60 2 00 51 0 Connector for 1 16 5 64 1 6 2 0 mm Wire 180 4 5 ui 160 4 0 03 x 45 76 x 45 ER e DIA HOLE 495 12 5 DIA MAX Connector for 023 052 19 0 18 9 mm Wire For all other dimensions See Diagram above Style B NOTE Connector part with 749 747 19 0 18 9 mm diameter should be made from brass if it is to be part of the welding current carrying circuit A Diameter Hole to be Concentric to 149 747 19 0 18 9 mm Diameter Within 008 20 F I M Wire Size in mm 068 5 64 17 20 125 1 8 3 2 mm Drill 1 16 1 6 078 5 64 2 0 mm Drill 045 amp 052 1 1 amp 1 3 062 1 16 1 6 mm Drill 23 035 0 6 0 9 055 1 4 mm 54 Drill All dimensions in inches and millimeters Switch Requirements 1 2 Amp AC 24 Volts Inductive 1 2 Amp DC 24 Volts Inductive To Gun Switch Connect Leads to Pins A amp C 12024 1 L E Part No Amphenol AN3057 10 or equiv 12020 6 L E Part No
6. Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HRUBS ISUCRSREUCT ez 12 Bo amp s ESSA due gulag cl ysl gua e dang READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplat
7. 0 6mm through 052 1 3mm solid electrodes have no teeth See section on Wire Feed Drive Roll and Guide Tube Kits for roll changing instructions Wire Reel Mounting 50 22 7kg and 6016 27 2kg Coils To prolong the life of the reel shaft periodically coat it with a thin layer of grease No maintenance of the two position adjustable brake is needed If the brake shoe wears through to the metal replace the brake assembly Wire Reel Mounting Readi Reels and 10 through 30lb 4 5 14kg Spools No routine maintenance required Do not lubricate 2 51mm spindle Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instruc tions e Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed Do not use excessive wire spindle brake settings Periodic Maintenance of Wire Drive Unit Wire Drive Motor and Gearbox Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease
8. Amphenol MS 3106A 18 11P or equiv POWER WAVE 450 LINCOLN B MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only Qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six months WARNING Prior to performing preventive maintenance it is impor tant to perform the following capacitor discharge pro cedure to avoid electric shock INPUT FILTER CAPACITOR DIS CHARGE PROCEDURE 1 Turn off input power and disconnect input power lines 2 Remove the hex head screws from the top and the sides of the machine Remove the handle bar and the wrap around machine cover 3 Remove the two case sides There are hex head screws each side CAUTION TO PREVENT DAMAGE TO MACHINE AVOID UNNECESSARY MOVEMENT OF FRONT PANEL 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure D 3 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE POWER WAVE 450 LINCOLN amp E 1 MAINTENANCE FIGURE D 1 RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN
9. FIGURE D 2 DISCHARGE LABEL lt T13086 117 FIGURE D 3 RESISTORS WITH LEADS CONNECTED Yes A 9 Check voltage across terminals 9 and 12 with a 10 DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capac itor discharge procedure Repeat discharge procedure steps 7 8 and 9 for each of the other three Switch Boards POWER WAVE 450 LINCOLN amp MAINTENANCE PREVENTIVE MAINTENANCE Perform the following preventive maintenance proce dures at least once every six months It is good prac tice to keep a preventive maintenance record a record tag attached to the machine works best 1 Remove the hex head screws from the sides top of the machine Remove the handle bar and the machine wrap around cover Remove the two case sides There are hex head screws on each side Perform the input filter capacitor discharge proce dure described at the beginning of the Maintenance Section Disconnect the shunt from the negative output terminal Failure to do this could cause damage to the shunt circuitry Clean the inside of the machine with a low pres sure airstream Be sure to clean the following components thoroughly Refer to Figure D 4 Display Snubber and Sh
10. 7 6m 1 Making certain the cables are protected from any sharp corners which may damage their jackets mount the cable assembly along the boom so the end with the female MS style connector pins is at the wire feed unit 2 Connect the 14 socket cable connector to the receptacle on the back of the wire feed unit con nection box 3 Atthe same end connect the electrode lead to the connection stud of the brass gun connection block on the front of the wire feed unit 4 Atthe control box end connect the 14 pin connec tor of the cable to the mating receptacle on the bot tom of the control box ELECTRODE ROUTING The electrode supply may be either from reels Readi Reels spools or bulk packaged drums or reels Observe the following precautions 1 The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum and also that the force required to pull the wire from the reel into the wire feed unit is kept at a minimum 2 The electrode is hot when the gun is energized and must be insulated from the boom and struc ture 3 If more than one wire feed unit shares the same boom their wire and reels must be insulated from each other and insulated from their mounting struc ture See later in this section for mounting of the K299 wire reel assembly POWER WAVE 450 LINCOLN B ACCESSORIES DRIVE ROLL AND GUIDE TUBE KITS Steel Wire Sizes 4 Roll 068 3 32 1 7 2 4mm
11. When the Power Wave is welding procedure for which you want to set lim turned on the following message appears in the its Then press the RECALL FROM MEMORY key display window for a few seconds followed by the MEMORY LOCATION NUM LINCOLN ELECTRIC BER key for the selected procedure Version X X If no procedure was saved in the selected memo This display is followed by ry location the following message appears OVERLAY ID CENT NUMBER z4 This message is then replaced by the following SPICE anOMIe oca ont message SET LIMIT KEY SELECT A MEMORY AND LIMIT UP DOWN KEYS 4 RECALL FROM MEMORY KEY The SET LIMIT key and LIMIT UP LIMIT DOWN AND keys are used to set the maximum and minimum 3 MEMORY LOCATION NUMBERS allowed wire feed speed and voltage trim or arc The RECALL FROM MEMORY key is used to recall a welding procedure from memory length trim values of the procedure that was recalled from memory POWER WAVE 450 LINCOLN amp 13 13 OPERATION Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value Press the SET LIMIT key again The new maximum and old minimum wire feed speeds will be dis played Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value Press the SET LIMIT key The present maximum and minimum voltage trim or arc length trim will be displayed Refer to Table B 3 to see how voltage
12. 7 OPERATION PULSE GMAW FCAW AND STICK TIG PROCESS SELECTION OVERLAY An operator can use this overlay to create a new welding procedure save a newly created welding procedure view an existing welding procedure recall an existing welding procedure and clear a memory location See Figure B 4 The steps for performing each of these functions are given below FIGURE B 4 PULSE GMAW FCAW STICK TIG PROCESS SELECTION OVERLAY olo ELECTRODE CLASS a o PANEL 1 PULSE GMAW FCAW STICK TIG PROCESS SELECTION UN THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 olo f ELECTRODE SIZE ELECTRODE GAS TYPE LCD DISPLAY WINDOW PROCESS SELECT KEY ELECTRODE CLASS UP DOWN KEYS ELECTRODE SIZE UP DOWN KEYS ELECTRODE GAS TYPE UP DOWN KEYS WAVE CONTROL UP DOWN KEYS OU 1 LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears on the display for a few seconds LINCOLN ELECTRIC VERSION This display is followed by OVERLAY ID NUMBER 1 A welding procedure is made up of seven compo nents process material type wire diameter program wire feed speed voltage or arc length trim and wave control A new welding procedure is created by 7 DISPLAY RECALL KEY 8 SAVE TO MEMORY KEY 9 MEMORY LOCATION NUMBER KEYS 10 RECALL FROM MEMORY KEY 11 HIGH TEMPERATURE LIGHT NOTE The foll
13. 80IPM The forward wire inch command is gener ated by active low welding output 4 WDO4 The reverse wire inch command is generated by active low welding output 5 WDO5 When either of the two sig nals is received an isolated inch command is generat ed and tied to the interface wire inching input At the same time the motor drive relays switch to the correct direction The default direction for the motor drive relays is forward if both the signals are low at the same time then the motor drive relays are set for reverse No damage will be caused by driving both signals low at the same time 4 14 DUAL PROCEDURE SWITCH COMMAND The dual procedure switch command is generated by active low welding output 7 WDO7 The signal is then isolated from the robot ground and tied to the interface dual procedure input 4 15 WIRE STICK DETECT The wire stick detect signal is generated by a voltage check across the output studs The robot controller samples this signal a predetermined time after the Arc Enable signal changes from enabled to disabled The signal is then isolated from the control ground and tied to the robot controller wire stick detect inputs WDI amp WDI POWER WAVE 450 LINCOLN 5 5 1 5 2 WELD SYSTEM SETUP MONITORING FUNCTIONS 1 Arc loss 2 Gas shortage 3 Wire shortage 4 Wire stick 5 Power supply failure 6 Coolant shortage WELD RESTART FUNCTION 7 Return to path 8 Overlap distance 9 Return to p
14. Cut and remove the remaining tie wires CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlashing of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 6 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub locking the reel in place Feeding Electrode 1 Turn the reel until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end 2 Straighten the first 6 150mm and cut off the first 1 25mm Insert the free end through the incoming guide tube Press the Cold Inch key or the gun trigger and push the electrode into the drive roll Feed the electrode through the gun If the electrode is not prop erly straightened it may not feed or may not go into the outgoing guide tube causing birdnest A WARNING When feeding with the gun trigger the electrode and drive mechanism are always HOT to work and ground and could remain HOT several seconds after the gun trigger is released Wire Loading of 13 14lb 6kg Innershield Coils Requires use of K162H Spindle Kit and K435 14 Ib TIE WIRE Coil Adapter REEL SPRING LOADED ARM POWER WAVE 450 LINCOLN D 8 D 8 ACCESSORIES Routine Ma
15. RE tae 2 2 10 CURRENT FEEDBACK tertie eae e e e eee e RT 2 2 11 WEED START e ro b ede race dt dep dt 2 2 12 GAS START EUR ER 2 2 13 TOUCH SENSE COMMAND t RR dened d d dena 2 2 14 WIRES tee 2 2 15 WAR ESS er etta 2 2 16 WIRE STICK ALARM ona erred ied 2 2 17 DUAL PROCEDURE SWITCH 20 1 66 3 2 18 WIBESSTIGK DETEGT gern e A 3 3 INTERFACE CIRCUIT DESCRIPTIONS eerren 3 3 1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS 3 3 1 1 DIGITAL OUTP UTS utt n ERR eno RR EC eg aa e OR 3 3 1 2 DIGITAL INPUTS iii o e hah ee e t io ee e e eer o Ee a d E de 3 3 1 3 ANAEO G OUTPUTS et oh C e Ce dod te e db o E UT ded 3 3 1 4 ANALOG INPUTS ra eti e t ea ERR OR ELM ri nn 3 vii viii 3 15 WIRE STICK DETECT ivernar A C 3 POWER WAVE CIRCUITS entend eedem edt ge Hd RE C 3 4 Tl VOLTAGE COMMAND ct e etae a EAR HERRERA a daga C 3 4 2 WIRE SPEED COMAND ententes Rein a EL e ge C 3 4 3 TOUCH SENSE SIGNAL riens imminente De b P aede terreat C 3 ZA ARC DETECT sr pe
16. This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page ale dated i iv Installation ete ri y ep te e E Section A Technical Specifications 7 3 rei na e a de er e MO lied us sa A 1 Safety Precautions osrin UR e oe ix nent de ebd Lm Dd au Re et dun A 2 Select S uitable lGCatlOm s o ee Ded dte e Pe RR rg xr ees A 2 STACKING eld biete ola Cat iter ead A 2 Uer M A 2 RE 2 High Frequency sense 2 Input Contiectiors 2 de etiem te Ai oh ug Genel En A 2 Grourid Gonnectlors te Ri A 3 Input Power Connections i e ee e e Eg d c E e nr a A 3 Input Fuse and Supply Wire Connections 4 A 3 Input Voltage Reconnect Procedure emere nen A 3 Output Connections e diee ie gi ege ade ge A 4 Work and Electrode Cable lt eene A 4 Water Cooler Connections uoce ome e doge b REGE Ee Rape A 4 Wire Feeder Connections tete e be e Ee cede ce n et e A 4 Dimension PIN are eter te de eee A 5 Component aep Pp cr de EE e Rp ad p MER ue A 6 Operation uode ehm d et eee E e ei ite
17. and a voltage trim for that selected wire feed speed setpoint The solution to this problem is already built into the Power Wave At every arc end the Power Wave automatically goes through its own burn back routine 1 3 WIRE STICK RESET FUNCTION The wire stick reset function controlled by the robot controller will not operate properly This function is very similar to the burnback function It was intended to use a wire feed speed of zero while setting the welding voltage to some level For the same reasons as wire burnback it will not operate properly The burnback routines in the Power Wave have been optimized for each weld ing procedure and are very reliable If any wire stick problems occur the burnback routines in the Power Wave can be programmed to correct the problem 1 4 COLD WIRE INCHING FUNCTION The cold inching wire feed speed cannot be changed by the robot controller It is always set to 80 IPM A variable cold inching speed is not possible with the current architecture of the inter face 2 ROBOT SIGNAL DESCRIPTIONS 2 1 VOLTAGE COMMAND This is an analog output from the robot controller with a range of 0 to 10V Since the Power Wave is always running in the synergic mode an output voltage cannot be set The voltage command is used as a voltage trim for the active workpoint The voltage command limits in the robot con troller are entered as 50 to 150V This is done so that the nominal trim setting 100V
18. arc current sig nal in the Power Wave is multiplied by 4 and iso lated to produce the current feedback signal A current feedback signal of 8 317V is equal to an arc current of 750A 2 11 WELD START This is an active low output from the robot con troller which commands the Power Wave to start an arc 2 12 GAS START This is an active low output from the robot con troller which commands the Power Wave to open the shielding gas solenoid 2 13 TOUCH SENSE COMMAND This is an active low output from the robot con troller which commands the Power Wave to turn on touch sensing When touch sensing is enabled the Power Wave regulates a pulse volt age wave form while monitoring the current through the electrode If current flows through the electrode then the touch sense signal is held low to report a touch to the robot controller 2 14 WIRE This is an active low output from the robot con troller which commands the Power Wave to cold inch wire at 80 IPM 2 15 WIRE This is an active low output from the robot con troller which commands the Power Wave to cold inch wire at 80 IPM 2 16 WIRE STICK ALARM This is an active low output from the robot con troller used to indicate a wire stick This signal is not connected in the Power Wave POWER WAVE 450 LINCOLN B APR97 3 ROBOTIC INTERFACE 2 17 DUAL PROCEDURE SWITCH COM MAND This is an active low output from the robot con troller used to activate the dual pr
19. b Turn the machine ON C Selectthe desired welding PROCESS PULSE GMAW e 5 i STICK SELECT PROCESS olo ELECTRODE CLASS aa d Select ELECTRODE CLASS ELECTRODE SIZE MM IN e Select ELECTRODE SIZE JP i Ww oo ELECTRODE GAS TYPE f Select ELECTRODE GAS TYPE JP 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 WAVE CONTROL EG Step 2 Adjust the wire feed to speed WFS and voltage V or arc length T if necessary a Press the DISPLAY RECALL key view additional procedure information DISPLAY RECALL to 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 appro priate 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 recommenda tions Therefore selecting certain options may limit other option selections The wave control scale displayed shows the default setting The higher the sett
20. characteristics This improves the sound ness 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 proce dures 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 oper ation 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 volt ages 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 eith
21. coolants have been determined to be compatible with the wetted materials used in the G3503 cooler assembly Distilled or deionized water Potable tap water Sediment free mixtures containing maxi mum of 50 ethylene glycol or automotive grade antifreeze and the balance of distilled or deionized water 2 Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water 3 Consult gun torch and wire feeder manuals for coolant recommendations and select one from the above list 4 Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphazard ly discarded especially by pouring liquids down the drain Contact the local EPA office for responsible disposal methods or for recycling information 5 The cooler s reservoir has a nominal liquid capacity of 1 6 gallons PRIMING THE COOLER 1 Select a recommended coolant and fill cooler to specified level see Fig D 2 2 Attach desired water cooled accessory gun and wire feeder or torch to coolers QDs 3 Prime the cooler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level c Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is ill
22. procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Ele
23. scratched off areas only If a large area of the bar code is scratched off the machine either will not recognize the overlay or will mistake the overlay for another one Inspect gun and cables for good condition POWER WAVE 450 LINCOLN amp 5 5 MAINTENANCE RECOMMENDED TOOLS FOR INSTAL LATION OR SERVICE OF COOLER absorbent towels alcohol wipe e 3 mm allen wrench G3503 only socket wrench 4 inch long minimum socket extension 1 4 5 16 and 3 8 hex standard depth sockets 5 32 allen socket medium blade slotted screwdriver e large blade slotted screwdriver 8 inches long minimum two 7 16 open or box end wrenches one 7 8 open or box end wrench needlenose pliers two 10 inch long adjustable wrenches wire cutter molex pin removal tools tape measure small mechanic s mirror e flashlight dental pick digital multimeter DMM G3503 INSTALLATION OR SER VICE TOOL USAGE Shroud to cooler base Quick Disconnect QD bracket Heat exchanger to cooler base Relay to cooler base Screw to fasten reservoir to cooler base all use 5 16 hex screw and 3 8 hex nut Relay may require large blade slotted screwdriver 8 in long min 3 mm allen wrench G3503 only 5 16 Hex Socket G3503 1 only Hose Clamp 1 4 hex or medium slotted screwdriver Fan set screw 5 32 allen socket with wrench and 4 in min extension eem carbonator clamp screw 5 16 hex socket with ratc
24. 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 LINCOLN amp 3 INSTALLATION CAUTION Failure to follow these instructions can cause immedi ate failure of components within the welder GROUND CONNECTIONS The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper ground ing methods 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 recon nect 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 recom mended 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 cir cuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machi
25. the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual volt age The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known In this case it is not practical to preset an actual voltage for the pro cedure Instead an arc length adjustment is provided The machine knows what the best arc length is at the given wire feed speed but allows the operator to change it The arc length can be adjusted between 0 5 and 1 5 on the wire feeder s Voltage display An arc length trim of 1 0 means that no adjustments will be made to the pre set arc lengths An arc length trim greater than 1 0 increases the preset arc lengths An arc length trim less than 1 0 decreases the pre set arc lengths The arc length adjustment is factored in at all wire feed speed settings Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length set tings of the procedure by 10 percent In the Pulse process the display shows the Procedure Description WFS and Arc Length Trim Arc length trim is pro grammed to a default at the factory and may be adjust ed on the wire feeder When the trigger is pulled the WES Actual Arc Voltage and Actual Arc Current dis played WAVE CONTROL The wave control settings of all procedures can be changed on the Power Wave 450 GMAW P
26. the water cooler and accessory hoses for kinks internal obstructions or block age or ruptures If such problems were found then correct them and turn the machine off and on to check if the beeping has been elimi nated 3 Check the water cooler fluid level Low coolant level could cause the pressure to drop 4 Prime the water cooler Refer to the Setup Overlay section of this manual for instructions RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN B 8 8 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Machine loses output while weld ing Fans and display are function ing properly For no apparent reason the weld characteristics have changed Machine often noodle welds with a particular procedure POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check for proper input voltages per machine nameplate 2 Check for balanced three phase input supply voltage 3 Check electrode and work cables for loose or po
27. to 30 in lbs of torque h Attach coolant lines to QD and reservoir i Wipe dry all areas wetted by coolant Dispose of tow els in an environmentally responsible manner see Recommended Coolants j Reinstall cooler into machine 4 Motor removal or replacement Do not reuse the 4 internal tooth star washers Replace with new parts 5 Installing the fan Slide onto motor shaft until the fan is located between 0 25 to 0 50 inches from the heat exchanger Tighten set screw with 65 to 75 in Ibs of torque against motor shaft s flat Fan rotation is counterclockwise as viewed from fan end of motor s shaft Fan pulls air through the heat exchanger blows it over the motor then exhausts it through the reser voir 7 7 MAINTENANCE FIGURE D 4 GENERAL COMPONENT LOCATIONS KA 0 4 SEWN POWER WAVE 450 LINCOLN 1 DISPLAY BOARD BACK OF PANEL 2 POWER SWITCH 8 OVERLAY BAR CODE SENSORS 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 9 TERMINAL STRIP LOCATION 3 MAIN TRANSFORMER 6 HEAT SINK FINS 7 OUTPUT TERMINALS TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE A WARNING This Troubleshooting Guide is designed to be used by the machine Owner Operator Unauthorized repairs per formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety please observe all safety notes and precautions d
28. trim affects preset voltage Refer to Table B 6 to see how arc length trim affects preset arc length Use the LIMIT UP and LIMIT DOWN keys to change the maximum value The maximum for either type is 1 5 Press the SET LIMIT key The new maximum and old minimum voltage trim or arc length trim will be displayed Use the LIMIT UP and LIMIT DOWN keys to change the minimum value The minimum for either type is 0 5 SAVE TO MEMORY KEY The SAVE TO MEMO RY KEY is used to save the procedure with the newly set limits to memory Press the SAVE TO MEMORY key sa followed by the MEMORY LOCATION NUMBER key of the desired memory location This does not have to be the original location from which the procedure was recalled Step 6 can be performed any time during the limit setting process You do not have to set all the available limits When you have set all the desired limits save the procedure to memory To clear any previously set limits recall the proce dure from memory and change the limits to the maximum range available Then save the proce dure to memory DISPLAY RECALL KEY To view other information about the active welding procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions will be displayed for a few seconds MEMORY
29. 16 16 OPERATION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING FCAW AND GMAW PROCEDURES For each wire feed speed a corresponding voltage is preprogrammed into the machine by welding experts This preprogrammed voltage is the best average volt age for the procedure at the given wire feed speed If the wire feed speed is changed on the wire feeder the voltage automatically changes with it In some cases the operator may want to change the preprogrammed voltages for example to compensate for cable and fixture voltage drops The preset voltages can be adjusted on the wire feeder s Voltage display When a change is made to the voltage at one wire feed speed this change is applied to all other wire feed speed settings For example if the operator turns up the voltage by 10 percent the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent In the GMAW and FCAW process the display shows The Procedure Description WFS and Preset Voltage The preset voltage which was pro grammed at the factory may be changed on the wire feeder voltage display Note that if you change the default preset voltage up or down a respective or sign will be dis played after the preset value When the gun trigger is pulled note that the display changes to show WFS Actual Arc Volt age and Actual Arc Current See Table B 4 for display summary PULSE PROCEDURES In these procedures
30. 3 2 cm In the low and high end of the wire feed speed ranges of most processes the adaptive behav ior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process It is possible to achieve adaptive behavior for longer stickout lengths However shielding gas is often lost when the stickout is too long A longer electrical stickout is often used with the puls ing process at higher deposition rates A long stickout will increase the melt off rate of the wire In pulse welding like other wire welding processes the arc length is determined by the voltage setting This voltage is programmed at the factory for each process and wire feed speed It may be changed using the Voltage setting on the wire feeder When adaptive processes are used the voltage will vary with stickout The machine must change the volt age to keep a stable arc It is very important to recog nize this Actual arc voltage when welding will vary because the stickout will seldom be held at the nominal 0 75 1 9 cm value OVERLOAD PROTECTION Thermal Protection The Power Wave has thermostatic protection from excessive duty cycles overloads loss of cooling and high ambient temperatures When the power source is subjected to any of the conditions mentioned above a thermostat will open The yellow high temperature light on the case front comes on See Figure B 1 for loca tion Machine output is disabled and w
31. CE 1 Preparation Always switch off the Power Wave machine power Always disconnect the Power Wave machine from service input power Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine whenever replacing major cooler components i e pump motor heat exchanger etc replacing hoses and electrical harnesses that are kinked or damaged cut abraded deteriorated or swollen etc investigating suspect coolant leakage 3 Pump replacement a Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants b Remove fan shroud c Place absorbent towels underneath pump head and wherever coolant system is opened d Carefully pull pump inlet hose and its elbow from reservoir bottom e Loosen pump outlet hose clamp at QD then carefully remove from fitting f Disconnect v band clamp from motor and remove pump Do not drop or lose drive coupling between pump and motor Do not discard old pump Remove both fittings Keep v clamp Seal old pump in a waterproof bag Package into protective container and Return to nearest Lincoln Electric FSS center g Install new pump and v band clamp Do not apply any lubricant to pump s drive coupling Pump body is properly oriented with its strainer at the 6 00 position e Tighten v clamp with 15
32. CTRODE GAS TYPE UP or DOWN Key until the desired program is displayed WAVE CONTROL UP DOWN KEYS Press one of the two WAVE CONTROL keys to display the pre sent wave control This is shown on a scale from LO to HI Use the WAVE CONTROL UP or WAVE CONTROL DOWN key to change the wave control to the desired level When this scale is shown the WAVE CONTROL setting can also be changed while welding on the fly Press the DISPLAY RECALL key to exit the wave control function For a description of how the wave control setting affects the welding procedure refer to the Overview of Welding Procedures sub section of the Operation section of this manual The wire feed speed and voltage or arc length trim desired for the new procedure can be changed from the wire feeder 7 DISPLAY RECALL KEY Since not all the informa tion about the procedure can be seen on the 2 line LCD display window at the same time use the DISPLAY RECALL key to display and verify all of the selected procedure information The normal default display window shows the Procedure Description WFS and preset voltage or arc length trim values Press and hold the DISPLAY RECALL key and the window shows the procedure de scription and gas type for as long as the key is held depressed Release the DISPLAY RECALL key and the window shows wire size material type and process description After a few sec onds the window changes back to the default dis play SAVE TO MEMORY
33. Cored KP655 3 32 1 16 1 6mm Cored or Solid KP655 1 16 045 052 1 2 1 4mm Solid KP655 052S 045 052 1 2 1 4mm Cored KP655 052C 035 0 9 1 0mm Cored KP655 035C 035 0 9 1 0mm Solid KP655 035S 030 0 8mm Solid KP655 030S 023 0 6mm Solid KP655 025S Aluminum Wire Sizes 1 16 1 6mm KP656 1 16A KP647 1 16A KP656 3 64A KP647 3 64A KP647 040A KP656 035A 3 64 1 2mm 040 1 0mm 035 0 9mm Drive rolls for only cored electrode sizes are stencilled with suf fix to the wire sizes Drive rolls for only solid electrode sizes are stencilled with an S suf fix to the wire sizes Drive rolls for aluminum wire sizes are stencilled with an A suffix to the wire sizes Not for Synergic 7FH model For use with Binzel European guns Installation instructions are included with these kits Also requires K489 2 Fast Mate Adapter PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring 0 When inching with gun trigger electrode and drive mechanism are hot to work and ground Turn OFF welding power source before installing or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personne
34. EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5 Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine See Figure D 1 Do not touch the resistors or any other internal machine component Using a DC voltmeter check for any DC voltage that may be present across the termi nals of each resistor and from each resistor to case ground 20 measurements in all If a voltage 5 present be careful not to touch these resistors WARNING e ELECTRIC SHOCK can kill Proceed with caution being care ful not to touch any internal machine components during the discharge procedure POWER WAVE 450 LINCOLN amp 3 3 MAINTENANCE Locate the 9 and 12 terminals identified by the Discharge labels on each of the four Switch Boards See Figure D 2 Using insulated needle nose type jumper leads and insulated gloves connect one jumper lead to one end of the resistor obtained in step 4 Connect the other jumper lead to the other end of the resistor Carefully connect the needle nose end of one of the jumper leads to terminal 9 See Figure D 3 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave resistor connected for 10 seconds DO NOT TOUCH TER MINALS RESISTORS OR INTERNAL MACHINE COMPONENT DURING THIS PROCE DURE
35. ER AND WATER COOLER CONNECTIONS 1 WIRE FEEDER CONNECTIONS LOCATION 2 WATER COOLER LINE IN 3 WATER COOLER LINE OUT 4 CIRCUIT BREAKER WATER COOLER 5 FILL SPOUT WATER COOLER WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler We recommend using the water cooler when welding above 300 amps with argon blends on a regular basis The gun heating from pulsing above 300 amps average current is often excessive and leads to reduced consumable life reduced gun life and opera tor discomfort Water cooling greatly increases the durability of the gun and parts at high current There are two water connections on the rear of the Power Wave See Figure D 1 Connect the water lines between these connectors and those on the wire feed er The water is fed through the feeder into the gun When a water cooler is used the water cooler must be enabled by using the Setup Overlay The water cooler contains a pressure switch which is closed when there is adequate pressure in the water cooler hose for normal operation If this pressure drops below the switch manufacturer s set point the pressure switch opens A couple of seconds after the pressure switch opens the water cooler shuts down If the water cooler is enabled and the pressure switch opens the machine beeps loudly indicating that there is a problem with the water cooler operation RECOMMENDED COOLANTS 1 The following
36. KEY This key is used to save a newly created welding procedure The Power Wave has eight memory locations which can be used to store all the settings of up to eight welding procedures Once stored in a memory location a procedure can be recalled for later use with the RECALL FROM MEMORY key To save a newly created welding procedure Press the SAVE TO MEMORY key and then one of the MEMORY LOCATION NUMBER keys Keep a record of this number for future reference Any previously created welding procedure stored in that location will be erased If you press the SAVE TO MEMORY key but decide not to save the procedure you can exit this function by pressing the DISPLAY RECALL key MEMORY LOCATION NUMBER KEYS To view information about any stored welding procedure simply press its MEMORY LOCATION NUMBER key As you hold down the selected key the procedure description and gas type of the procedure appear in the display window The process type is shown by the indicating light opposite the appropriate process symbol When you release the selected key the wire size material type and process description appear for a few seconds This function does not display the wire feed speed and voltage or arc length trim settings To view these you must recall the procedure from memo ry with the RECALL FROM MEMORY key POWER WAVE 450 LINCOLN amp OPERATION 10 RECALL FROM MEMORY KEY This key is used to recall an existing
37. LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory is active at any given time POWER WAVE 450 LINCOLN amp OPERATION SETUP OVERLAY The Setup Overlay is used to control the water cooler operation on off and prime the water cooler and to set up the voltage sensing configuration of the machine and wire feeder s connected to the Power Wave See Figure B 7 FIGURE B 7 SETUP OVERLAY o re ete ua Gaye See N a INVERTEC POWER WAVE 22 71 ELECTRIC 350 450 500 1 LCD DISPLAY WINDOW 2 WATER COOLER ON OFF KEY 3 WATER COOLER PRESSURE LIGHT 4 PRIME WATER COOLER KEY WIRE WIRE FEEDER 1 FEEDER 2 eae G 2 uS WATER COOLER SETUP P LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 0 This message is then replaced by the following message POWER WAVE SETUP WATER COOLER ON OFF KEY Press this key to toggle the water cooler between being enabled and disabled The present status of the water cooler is indicated by the WATER COOLER ON light 5 WIRE FEEDER 1 POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY WATER COOLER PRESSURE LIGHT This light indicates wheth
38. NT Sorry No C O D Orders CHECK ONE Address Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only Credit Card Signature as it appears on Charge Card er No III ee ate LI Ly i USE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 5 00 L formation Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H Lec wies i et Incentive Management IM al al New Approach to Industrial Economics 5 00 NA Educational Video Information ED 93 Lames F Lincoln Arc Welding Foundation Book Information JFLF 515 Welding Preheat Caiua 300 WC8 Pipe Welding Charts 450 EDV I SUB TOTAL Aeon Shipping Costs pe TOTALCOST Ce ee ee ee ee l WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulat
39. Nameplate AWG IEC AWG IEC Size Amps Sizes MM Sizes MM 200 50 60 60 230 50 60 60 400 50 60 60 460 50 60 60 575 50 60 60 200 50 60 100 230 50 60 100 400 50 60 100 460 50 60 100 575 50 60 100 Weight 138 kg 304 Ibs OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 to 40 C 50 to 85 C POWER WAVE 450 LINCOLN 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 K 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 fil ters Failure to observe these precautions can result in excessive operating temperatures and nuisance shut downs The Power Wave may be used outdoors Power Wave power sources carry an IP23 enclosure rating They are rated for use in damp dirty environments sub
40. OURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN B 5 5 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The voltage and or wire feed speed will not adjust to user satis faction The voltage and or wire feed speed can be adjusted on the wire feeder but the changes are not shown on the Power Wave The Dual Procedure overlay is installed The user cannot change from procedure to procedure or vice versa The display can not be seen clear ly or can not be seen at all Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Certain limits may have been imposed on the welding parame ters Refer to the Limits Overlay section in the Operations section of this manual to change the set limits 1 When the Limits Overlay or the Setup Overlay is placed on the machine the Power Wave s and feeder s displays do not match These overlays can not be used for welding 2 If two wire feeders connect ed to the Power Wave only one
41. OWER SOURCE POWER WAVE 450 LINCOLN B 1 1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING 0 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 40 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 com bustibles ARC RAYS can burn RE Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual HOT COOLANT can burn skin dm Always be sure coolant is not hot before 2 doing any work on cooler parts POWER WAVE 450 LINCOLN amp 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
42. RETURN TO MAIN MENU IM542 D INVERTEC POWER WAVE s 450 ROBOTIC For use with machines having Code Numbers 10344 10513 10611 10345 10514 10346 10515 10347 10516 10431 10608 10432 10609 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 him proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN UAL AND THE SAFETY PRE CAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful ELLE OPERATOR S MANUAL 2 150 9001 m an i e 3 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LINCOLN Copyright 2001 Lincoln Global Inc e World s Leader in Welding and Cutting Products e 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 i SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of Califo
43. RW1 30 WDO8 Spare robot output P82 Z J104 10 Display analog GND D K J10 13 CRW1 31 WDI Wire stick detect P82 N J104 11 Water GND D K J16 12 CRW1 32 WDI Wire stick detect P82 P J104 12 67 Sense lead SNUB J60 8 CRW1 33 24V Robot PWR P82 r CRW1 34 24V Robot PWR P82 r J105 1 Isolated voltage signal P82 J ADCH1 82 9 105 2 Isolated current signal P82 L ADCH2 J105 3 Abnormal operation signal P82 h WDI6 1105 4 Arc start command P82 WDO1 P82 R Fanuc models J105 5 Arc detect signal P82 d WDI2 L P82 C Motoman models J105 6 Gas flow command P82 S WDO2 J105 7 Gas shortage signal P82 e WDI3 J105 8 DPS command P82 X WDO7 J105 9 Positive inch command P82 U WDO4 6 3 MISCELLANEOUS CONNECTIONS J105 10 Negative inch command P82 V WDO5 J105 11 Short detect signal P82 N WDI 4105 12 Short detect signal P82 P WDI P84 Gas shortage input 4105 13 Isolated water signal P82 g WDI5 P84 B Gas shortage GND J105 14 Touch sense command P82 T WDO3 J105 15 Voltage command P82 A DACH1 J105 16 WFS command P82 E DACH2 J106 1 Touch sense signal CTRL J24 4 J106 2 Isolated touch sense signal P82 c WDI1 J106 3 Robot 24V P82 r 24E J106 4 Robot GND P82 a 0V J106 5 Robot analog GND P82 F COMDA2 J106 6 Spare robot output P82 Z WDO8 J106 7 Gas shortage input P84 A J106 8 Gas shortage GND P84 B POWER WAVE 450 Nov97 LINCOLN jo ELECTRIC D 1 D 1 ACCESSORIES FIGURE D 1 WIRE FEED
44. S command P82 E J101 4 Serial loop CTRL J27 4 CRW1 4 COMDA2 WFS command GND P82 F CRW1 5 WDI1 Touch sense signal P82 c J103 1 42VDC Full wave bridge cows NDS Are detect P82 d as fault P82 e J103 2 42VDC Full wave bridge CRW1 8 WD P82 f J103 3 Touch 2 4 output 2 PROT J34 4 CRW1 9 WDI5 Water fault P82 g J103 4 Touch 2 4 output 4 PROT J34 7 CRWA1 10 WDIG Power fault P82 h J103 5 Tach PWR P83 G CRW1 11 WDI7 P82 J103 6 Tach signal P83 F CRW1 12 WDI8 P82 k 41037 Tach GND P83 H CRW1 13 ADCH1 Voltage feedback P82 J 40928 Mole POSA CRW1 14 COMAD1 P82 K J103 9 Motor P83 B J103 10 Weld 2 4 output 2 PROT J34 11 CRIS ORG Current egbaek Say J103 11 Weld 2 4 output 4 PROT J34 14 CRW1 17 J103 12 Gas solenoid P83 C CRW1 18 J103 13 Gas solenoid P83 D 103 14 67S icad P83 N CRW1 19 OV Robot GND P82 a 340345 ae CRW1 20 OV P82 b 710316 CRW1 21 OV P82 m CRW1 22 OV P82 n CRW1 23 WDO1 Weld start P82 R 4104 1 Voltage signal CTRL J21 4 CRW1 24 WDO2 Gas start P82 S J104 2 Current signal CTRL J21 7 CRW1 25 WDO3 Touch sense P82 T J104 3 Water PWR D K J16 4 command J104 4 output signal SNUB J60 3 CRW1 26 WDO4 Wire P82 U J104 5 output signal SNUB J61 4 CRW1 27 WDO5 Wire P82 V J104 6 Water signal D K J16 5 CRW1 28 WDO6 P82 W J104 7 Control GND CTRL J24 11 CRW1 29 WDO7 Dual procedure switch P82 X J104 8 TRIM command D K J10 12 TIG command J104 9 WES command D K J10 2 WF 1 C
45. T S OUTPUT PROBLEMS 1 Each time an overlay is changed make certain that the machine is powered up with the new overlay in place 2 Make certain that the correct overlay ID number is displayed on power up Refer to the Operation Section of this manual 3 In some cases some of the keys on the overlay may be locked out Refer to the Operation Section of this manual for the overlay descriptions 1 Make certain the overlay is installed properly 2 Inspect the overlay bar code sensors on the front panel Fig 17 Item 8 If they are dirty blow them out with low pressure air and clean with soft cloth 3 Inspect for damage to the Bar Code s on the back of the overlay 1 Contact your local Lincoln authorized Field Service Facility for Technical assistance RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The Beeper Piezoelectric Buzzer cannot be heard machine operating normally The welding parameters that were saved in memory are different when recalled The
46. a n eat ei e es C 4 4 5 GAS FAULT iin RUPTURE RM Hg e UE RC gd C 4 4 6 WATER FAULT nri e eee tiie READ Er nl dear C 4 44 POWER FAULT an pte p Sedan dines ane eae C 4 4 8 VOLTAGE FEEDBACK nn pede ele nn dt C 4 4 9 CURRENT FEEDBACK rare e dai aide OO tities eine tail 4 4 I0 WEED START er hide ERE P E E ELA C 4 4 II GAS START Lt 4 4 12 TOUCH SENSE 0 21 0 ne eee nese teeter C 4 S WIRE eto ete nai Aneta ae 4 4 14 DUAL PROCEDURE SWITCH 1 01 4 4 15 WIRE STICK DETECT ene De Pe RED pe ue tiber C 4 5 ROBOT CONTROLLER SETUP C 5 5 1 WELD SYSTEM SETUP eine A Pe ee id C 5 5 2 WELD EQUIPMENT SETUP cite er itc ED hr ain riens C 5 5 3 SYSTEM VARIABLES etn ett e ERO ean RR e ERO RE RAR tr ns C 5 5 4 TOUGH SENSING SETUP nete eee ne HERR eee Pd C 5 6 CONNECTIONS e e tu e UO Rb ped ed pd C 6 6 1 POWER WAVE INTERFACE BOARD seems C 6 6 2 ARCTOOL WELDING INPUTS AND 5 222 4 00 0 0 C 6 6 3 MISCELLANEOUS CONNECTIONS ire C 6 Accessories en re ein Hs ru age Section D Water Cooler Usage 5 p b b e e nettes b ded p e en D 1 Reco
47. am ination Carefully remove hardened debris with den tal pick if necessary without scratching inside of the pump Reinstall strainer and acorn nut tightening with 75 15 in Ibs of torque Wipe dry all areas wetted by coolant Dispose of towels in an environmentally responsible manner see Recommended Coolants 4 Gently rinse the reservoir s strainer under running water to thoroughly clean it 5 Remove fan shroud and inspect hoses and electrical har nesses for kinking or damage cut abrasion swelling etc Replace if necessary 6 Remove accumulated dust from cooler especially from the motor and heat exchanger by blowing it off with shop air or vacuuming it out The heat exchanger fins are sharp but can be easily bent Treat them with care to avoid personal injury and damaging them Remove the cooler from the machine for a more thor ough cleaning job 7 Motor lubrication is recommended once a year Remove plug over lube port at top of motor near fan end Add 20 drops of electric motor or SAE 10 oil then reinstall plug 8 Flush coolant from the system and replace with fresh rec ommended coolant at least once a year More frequent flushing may be necessary depending upon a user s par ticular system or its usage NOTE Never run the pump dry Always use a recommended coolant otherwise pump damage may result 9 Reinstall the G3503 cooler into the Power Wave machine G3503 COOLER SERVI
48. ath speed SCRATCH START FUNCTION 10 Scratch start 11 Distance 12 Return to start speed ON THE FLY FUNCTION 13 On The Fly 14 Voltage increment 15 Wire feed increment 16 Current increment OTHER FUNCTIONS 17 Weld from teach pendent 18 Runin 19 Wire burnback retract ROBOTIC INTERFACE 5 ROBOT CONTROLLER SETUP ENABLED DISABLED DISABLED ENABLED ENABLED ENABLED DISABLED Omm 200mm s DISABLED 5mm 12mm s ENABLED 1 0V 5 0IPM 5 0A ENABLED DISABLED DISABLED WELD EQUIPMENT SETUP 1 Weld process 2 Remote arc enable 3 Weld power control 4 Wire feed control 5 Wire Wire speed 6 Wire feed speed units WELD RUN IN 7 Voltage 8 Current 9 Wire feed 10 Time WIRE BURNBACK RETRACT 11 Voltage 12 Current 13 Wire feed 14 Time TIMING 15 Arc start error time 16 Arc detect time 17 Arc loss error time 18 Gas detect time 19 Gas purge time 20 Gas preflow time 21 Gas postflow time WIRE STICK FUNCTION 22 Reset 23 Resettries 24 Voltage 25 Time VOLTAGE OUTPUT SCALING 26 Minimum reference 27 Maximum reference 28 Minimum output 29 Maximum output CURRENT OUTPUT SCALING 30 Minimum reference 31 Maximum reference 32 Minimum output 33 Maximum output C 5 DISABLED 1 50 0V 0 00s 0 60V 9 60V 50 0V 150 0V 0 00V 10 00 0 0A 400 0A WIRE FEED SPEED OUTPUT SCALING 34 Minimum reference 35 Maximum reference 36 Minimum output 37 Maximum output VOLTAGE INPUT SCALING 38 Min
49. biet eite teda Section B Safety INStructions rss sin ee UE COPS E B 1 Quick Start Reference for Process Selection 0 B 2 G n ral Description resns dent e e e GR d de eg cit Ur o e B 3 Synergic Welding Ene tb etae be ee etre ttes B 3 Recommended B 3 Operational Features and Controls ss B 3 Design Features and Advantages emen nennen enne nnne B 3 Welding Capabilityz rrt rit tri rr ra eue rre tu torio nes Dea ere gen d an B 3 3 Controls and Settings cie cet et P P e s B 4 Gase Front COntrolS oorr rete t nte ep tv tct rebat perd tup baci PER de nn B 4 Operating Overlays sessi eios nti ei Wai anal e eed ed e eh B 5 OVerVIew uc iE eta eR e a trata e even B 5 Installingan OVenay 5 Overlay et eo B 6 Pulse GMAW FCAW Stick Overlay siens B 7 Robotic Interface Weld from Memory Dual Procedure B 10 Vii Limits Overl y uaa dut t e p ee tee B 12 Setup Overlay stg e de ie e e ie PU e RR d i a P ET il B 14 Wire Feeder Setup Description ss B 15 Overview of Welding Procedures iii B 16 FCAW and GMAW iude re e eet o ri lv qe ENTER iii B 16 Pulse Proc du
50. bout the selected procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the se lected procedure for as long as the key is held depressed When the key is released material type wire size and process descriptions will be displayed for a few seconds 5 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out 6 MEMORY LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory is active at any given time 7 TOUCH SENSE LED This light comes on during the touch sensing sequence when a touch sensing robot controller is used POWER WAVE 450 LINCOLN 12 12 OPERATION LIMITS OVERLAY OPTIONAL The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length trim for any welding procedure stored in memory See Figure B 6 FIGURE B 6 LIMITS OVERLAY POWER WAVE 450 LINCOLN ELECTRIC WELDING PROCEDURE LIMITS 1 LCD DISPLAY WINDOW 2 RECALL FROM MEMORY KEY 3 MEMORY LOCATION NUMBER KEYS LIMIT UP DOWN KEYS SAVE TO MEMORY KEY DISPLAY RECALL KEY 4 SET LIMIT KEY onou MEMORY LIGHTS 1 LCD DISPLAY WINDOW Power up the machine Determine the memory location number of the with this overlay in place
51. c or when the engine is running Stop the engine and allow it to cool before refuel ing 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 6 some cases it may be necessary to remove safety ae T minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possib
52. called from memory the display window will show the SELECT A MEMORY procedure description wire feed speed and the LOCATION preset voltage or arc length trim of the LAST pro cedure welded with 2 MEMORY RECALL KEYS The following four With this overlay in place the wire feed speed and m mo paite are available on this overlay the preset voltage or arc length trim can be y changed from the robot controller The new values Memory 1 and Memory 2 will replace the previous values and become a per Memory 3 and Memory 4 manent part of the procedure Memory 5 and Memory 6 Memory 7 and Memory 8 If limits have been set on the wire feed speed volt age or arc length trim of the selected procedure these limits will be active when this overlay is in Select a memory location PAIR for the two desired place They cannot be overridden from this over welding procedures by pressing either of the two lay corresponding MEMORY RECALL NUMBER keys If no procedure was saved to one of the memory pair locations the following message appears MEMORY LOCATION 15 EMPTY In this case select another memory pair POWER WAVE 450 LINCOLN amp 11 OPERATION 3 PROGRAM LIST The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory A Dry Erase mark er should be used for this purpose 4 DISPLAY RECALL KEY To view other information a
53. ce la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la
54. cotter pin it is held in place by a friction fit POWER WAVE 450 LINCOLN B D 7 D 7 ACCESSORIES To Mount 50 601 22 7 27 2kg Coil 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull it out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor loosen the spinner nut and remove the cover plate 3 Before cutting the tie wires place the coil of elec trode on the reel so it unwinds as the reel rotates clockwise a Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires see illustration below b When loading 030 045 0 8 1 2mm elec trode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil sides need ed for trouble free wire feeding see illustration c Put the cover plate on the reel so that the four arms of the cover straddle and are in line with the spring loaded arm of the reel proper SPINNER NUT COVER PLATE SLOTS CARDBOARD COIL LINER 4 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms 5 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back
55. ctric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4 th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYME
56. d in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY iv PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toute
57. debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN V V for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product ee as much pride as we have in bringing this product to you 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 for future reference This information can be found on your machine nameplate Model Name amp Number Code amp 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION
58. dicates that the shielding gas is missing The Power Wave has external connections avail able for a normally open gas pressure or flow switch If a switch is installed and the gas fault function is enabled then gas loss errors will be reported to the robot controller WIRE FAULT This is an active low input to the robot controller which indicates a wire feeding problem or the lack of welding wire This signal is not connect ed in the Power Wave WATER FAULT This is an active low input to the robot controller which indicates a water cooling problem The Power Wave monitors the water cooling pressure to decide if a water fault has occurred If the water cooling pressure drops below 5 8psi then the water fault signal is held low to report an error to the robot controller POWER FAULT This is an active low input to the robot controller which indicates a power fault in the Power Wave If for some reason the 15V power supply in the Power Wave is below 15V then the power fault signal is held low to report an error to the robot controller VOLTAGE FEEDBACK This is an analog input to the robot controller with a range of 0 to 10V The internal arc voltage sig nal in the Power Wave is multiplied by 2 and iso lated to produce the voltage feedback signal A voltage feedback signal of 7 620V is equal to an arc voltage of 80 0V 2 10 CURRENT FEEDBACK This is an analog input to the robot controller with a range of 0 to 10V The internal
59. disabled voltage sensing is done at the Power Wave output terminal When enabled the WIRE FEEDER 1 ELECTRODE SENSE LEAD ENABLED light will be illuminated WIRE FEEDER 1 WORK SENSE LEAD KEY Use this key to disable work sense 21 lead sensing in all robotic applications Press this key until the WIRE FEEDER 1 WORK SENSE LEAD ENABLED LED is OFF WIRE FEEDER 2 controls are used for touch sensing They must be set to polarity electrode sense lead enabled and work sense lead disabled WIRE FEEDER SETUP DESCRIPTION The Power Wave may be Set up for either positive or negative arc voltage sensing using any two of the following places 1 the positive output terminal of the Power Wave 2 the negative output terminal of the Power Wave 3 the electrode sense lead 67 lead of the wire feeder The SETUP Overlay allows you to select between which two places arc voltage will be sensed Once the selection is made it is not necessary to reconfirm the selection every time a new overlay is used or a wire feeder is replaced with another one The selection will remain until it is changed with the SETUP Overlay When welding with a stick procedure the arc volt age is automatically measured between the Power Wave s output studs POLARITY KEY A Positive Polarity Voltage Sensing In most welding applications the electrode cable is connected to the output terminal and the work cable is connected to the output terminal
60. e 30VDC miscellaneous output 4 bit 3 on the control board Maximum Load Current 0 2A The signal is then isolated from the control ground Transistor Type Open collec inverted and tied to the robot controller welding input 1 tor NPN WDI1 The active state table is responsible for set POWER WAVE 450 LINCOLN B C 4 C 4 ROBOTIC INTERFACE ting and clearing the miscellaneous output 4 4 4 ARC DETECT The arc detect signal is generated from the voltage and current signals on the control board The arc detect cir cuit is calibrated to detect a minimum arc of 15V and 30A The signal is isolated from the control ground and tied to the robot controller welding input 2 WDI2 45 GAS FAULT This signal is not connected to anything on the inter face board The signal WDI3 is simply re routed from the robot connector P82 to the miscellaneous con nector P84 A gas fault is generated when this signal is tied to the robot ground 4 6 WATER FAULT The water fault signal is generated by an active high w low water pressure reading signal on the display board The signal is then isolated from the display ground inverted and tied to the robot controller weld ing input 5 WDI5 4 7 POWER FAULT The power fault signal is generated by checking the 12 8V supply on the interface board If the supply volt age on the interface board drops below 11 2V then a power fault signal is generated The signal is then iso lated from t
61. e has no output no fans no display Main input fuses are open indicating excessive input current draw Machine has no output no dis play fans run Machine has no output no dis play fans run circuit breaker 5 amp repeatedly trips Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check for proper input voltage connections 2 Make certain the reconnect panel is configured properly for the applied voltage 3 Replace the input fuses with proper size and ratings If the fuses fail again contact your local Lincoln Authorized Field Service Facility 1 Check circuit breaker 5 amp located on the front panel Reset if necessary 1 Remove the feeder control cable from the machine If symptoms disappear feeder or control cable is faulty RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN B TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output fans run display is on Machine re
62. e is evident when the sheet metal cover s are removed Machine is dead no output no fans no displays Machine has no output fans are running display is on a click ing sound is heard coming from the machine POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance 1 Make certain that the input power switch S1 is in the ON position 2 Check for proper input voltage must match the rating on the machine nameplate 3 Make certain the reconnect panel is configured properly for the applied voltage 4 Check fuse F1 in the recon nect panel If faulty replace with 5 amp slow blow fuse 1 Turn power OFF immediately 2 Check for proper input voltage per machine nameplate 3 Make certain the reconnect panel is configured properly for the applied voltage RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN 3 F 3 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machin
63. e yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra 79 OHLMPT APYORAPHRBS NTWSHRELTFSU RREAN 945 CE EC SUE yee Xe su nisle e 2x9 AXE HZA ole gu do ill elay QuAL ye aual ay ASI gl uit asi Qu YJE tn e Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez a l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CRAP TUSEOOM CORRE THEN EA e i 9 E Vi en BET 12 AS AIX uie Jo ALD a gll pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps
64. econnect your machine for the proper input volt age see the reconnect instructions on your input access door and 1 Move the large input voltage switch to the proper position according to your input volt age and the labels near the switch 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 recepta cle 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 70mm 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 exces sive 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 f
65. elding is not possible until the machine is allowed to cool and the High Temperature Light goes out Current Protection The Power Wave is limited to producing 750 amps peak current If the average current exceeds 540 amps the peak current will automatically be cut back to 100 amps until the average current decreases to 50 amps POWER WAVE 450 LINCOLN amp ROBOTIC INTERFACE 1 INTERFACE DESCRIPTION This interface is designed for a Power Wave 450 Fanuc robot using ArcTool software V1 30P with touch sensing and through arc tracking The interface responds to all of the ArcTool welding inputs and out puts except wire fault and wire stick alarm All of the circuitry for touch sensing is internal to the Power Wave no external power supply is required The cur rent signal for through arc tracking is supplied by the Power Wave no external current sensor is required The interface does not control wire feed speed and welding voltage independently Rather the Power Wave is always operating in a synergic mode and the welding voltage is programmed as a function of the wire feed speed ArcTool software was designed to control wire feed speed and voltage independently Since the Power Wave system uses an arc length trim the volt age cannot be directly controlled The welding voltage settings in the robot controller are interpreted by the Power Wave as a trim setting Any ArcTool function which tries to set the voltage to z
66. en feeding with the gun energized the electrode and drive mechanism are always HOT to work and ground and could remain HOT several seconds after the gun trigger is released 2 While tightly holding the electrode cut off the bent end and straighten the first 6 150mm Cut off the first 1 25mm If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest CD TZ Insert the free end through the incoming guide tube E Press the Cold Inch key or the gun trigger and push the electrode into the drive roll 5 Feed the electrode through the gun O Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with lit tle or no overrun when wire feeding is stopped Do not overtighten Wire Reel Loading 50 6016 22 7 27 2kg Coils K299 Wire Reel Mounting Kit Adjustable Wire Reel Brake The mount for standard 50 60 Ib 22 7 27 2 kg elec trode coils includes a two position brake assembly Generally the brake should be at the inner position nearest to the wire reel shaft for wire feed speeds below 400 in min 10m m It should be at the outer position for the faster wire speeds often used when feeding small diameter electrode To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the
67. er enough coolant pressure exists for normal water cooler operation If the water cooler loses the required pressure it will shut down within a couple of seconds and the water cooler pressure light will turn off If the water cooler does not have enough pressure to operate when enabled the machine also sounds a buzzer PRIME WATER COOLER KEY The water cooler may have to be primed if there is not enough pres sure in the water cooler hose for operation Make sure that the water cooler has been turned on before it is primed The WATER COOLER ON light should be turned on Check reservoir for proper coolant level See Water Cooler informa tion in ACCESSORIES section To prime the water cooler hold the PRIME WATER COOLER key down While this key is pressed the display will show PRIME WATER COOLER POWER WAVE 450 LINCOLN amp 15 15 OPERATION When the WATER COOLER PRESSURE light turns on release the key WIRE FEEDER 1 POLARITY KEY Press this key to change the present voltage sensing polari ty of wire feeder 1 The present polarity of wire feeder 1 is indicated by the WIRE FEEDER 1 POLARITY light If wire feeder 1 is set for positive voltage sensing polarity this light is turned on WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY Press this key to enable or disable the elec trode sense lead lead 67 of wire feeder 1 When enabled voltage sensing is done by the electrode sense lead When
68. er 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 appli cation WELDING CAPABILITY The Power Wave 450 is rated at 500 amps 40 volts at 6096 duty cycle based on a ten minute time period It is capable of higher duty cycles at lower output cur rents If the duty cycles are exceeded a thermostat will shut off the output until the machine cools to a rea sonable operating temperature LIMITATIONS The Power Wave is not recommended for process es other than those specified by available overlays The Power Wave is not recommended for pipe thawing POWER WAVE 450 LINCOLN amp 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 1 CASE FRONT CONTROLS Y LCD DISPLAY POWER SWITCH HIGH TEMPERATURE LIGHT REMOTE CONTROL AMPHENOL RECEPTACLE 5 AMP CIRCUIT BREAKER LCD DISPLAY ADJUSTMENT LN H CASE FRONT CONTROLS Refer to Figure B 1 for the location of the following controls 1 LCD DISPLAY Provides welding pr
69. ero and control the wire feed speed is actually only setting the arc length trim to the minimum Refer to the Operation section for a complete description of arc length trim Any function which tries to set the wire feed speed to zero and con trol the voltage is actually only setting the wire feed speed to the minimum speed of the selected process The following is a list of functions which do not work as intended by Fanuc due to the synergic operation of the Power Wave 1 1 WELDING VOLTAGE In this interface all welding voltage settings must be thought of as an arc length trim This arc length trim will increase or decrease the arc volt age for a specific wire feed speed setpoint The scaling in the robot controller is setup to allow voltage numbers between 50 and 150 A voltage number in the robot controller of 100 equals the nominal voltage no trim adjustment for the selected wire feed speed If the arc length needs to be increased then the voltage trim number is increased For example if a voltage number of 115 is used then the arc voltage will increase too approximately 15 above the nominal voltage for the wire feed speed setpoint in use 1 2 WIRE BURNBACK FUNCTION The burnback function controlled by the robot controller will not operate properly The function was setup to use a wire feed speed of zero while setting the welding voltage to some level The system will produce the minimum wire feed speed for the selected procedure
70. etailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment This Troubleshooting Guide is provided to help you lo cate and correct possible machine misad justments Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting Step 2 PERFORM EXTERNAL RECOMMEND ED TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious exter nal pos sibilities that may contribute to the machine symptom Perform these tests checks in the order listed In gen eral these tests can be conducted without removing the case wraparound cover Step 3 CONSULT LOCAL AUTHORIZED FIELD SERVICE FACILITY If you have exhausted all of the recommended tests in step 2 consult your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN amp TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam ag
71. gularly overheats yel low light LED on the front panel glows indicating a thermal over load The fans run and the display is on Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure that the machine was powered up with a properly installed overlay With no overlay on the machine or an invalid over lay the machine will have no out put 2 Check to see if the Limits or Setup overlay is installed on the front panel These two overlays can not be used for welding 3 Check for proper input voltage per machine nameplate 4 Make certain the reconnect panel is configured properly 5 Check that when the trigger is pulled on the wire feeder the wire feeder s voltage display changes to indicate arc voltage If this does not happen feeder may be faulty 6 Check feeder control cable for loose or faulty connections 7 If the machine is connected for 380 VAC or higher and has not been used for a long period of time the capacitors may require conditioning Let the machine run at an idle state no load for 30 minutes 1 Welding application may exceed recommended duty cycle 2 Dirt and dust may have clogged the cooling channels inside the machine Refer to the Maintenance Section of this man ual 3 Air intake and exhaust louvers may be blocked due to inade quate clearance around machine RECOMMENDED C
72. he control ground and tied to the robot con troller welding input 6 WDI6 4 8 VOLTAGE FEEDBACK The arc voltage feedback signal is generated on the control board The interface board then filters multi plies by 2 and isolates the signal from the control ground The signal is then tied to the robot controller analog input 1 ADCH1 A voltage feedback signal of 7 62V is equal to an arc voltage of 80V 49 CURRENT FEEDBACK The arc current feedback signal is generated on the control board The interface board then filters multi plies by 4 and isolates the signal from the control ground The signal is then tied to the robot controller analog input 2 ADCH2 A current feedback signal of 8 32V is equal to an arc current of 750A 4 10 WELD START The weld start command is generated by active low welding output 1 WDO1 The signal is then isolated from the robot ground inverted and tied to the inter face trigger input 4 11 GAS START The gas start command is generated by active low welding output 2 WDO2 The signal is then isolated from the robot ground and tied to the gas solenoid dri ver 4 12 TOUCH SENSE COMMAND The touch sense command is generated by active low welding output 3 WDO3 The signal is then inverted and isolated from the robot ground with an output made to conduct 24VAC The 24VAC connection is the wire feeder 2 trigger 4 13 WIRE amp WIRE These two signals work together to cold inch the wire at
73. het wrench Motor mounting bolts two 7 16 open end wrenches Motor harness ground at motor 1 terminals 2 relay terminals 1 and 2 2 large blade slotted screwdriver 8 in minimum long relay terminals 3 and 4 medium slotted screwdriver All plumbing components two 10 inch adjustable wrenches 1 4 hex socket with wrench 1 4 hex socket with wrench needlenose pliers REMOVING AND INSTALLING THE G3503 1 COOLER 1 Preparation Always switch off the Power Wave machine power Always disconnect the Power Wave machine from service input power 2 Remove cooler assembly G3503 a remove gas cylinder s from tray b remove cooler access panel c Remove both fasteners from base that hold cool er in place Remove ground lead if present Carefully pull cooler assembly rearward until cooler s Molex connectors are visible d disconnect cooler s connectors from the P3 and P4 harnesses Continue pulling the cooler out of the Power Wave 3 If necessary perform periodic maintenance or ser vice on the cooler 4 Reinstall cooler by reversing tasks in step 2 Be sure to reattach ground lead if previously removed 5 If necessary fill cooler with selected coolant to spec ified level see Fig 1 6 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs 7 Reconnect service input power to the Power Wave verify that the reconnect panel setting and lead p
74. imum reference 39 Maximum reference 40 Minimum output 41 Maximum output CURRENT INPUT SCALING 42 Minimum reference 43 Maximum reference MIG 44 Minimum output DIO 45 Maximum output Wire FD AO 5 3 SYSTEM VARIABLES 80IPM AWEUPR WSTK ENA DLY IPM 5 4 TOUCH SENSING SETUP 50 0V Sensor port type 250 0A Sensor port number 200IPM Circuit port type 0 00s Circuit port number 50 0V 250 0A 0 005 2 00s 0 10s 0 30s 0 05s 1 00s 0 50s 0 00s POWER WAVE 450 LINCOLN 0 60V 9 60V 50IPM 770IPM 0 0219V R 7 268 7 620 7 289V ZERO 0 020 0 0V 80 0V 0 7848V R 8 32 8 317 9 104V ZERO 0 58 0 80 0 0A 750A 0 10s WI WO APR97 ROBOTIC INTERFACE 6 CONNECTIONS 6 1 POWER WAVE INTERFACE BOARD 6 2 ARCTOOL WELDING INPUTS AND OUTPUTS J101 1 Serial loop CTRL J27 1 CRW1 1 DACH1 Voltage command P82 A J101 2 High speed sense 1 P83 K CRW1 2 COMDA1 P82 F J101 3 High speed sense 2 P83 L CRW1 3 DACH2 WF
75. ing the softer the arc If you change the setting your new setting will be dis played POWER WAVE 450 LINCOLN amp OPERATION GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance digitally controlled inverter welding power source Capable of complex high speed wave form control It uses three phase input power only The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder 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 more things working together to achieve an effect which nei ther 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 syner gic system the wire feeder and power source must talk together This means that only certain wire feed ers 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
76. intenance of Wire Feed Unit A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring 0 When inching with gun trigger electrode and drive mechanism are hot to work and ground Turn OFF welding power source before installing or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should do main tenance or troubleshooting work Observe all additional Safety Guidelines detailed throughout this manual Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lubri cant out of the bearing The driver roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll s is to be used the roll s and guide tubes must be changed The drive rolls for 045 1 2mm and 052 1 3mm cored electrode and 1 16 1 6mm 068 1 7mm 5 64 2 0mm and 3 32 2 4mm electrode have a double set of teeth so they can be reversed for addi tional life Between the two knurled rolls except 1 16 1 6mm and smaller roll s is a shim washer which limits the damage to the electrode if wire feeding prob lems occur Drive rolls for 023
77. is not con fused with a welding voltage 2 2 WIRE FEED SPEED COMMAND This is an analog output from the robot controller with a range of 0 to 10V The wire feed speed command sets both the wire feed speed and the synergic output of the Power Wave The wire feed speed command limits in the robot con troller are entered as 50 to 7701 PM for a stan dard drive head and 80 to 1100 IPM for a high speed drive head POWER WAVE 450 LINCOLN 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 ROBOTIC INTERFACE TOUCH SENSE SIGNAL This is an active low input to the robot controller which indicates that the welding electrode has touched the work piece To start touch sensing the touch sensing command must be held low by the robot controller Then the Power Wave mon itors the current through the electrode to deter mine if it is touching the work piece If the touch sense command is held low and the electrode is touching the work piece then the touch sense signal will be held low to report a touch to the robot controller ARC DETECT This is an active low input to the robot controller which indicates that a welding arc has been detected The Power Wave monitors the arc volt age and current to determine if an arc is estab lished If an arc is not established then the arc detect signal is held high to report an error to the robot controller GAS FAULT This is an active low input to the robot controller which in
78. ject to occasional falling water such as rain However the best practice is to keep the machine in a dry sheltered area since a wet environment speeds corrosion of parts Do not place the machine in puddles or other wise submerge parts of the machine in water This may cause improper operation and is a possible safe ty hazard STACKING Power Wave machines cannot be stacked TILTING Each machine must be placed on a secure level sur face 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 loca tion of the rating plate FIGURE A 1 RATING PLATE LOCATION 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 electri cal codes and the connection diagram located on
79. l should perform this installation Observe all additional Safety Guidelines detailed throughout this manual Standard 4 Roll Kits KP655 and KP656 1 Turn off welding power source 2 Release both quick release levers by sliding the levers sideways into the open positions 3 Remove clamping screw amp clamping collar from the drive shaft closest to the incoming side of the feeder 4 Install drive roll onto keyed shaft Do not exceed the maximum wire size rating of the wire drive Replace collar and tighten clamping screw 5 Back out the set screw for the middle guide tube Install the middle guide tube and slide it up against the drive roll DONOT TIGHTEN THE MIDDLE GUIDE AT THIS TIME O Install the outgoing drive roll following the same procedure as steps 3 amp 4 7 Center the middle guide between the two drive rolls and tighten in place 8 Back out the screws for the incoming and outgoing guide tubes 9 Install the longer guide tube in the rear hole near the incoming drive roll Slide the tube in until it almost touches the roll Tighten in place 10 Install the remaining guide tube in the front hole Be certain that the proper plastic insert is used Fine wire chisel point tube must have largest radius next to drive roll Tighten in place 11 Re latch both quick release levers 12 To start new electrode straighten the first 6 150mm and cut off the first 1 25mm Insert free end
80. lacement match the service voltage 8 Prime the cooler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level Fig 1 Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 9 Check coolant level Add if required POWER WAVE 450 LINCOLN 6 6 MAINTENANCE G3503 COOLER PERIODIC MAINTENANCE 1 Preparation Always switch off the Power Wave machine power Always disconnect the Power Wave machine from service input power Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine 3 Clean the pumpss inlet strainer Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants Place absorbent towels underneath pump head Hold pump head to apply countertorque when loos ening strainer s 7 8 acorn nut Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head Gently rinse strainer under running water to thor oughly clean it Use the mirror to inspect inside of pump for cont
81. le 2 d 2 Never coil the electrode lead around your body 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 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 X 8 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 5 Do not work next to welding power source Mar 95 LINCOLN 8 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 scaffold
82. mmended Coolant etre ec deleto ond a ea ten e eR TED ET D 1 Priming the Coolere HU futt danni rae tetas Boe eat D 1 Wire Feed Unit Dimension Print ire D 2 Mounting the Wire Feed Unit me dee beet i Pe eie eee D 3 Connecting Wire Feed Unit to Power 5 2 ss D 3 Electrode Routing eim EHE bad vo eb aibi eai D 3 Drive Roll and Guide Tube Kits D 4 Procedure to Install Drive Roll amp Guide Tubes VV D 4 Idle Roll Pressure Setting sise D 5 K659 1 Gas Guard Regulator seen D 5 VUE ICI Br Te To D 5 Routine Maintenance of Wire Feed Unit D 8 Gun Cable Connector Requirements sn D 9 viii tide ete tide euet Section E Safety Precautions ata t tea d at anne OR de Pre P t En E 1 Routine and Periodic Maintenance E 1 Input Filter Capacitor Discharge Procedure eene E 1 Resistor Locations ere e EE ee ETE REPRE E 2 BIEdenzIe ME lem E 3 Resistors With ee rete a gH Dd aide RR C E ER EQ ERR E 3 Preventive aintenancCe nennen nennen nennen nre nenne nennen E 4 Recommended Tools for Installation or Service of Cooler E 5 G3503 Installation or Service Tool Usage nnn E 5 Removing and Installing the G3503 Cooler E 5 G3503 Cooler Periodic
83. must be paid to the weld to avoid losing the puddle Speed is a matter of deposition rate All things being equal regarding the joint being welded the speed will depend on the wire feed speed The travel speed is maximized by maintaining a very short arc Often the process is trimmed down until the arc crackles The spatter increases slightly but many of the advantages of pulsing are retained When welding steel the Power Wave is designed to run well in this region between pulse and short arc The pulsing process greatly affects the heat input to the workpiece This can be a valuable tool for either increasing or decreasing the heat input with a given process For instance it is possible to greatly increase the heat input when welding steel at high deposition rates On the other hand it is possible to reduce the heat input using the pulsing process For example heat input is reduced greatly with some of the low current stainless steel procedures using the processes pro grammed into the Power Wave In all cases the Power Wave procedures have been checked for their ability to deliver a sound weld However the fusion of the weld metal into the workpiece may be affected It is the responsibility of the user to determine if the welds pro duced are suitable and sound The Power Wave is optimized for use with a 0 75 1 9 cm stickout The adaptive behavior is pro grammed to support a stickout range from 0 5 to 1 25 1 3 to
84. ne is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE 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 Welders are shipped connected for the highest input voltage listed on the rating plate To change this con nection for a different input voltage refer to reconnect instructions which follow and to the reconnect dia gram supplied with your machine located inside your reconnect access door See example Figure 2 FIGURE A 2 CONNECTION DIAGRAM ON RECONNECT INPUT ACCESS DOOR NOTE Turn main input power to mthe machine OFF before perform ing reconnect procedure Failure to do so will result in damage to the machine DO NOT switch the re connect bar with machine power ON SHOWN TO GROUND PER INPUT SUPPLY CONNECTION DIAGRAM NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 440 OR 460 VOLTS CONNECT 11 12 amp L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF CRI CONTACTOR AS 2 CONNECT LEAD MARKED ELECTRICAL CODE n lt y ae 4 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE NY o VOLTAGE 200 208V CE NC 1 1 8208889 WARNING ELECTRIC SHOCK KILL
85. ng Engage both idle rolls before welding In most applications best wire feeding will occur when both idle roll pres sures are set the same K659 1 Gas Guard Regulator Adjustable flow regulator with removable adjustor key for CO and Argon blend gases Mounts onto wire feed unit inlet and reduces gas waste and arc start blow by reducing surge caused by excess pressure in sup ply hose Gas Guard Regulator Optional K659 1 Setting 1 With the gas supply shut off the Gas Guard regu lator flow adjusting key should be set to maximum full clockwise which is rated to be 60 SCFH 28 Its min 2 Adjust gas supply flow rate for a level higher than will be required then adjust Gas Guard flow adjust ing key counterclockwise to the desired gas flow rate 2 IN O D SPINDLE ADAPTER RETAINING SPRING GROOVES READI REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR Wire Reel Loading Readi Reels and Spools using K162H Spindle Kit with 2 51mm spindle TO MOUNT A 30 LB 14 KG READI REEL PACKAGE USING THE MOLDED PLASTIC K363 P TYPE ADAPTER 1 Make certain that the threaded locking collar is tight and securely locks the adapter on the spindle see figure above 2 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 3 Position the Readi Reel so that it will rotate in a clockwise direction when feeding wire is to be de reeled from bottom of the coil 4 Se
86. ocedure infor mation and parameters such as wire type gas type WFS trim etc 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 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tempera ture situation occurs Output is disabled until the machine cools down At that point the light goes out and output is enabled again REMOTE CONTROL AMPHENOL RECEPTACLE Allows remote current control during stick welding via a hand or foot Amptrol accessory 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 LCD DISPLAY ADJUSTMENT Use a small flat blade screw driver to adjust the viewing angle of the LCD display POWER WAVE 450 LINCOLN amp 5 OPERATION OPERATING OVERLAYS OVERVIEW The Power Wave is controlled by a panel of keys key pad located on the front of the machine The opera tor can access controls by placing an overlay over the keys An OVERLAY is a special plastic sheet with a number of keys and
87. ocedure switch When the Power Wave is running a dual proce dure overlay this output is used to switch between procedures If the output is held high by the robot controller then procedure A is active and if the output is held low then procedure B is active 2 18 WIRE STICK DETECT This is a resistance measuring input to the robot controller used to detect a wire stick The intended use for this resistance check is to mea sure the resistance between the output terminals of the weld equipment This is not directly possi ble with a Power Wave because the resistance between the output studs is always 40 Ohms or less Additional circuits have been added to allow the wire stick detect to work properly although it is not directly measuring the resis tance between the output studs If a resistance of approximately 100 Ohms or less is found then a wire stick error is reported by the robot con troller 3 INTERFACE CIRCUIT DESCRIP TIONS A CAUTION All of the signals between the Power Wave and the robot controller were designed to operate in a shielded cable No surge or high frequency protection has been added to the circuitry 3 1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS The following signals are referenced to the robot con trollers 24V supply unless otherwise noted total allowable load on the 24V supply is 0 7A The following is a brief description of the electrical characteristics for a full description see the Fan
88. of the feeder s settings can be dis played on the Power Wave at one time Pull the trig ger of the wire feeder whose settings you want displayed on the Power Wave 1 Check for proper installation of the Dual Procedure overlay 2 Check the Dual Procedure Gun Trigger or separate Dual Procedure switch 1 Adjust the viewing angle of the display Follow the instructions pro vided in the Operation Section of this manual Look under the LCD DISPLAY ADJUSTMENT in the CONTROLS AND SETTINGS sub section of the Operation sec tion RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN B 6 6 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Machine does not respond to keys being pressed or the machine has improper displays Machine display reads Error Invalid Overlay or it displays an incorrect overlay ID number on power up Machine displays ERROR S L NOT INITIALIZED on power up POSSIBLE AREAS OF MISADJUSTMEN
89. of the power source This is positive polarity voltage sensing When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of two ways These two ways are shown in Table B 1 Table B 1 Positive Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Electrode Sense 67 Lead Output Terminal Use the ELECTRODE SENSE LEAD KEY to select either the output terminal or the electrode sense 67 lead for the positive voltage reference B Negative Polarity Voltage Sensing In some welding applications such as shield the electrode cable is connected to the output terminal and the work cable is connected to the output terminal of the power source This is negative polarity voltage sensing When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of two ways These two ways are shown in Table B 2 Table B 2 Negative Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Electrode Sense 67 Lead Output Terminal Use the ELECTRODE SENSE LEAD KEY to select either the output stud or the electrode sense 67 lead for the positive voltage reference Select arc voltage sensing polarity first POWER WAVE 450 LINCOLN amp
90. or connec tions 1 Check for proper wire feed speed setting In the MIG MAG and FCAW Modes check for prop er voltage settings In the MIG MAG Pulse Modes check the arc length trim setting These con trols are on the wire feeder 2 Check for proper shielding gas and gas flow 3 Check for loose or faulty weld ing cables 1 The machine may be trying to deliver too much power When the average output current exceeds a maximum limit the peak current is drastically cut back Lower the welding parameter settings and or increase the stickout length to eliminate this problem RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and
91. or water cooler operation and recom mended coolants WIRE FEEDER CONNECTIONS Refer to the Accessories section for Wire Feeder Con nections Refer to Setup overlay in Operation section for Wire Feeder Configuration POWER WAVE 450 LINCOLN B INSTALLATION POWER WAVE 450 ROBOTIC DIMENSIONS ry S 2 m HERE N Y ow 15 50 L 18 76 19 50 i 35 82 Too 38 82 Y POWER WAVE 450 LINCOLN B 6 6 INSTALLATION POWER WAVE 450 ROBOTIC SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM POWER WAVE 450 ROBOTIC SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM SYNERGIC 7F WIRE DRIVE K679 1 LOW SPEED K679 2 HIGH SPEED CONSULT IM559 FOR CE LATEST INFORMATION DRIVE ROLLS CONSULT IM559 FOR LATEST INFORMATION POWER WAVE 450 ROBOTIC CUSTOMER MUST PROVIDE COOLERI WIRE DEREELING METHOD K1447 2 WI WATER COOLER K680 681 T5 ROBE CONTROL TO WIRE DRIVE CABLES CONTROLLER REQUIRED APPROPRIATE WORK CABLE SIZE AND LENGTH TO WORK APPROPRIATE MAGNUM GUN AND CABLE ASSEMBLY AND ADAPTER IF REQUIRED WIRE FEEDER CONTROLS ARE LOCATED WITHIN THE POWER WAVE 450 ROBOTIC P
92. 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 LINCOLN amp 6 6 OPERATION OVERLAY TYPES Overlay Overlay Figure Four types of overlays can be used with the Power Wave 1 GMAW PULSE GMAW FCAW STICK PROCESS 1 Process Overlays These overlays are used to SELECTION OVERLAY BA create save and recall specific welding proce dures by selecting and adjusting the various weld 2 ROBOTIC INTERFACE ing settings that have been programmed into the WELD FROM MEMORY Power Wave at the factory DUAL PROCEDURE OVERLAY B 5 2 Weld From Memory Overlays These overlays 3 LIMITS OVERLAY B 6 also called Shop Overlays provide a simple way 3 SETUP OVERLAY B 7 for operators to recall and use any of the welding procedures that have been stored in the memory This overlay IS optional See Accessories Section of the Power Wave for Order Numbers 3 Setup Overlays These overlays provide specific machine setup information such as operating lim its for the welding procedures stored in memory 4 Special Purpose Overlays These are custom overlays for specific customer applications Detailed information on how to use currently available Power Wave overlays follows POWER WAVE 450 LINCOLN amp
93. owing four selections should always be performed in this order process elec trode class electrode size electrode gas type Selecting a setting for one component narrows your choice of available settings in remaining com ponents This is why the order of performing the steps is important However if you make compo nent selections out of order the machine will prompt you to make a new selection for any set tings that do not apply 2 PROCESS SELECT KEY Use the PROCESS SELECT key to select from the processes avail able in the machine Press the PROCESS SELECT key until the light by the desired process selecting a combination of these components from the EE ones that have been programmed into the Power Wave See Figure B 4 for key locations POWER WAVE 450 LINCOLN B OPERATION ELECTRODE CLASS UP DOWN Use the ELEC TRODE CLASS UP or DOWN keys to select from the material types available for the selected process Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis played ELECTRODE SIZE UP DOWN Use the ELEC TRODE SIZE UP or DOWN keys to select from the wire diameters available for the selected process and material type Press the ELECTRODE SIZE UP or DOWN key until the desired wire diameter is displayed ELECTRODE GAS TYPE UP DOWN KEYS Use the ELECTRODE GAS TYPE UP or DOWN keys to select from the programs available for the select ed process material type and wire diameter Press the ELE
94. pors 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 Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area 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 LINCOLN 8 CYLINDER may explode or s 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 maintaine
95. procedure from memory You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations Simply press the RECALL FROM MEMORY key and then the appropriate MEMORY LOCATION NUMBER key If you press the RECALL FROM MEMORY key and then change your mind you can exit this function by pressing the DISPLAY RECALL key If the memory location you select does not contain a stored welding procedure this will be indicated in the display window Select another memory loca tion It is not necessary to save a procedure back to memory after it is recalled from memory When a procedure is saved into a memory location it can be recalled from there until another procedure is stored in that location or the location is cleared The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location Press the SAVE TO MEMORY and then the RECALL FROM MEMORY key Recan Do not press both keys at the same time A message in the display window will ask you to press the MEM ORY LOCATION NUMBER key of the memory location you want to clear If you press the SAVE TO MEMORY and RECALL FROM MEMORY keys and then change your mind you can exit this function by pressing the DISPLAY RECALL key 11 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high
96. res ete ed eec S RE lea B 16 Wave Cohtrol RR PRAEFERT EAT ER AUCH Pia adel El tete B 16 Pulse Welding ee t ee qr e pe b e c d e dE ond ua B 18 Overload PtotectiOn iucd ceo ei e Aaa hein eerte eb bud b PR Bad B 18 Thermal Protection ai recen tr e e B 18 Current Protection ced e ced ei e behead baie B 18 UR eU tra MEG x eran Section C INTERFACE DESCRIPTION 1 Tel WELDING VOLTAGE eicit ord reet eere eh Poser eges Pee sir 1 1 2 WIRE BURNBACK FUNCTION Ne 1 1 3 WIRE STICK RESET FUNCTION et b e E 1 1 4 COLD WIRE INCHING FUNCTION inner 1 2 ROBOT SIGNAL DESCRIPTIONS sese 1 2 1 VOLTAGE COMMAND tit ore c e e RE E ER d AE 1 2 2 WIRE FEED SPEED COMMAND 2 271 02 6 00 1 2 3 TOUCH SENSE SIGNAL de te Ee UR REX RECO E ACE Ta 2 2 4 ARC DETECT tender re cr e RR RR AERE BEER nn Tu ena dd 2 2 5 GAS FAURE e re debet s 2 2 6 WIRE FAU T es are ERR ER casts RR 2 e Pre er Pre e na nA e ae 2 2 8 POWER FAULT ne ter eds rete e tov tar etre tete rent ater dd 2 2 9 VOLTAGE FEEDBACK anses et anna men tan adit
97. rnia to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 pur chase of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 em MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame weld ing ar
98. s 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc
99. s les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du
100. s 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 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 employers safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAFETY 7 WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 va
101. sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on pla
102. symbols printed on one side and a bar code printed on the other See Figure B 2 The print ed 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 Ecran THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA INVERTEC POWER WAVE HIGH TEMP Before Power Wave is turned ON the operator selects the desired overlay and mounts it in the over lay 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 for ward See Figure B 3 for door location FIGURE B 3 OVERLAY ACCESS DOOR 1 OVERLAY ACCESS DOOR 2 OVERLAY FRAME 3 ACCESS DOOR INDENT 4 TRACKS 5 LOCATING PINS 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
103. t one of the Readi Reel inside cage wires on the slot in the retaining spring tab 5 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter O Slide cage all the way onto the adapter until the retaining spring pops up fully A WARNING Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding electrode POWER WAVE 450 LINCOLN B D 6 D 6 ACCESSORIES 7 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle To Mount 10 to 44 Ib 4 5 20kg Spool 12 300mm Diameter For 8 200mm spools a K468 spindle adapter must be used REQUIRES INSTALLATION OF 2 51MM K162H SPINDLE KIT 1 Remove the locking collar on the 2 51mm diame ter spindle 2 Place the spool on the spindle making certain the brake holding pin enters one of the holes in the back side of the spool Be certain the wire comes off the reel in a clockwise direction when de reeled from the bottom of the coil 3 Replace and tighten the locking collar Feeding Electrode and Brake Adjustment 1 Turn the Readi Reel or spool until the free end of the electrode is accessible A WARNING Wh
104. temperature light goes out POWER WAVE 450 LINCOLN amp 10 10 OPERATION ROBOTIC INTERFACE WELD FROM MEMORY DUAL PROCEDURE OVERLAY The Weld From Memory Dual Procedure Overlay lets an operator recall and use any welding procedure stored in one of eight memory locations See Figure B 5 FIGURE B 5 ROBOTIC INTERFACE WELD FROM MEMORY DUAL PROCEDURE OVERLAY RE cet cree om mr T T n POWER WAVE 450 1 LCD DISPLAY WINDOW 2272 2 MEMORY RECALL KEYS Omat ss 3 PROGRAM LIST p Ex suite 4 DISPLAY RECALL KEY A 5 HIGH TEMPERATURE LIGHT O O 6 MEMORY LIGHTS O 7 TOUCH SENSING LIGHT 20 568 O 1 LCD DISPLAY WINDOW Power the machine Set the dual procedure switch or gun trigger to the with this overlay in place When the Power Wave position for PROCEDURE A or PROCEDURE B is turned on the following message appears in the Position A activates the welding procedure from display window for a few seconds the odd numbered memory locations 1 3 5 or 7 LINCOLN ELECTRIC Eod B activates the welding procedure Ln Version X X the corresponding even numbered memory loca tions 2 4 6 or 8 For example if memory loca This display is followed by tion 3 was selected Position A activates the procedure from memory location 3 Position B OVERS ID activates the procedure from memory location NUMBER 10 DR eco When a pair of welding procedures are re
105. through the incoming tube Press gun trigger amp push wire into the drive roll POWER WAVE 450 LINCOLN B D 5 D 5 ACCESSORIES Idle Roll Pressure Setting The idle roll pressure is set at the factory backed out three turns from full pressure on 4 roll feeders This is an approximate setting For small wire sizes alu minum wire up to 9 or 10 turns out may be required to minimize birdnesting The optimum idle roll pressure varies with type of wire surface condition lubrication and hardness The optimum idle roll setting can be determined as follows 1 Release the incoming idle roll pressure arm then press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the pressure setting out 1 2 turn run new wire through gun and repeat above steps 3 If the only result is drive roll slippage disengage the gun locking nut and pull the gun cable forward about 6 150mm There should be a slight wavi ness in the exposed wire If there is no waviness the pressure is too low Increase the pressure set ting 1 4 turn reconnect the gun tighten the locking nut and repeat the above steps 4 After the outgoing pressure is set determine how many turns away from full pressure the setting is Set both idle roll tensions to this setti
106. u minated e Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated POWER WAVE 450 LINCOLN amp D 2 4 Check coolant level Add more if required Rear Panel of Power Wave Reservoir Screen 2 Visible Coolant Level D 0 25 to 0 50 inches Figure D 2 D 2 ACCESSORIES Do Not Use Any prepacked welding industry coolant mixture such as those offered by Miller OKI Bernhard or Dynaflux These coolants contain sub stances which attack plastic components and may shorten the life of the system Once added these sub stances are virtually impossible to purge from the sys tem DO NOT USE OIL BASED COOLANTS OF ANY TYPE L9777 WIRE FEED UNIT DIMENSION PRINT GUN CABLE FITTING SWING ARM CLOSED OF WIRE FOR THE LATEST SYNERGIC 7F INFORMATION CONSULT 559 1 17 8 06 el 281 HOLES FOR a MOUNTING WIRE FEED UNIT NN GAS FITTING 9 _ REMOTE 47 CONNECTOR P i 2 Le INLET ae 1 44 TYP e L O i 2 VU ry O TRIGGER CONNECTOR CONNECTOR
107. uc electrical connections manual 3 1 1 DIGITAL OUTPUTS C 3 3 1 2 DIGITAL INPUTS Maximum Input Voltage 28VDC High Input Voltage 20 to 28VDC Low Input Voltage 0 to 4VDC Input Impedance 3 3K Ohms Response Time 5 to 20mS 3 1 3 ANALOG OUTPUTS Weld equipment analog outputs are isolated from the robot controller 24V supply Maximum Output Range 0 to 10V Load Impedance 3 3K Ohms or more 3 1 4 ANALOG INPUTS Maximum Input Range 0 to 10V 3 1 5 WIRE STICK DETECT The wire stick detect output is isolated from the robot controller 24V supply 15VDC 85mA Maximum Output Voltage Maximum Output Current 4 POWERWAVE CIRCUITS 4 1 VOLTAGE COMMAND The voltage command from the robot controller 1 is directly connected to the TIG analog input on the display board of the Power Wave This signal is not connected to the robot or control ground Maximum Input Range 0 to 10V Typical Zero Offset 0 55 to 0 65V Typical Range 9 0V Input Impedance 200KQ 42 WIRE FEED SPEED COMMAND The wire feed speed command from the robot con troller DACH2 is directly connected to the WF1 ana log input on the display board of the Power Wave This signal is not connected to the robot or control ground Maximum Input Range 0 to 10V Typical Zero Offset 0 55 to 0 65V Typical Range 9 0V Input Impedance 200KQ 4 3 TOUCH SENSE SIGNAL Rated Voltage 24VDC The touch sense signal is generated by active high Maximum Applied Voltag
108. ulse GMAW and FCAW Stick Process Selection Overlay The wave control is a setup parameter that may be adjusted when the welding procedures are set This feature pro vides an easy way to change the arc behavior without creating a new procedure The wave control setting of a procedure limits the speed at which the current waveform of that procedure can change Typically each procedure is programmed to have aver age wave con trol at the center of the scale In Pulse processes The wave control adjustment allows the frequency set ting to vary Increasing the wave control allows the fre quency setting to increase and decreasing the wave control allows the frequency setting to decrease Varying the wave control setting affects the droplet trans fer and allows fine tuning for different welding positions In GMAW FCAW processes The wave control adjusts the inductance Inductance is inversely proportional to pinch Increasing the wave control setting decreases the inductance which results in the arc getting colder and pinched tighter Decreasing the wave control setting increases the induc tance which results in the arc getting wider POWER WAVE 450 LINCOLN amp 17 OPERATION TABLE B 3 ADJ USTBLE PARAMETERS Adjustable Pulse GMAW Parameters FCAW Wire Feed Wire Feed WES Display Speed Speed Arc Length Preset Voltage Display Trim Voltage Power Wave 450 Display with GMAW Pulse Wave Wa
109. unt printed circuit boards e Power Switch Main Transformer Auxiliary Transformers Input Rectifier Heat Sink Fins Input Filter Capacitors e Output Terminals Terminal Strip Examine the capacitors for leakage or oozing Replace if needed Examine the wrap around and side covers for dents and breakage Repair them as needed The covers must be kept in good condition to assure that high voltage parts are protected and that cor rect spacings are maintained Remove welding cables and check the electrical ground continuity Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case The meter reading should be 500 000 ohms or more If the meter reading is less than 500 000 ohms check for electrical components that are not prop erly insulated from the case Correct component insulation if needed 8 Reconnect the shunt and wire 467 to the nega 10 11 12 tive output terminal Make sure the connection is tight Replace and secure the machine covers and han dle bar Remove the overlay from the front panel of the machine Clean the plastic case with a low pres sure airstream Wipe the sensors Fig D 4 Item 8 with a clean soft cloth Make sure the sensors are not scratched in the process Check the back of the overlays If the bar code black square s on the back of the overlay is scratched apply a dull black spray finish to the
110. ve GMAW and FCAW Control Control Selection Overlay Frequency Inductance TABLE B 4 DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS Power Wave 450 Trigger Position Pulse GMAW FCAW WES and WFS Open Arc Length Trim Preset Voltage WES WFS Actual Arc Actual Arc Closed Voltage Voltage Actual Arc Actual Arc Current Current POWER WAVE 450 LINCOLN amp B 17 18 18 OPERATION PULSE WELDING Some people have trouble getting used to the behavior of the pulsing arc The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appearance There are however a few things to keep in mind when pulse welding Spatter levels are often very low with the pulse welding process Pulsing is often used to eliminate cleaning operations necessary when using other weld ing processes Fume levels are sometimes lower with the pulsing process Whether or not you will get lower fume levels depends on the pulsing programs used Certain wave form characteristics are necessary to get low fume lev els Unfortunately low fume procedures are harder to weld with than procedures designed to optimize the welding process The pulsing process is not slower than other pro cesses The process is sometimes less forgiving when the arc gets on or ahead of the puddle More attention
111. water cooler does not turn on The machine beeps without the keys being pressed TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Background noise may be too loud for user to hear beeper 1 Make certain that a remote control unit is not connected When a remote control unit is used the weld parameters are set by the remote control potentiometers 1 Make sure that the water cooler has been enabled Refer to the Setup Overlay descrip tion in the Operation Section of this manual 2 The cooler s circuit breaker may have tripped 3 If the water cooler is enabled but generates insufficient coolant pressure the machine will beep loudly and the water cooler will shut down In this case prime the water cooler Refer to the Setup Overlay description in the Operation Section of this manual If the water cooler is enabled and the pres sure switch inside the water cooler opens due to inadequate coolant pressure the machine indicates this by beeping This happens regardless of the overlay placed on the machine In this case do the following 1 Turn the machine off and on a couple of times and see if the beeping continues If the pressure dropped momentarily then turning the machine off and on eliminates the beep ing A momentary pressure drop could be due to someone stepping on the water cooler hose for example 2 Check
112. welding Headshield and filter lens should conform to ANSI 287 1 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 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 23 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 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 Shielding gase
113. zes Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5oUtREd 9 fsPBHEILTABSSUCFEU e Fat in es Bit SH7IAE else MASH 918 7AAIAZIU ARSHAIS os iua bacs jua 5 axial oe ial uc Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e LFF YA H ERIRUD PSB ETRRAT FE BETTE e HERES BEER e SFH HAS Jab pil gS jud ghil e Do not operate with panel open or guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas CRMBIFELEWTE EU

Lincoln Electric IM542-D User's Manual

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