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Lincoln Electric IM579 User's Manual

1. 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 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 B 6 B 6 OPERATION OVERLAY TYPES Overlay Overlay Figure Type Name No 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 B 4 create save and recall specific welding proce dures by selecting and adjusting the various weld 2 WELD FROM MEMORY ing settings that have been programmed into the OVERLAY B 5 Power Wave at the factory 2 WELD FROM M EMORY DUAL 2 Weld From Memory Overlays These overlays PROCEDURE OVERLAY B 6 also called Shop Overlays provide a simple way 2 DUAL WIRE FEEDERS DUAL for operators to recall and use any of the welding PROCEDURES OVERLAY B 7 procedures that have been stored in the memory of the Power Wave 3 LIMITS OVERLAY B 8 3 Setup Overlays These overlays provide specific 3 SETUP OVERLAY B 9 machine setup information such as operating
2. Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorized Service Facility WARRANTY REPAIR If Lincoln or Lincoln s Authorized Service Facility confirms the existence of a defect covered by this warranty the defect will be corrected by repair or replacement at Lincoln s option At Lincoln s request the purchaser must return to Lincoln or its Authorized Service Facility any Goods claimed defec tive under Lincoln s warranty FREIGHT COSTS The purchaser is responsible for shipment to and from the Lincoln Authorized Service Facility WARRANTY LIMITATIONS Lincoln will not accept responsibility or liability for repairs made outside of a Lincoln Authorized Service Facility Lincoln s liability under this warranty shall not exceed the cost of correcting the defect of the Lincoln product Lincoln will not be liable for incidental or consequential dam ages such as loss of business etc caused by the defect or the time involved to correct the defect This written warranty is the only express warranty provided by Lincoln with respect to its products Warranties implied by law such as the warranty of merchantability are limited to the duration of this limited warranty for the equipment involved This warranty gives the purchaser specific legal rights The purchaser may also have other rights which vary from state to state Equipment manufactured for the Lincoln Electr
3. Electrode Sense Lead CEE Wire Feeder E Block Cable Work Cable POWER WAVE 450 LINCOLN amp B 19 B 19 OPERATION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING FCAW AND GMAW PROCEDURES For each wire feed speed a corresponding voltage has been preprogrammed into the machine by welding experts This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed If the wire feed speed is changed on the wire feeder the voltage automatically changes with it In some cases the operator may want to change the preprogrammed voltages for example to compensate for cable and fixture voltage drops The preset volt ages can be adjusted on the wire feeder s Voltage dis play 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 auto matically increases the preset voltages at all the other wire feed speeds by 10 percent In the GMAW FCAW process the display shows the Procedure Description WFS and Preset Voltage The preset voltage which was programmed 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 A or V sign will be displayed after the preset value When the gun trigger is pulled note that the display changes to
4. 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 amp TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output no fans no display Main i
5. glows indicating a thermal over load The fans run and the display is on TROUBLESHOOTING E 4 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 COURSE OF ACTION If all reco
6. the WFS Actual Arc Voltage and Actual Arc Current are displayed STICK TIG PROCEDURES Stick welding can be performed with the Power Wave by attaching a remote control kit to the 6 pin amphe nol on the front of the machine The K941 1 remote control kit is recommended Select the stick process from either the GMAW Pulse GMAW FCAW stick process selection overlay or recall it from a previously stored memory location with a Weld From Memory overlay When this process is selected the Power Wave reads the current amps setting from the remote control kit It also controls the output of the machine based on the position of the Output Terminals switch which is also located on the remote control kit When this switch is in the ON position the output terminals of the Power Wave are electrically hot When the switch is in the OFF position the output terminals of the Power Wave are electrically cold and the machine cannot produce an output In the stick process the LCD display shows Procedure Description and Preset Current SET The Current Trim is always equal to 1 T 1 00 When the trigger is pulled the Preset Current Actual Arc Voltage and Actual Arc Current are dis played See Tables B 3 through B 6 for a summary of the infor mation discussed above WAVE CONTROL The wave control settings of all procedures can be changed on the Power Wave GMAW Pulse GMAW FCAW Stick Process Selection Overlay The wave control is a setup pa
7. Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria Es1 APSMERTLSICLT F n o BAPHECTIHIEBELTIA D ECETIA OCF AAA A ARE e zs SH7IAE YelsHiAle e S XACE E 2743 AAS AH FAAA H4 587E Assis aadi ye lue chal si A Gal bio ya d Aach Jaial Jg it a Mall Ge gaal saa S e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas Desligue a corrente antes de fazer servi o e N o toque as partes el tricas nuas XVLFFYA Y EAKRUD PRE EFE Y Fe DBF MTF e His RK eE Hol AHS AESHIALE Aie dy LJ y Jl ale e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas O N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas NAWPAN eEDRWALEEE CRMRBIEELEWTEEU ERA SAA SRR Ro emago Yel Je AS OAL L t Cols Vil la lu nde Aale Viel Al ll ta WARNING Spanish AVISO DE PRECA
8. 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 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 distort
9. drops the pressure switch opens A couple of sec onds 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 indi cating that there is a problem with the water cooler operation When the water cooled system is turned on for the first time the coolant lines must be bled To accom plish this open the return line at the quick connect fit ting on the back of the Power Wave power source The return line is the upper of the two coolant fittings Place the return hose FROM THE FEEDER into a bucket to catch any spilled coolant and turn the machine off and on several times Pause each time to allow the cooler to run a complete 3 second cycle After 8 to 15 cycles coolant will spray from the return hose with some force indicating that the system is purged of air Replace the return line into the quick connect fitting The system is bled and ready for oper ation To avoid damage from freezing the water cooler is shipped without coolant The fill spout for the water cooling unit is located on the back panel of the machine on the left hand side See Figure C 1 The water cooler reservoir must be filled with coolant before use Use When Ambient Temperature is Above Freezing Use tap distilled deionized or well water Do not use salt water Use When Ambient Temperature is Below Freezing Use a mixture of 50 water and 50 automotive antifreeze
10. lim These overlays are optional See Accessories its for the welding procedures stored in memory Section for Order Numbers 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 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 RA PULSE GMAW FCAW STICK TIG PROCESS SELECTION OVERLAY oo ELECTRODE CLASS O RS E El ojo ELECTRODE SIZE ELECTRODE GAS TYPE ia o PANEL 1 PULSE GMAW FCAW STICK TIG PROCESS SELECTION men O THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 EE POWER WAVE 450 Oo PULSE ef THERMAL a of ff 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 O UU UNA 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 ELECTR
11. listed below 2 Years e Power Arc 4000 Power Arc 5000 Weldanpower 125 1 Year e AC 100 Invertec V100 S Invertec V130 S Invertec V200 T Pro Cut 25 Handy MIG 101 Handy Core 100 All water coolers internal or external models All stick electrode welding wire and flux Arc welding and cutting robots and robotic controllers e All Environmental Systems equipment including portable units central units and accessories Does not include consumable items listed under 30 day warranty e All welding and cutting accessories including wire feed modules undercarriages field installed options that are sold separately unattached options welding supplies standard accessory sets replacement parts and Magnum products Does not include expendable parts and guns torches listed under 90 and 30 day warranties 90 Days All gun and cable assemblies TIG and plasma torches and spool guns 30 Days e All consumable items that may be used with the environ mental systems described above This includes hoses fil ters belts and hose adapters Expendable Parts Lincoln is not responsible for the replacement of any expendable part that is required due to normal wear aaa LINCOLN World s Leader in Welding and Cutting Products ELECTRIC CONDITIONS OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorized Service Facility about any defect claimed under Lincoln s warranty
12. overloads loss of cooling and high ambient temperatures When the power source is subjected to any of these conditions or any of the con ditions mentioned above a thermostat will open The yellow high temperature light on the case front comes on See Figure B 1 for location Machine output is disabled and welding is not possible until the machine is allowed to cool and the High Temperature Light goes out OVER CURRENT PROTECTION The Power Wave 450 is limited to producing 750 amps peak currrent If the average current exceeds 540 amps then the peak current will be limited to 100 amps until the average current decreases to under 50 amps POWER WAVE 450 LINCOLN amp ACCESSORIES FIGURE C 1 WIRE FEEDER AND WATER COOLER CONNECTIONS OPTIONS ACCESSORIES e Synergic 7 wire feeder K632 1 standard speed or K632 2 high speed e MAGNUM 400 gun K471 2 or 550 gun K598 e Remote control stick welding K941 1 e Limits Overlay K946 4 e Dual Wire Feeders Dual Procedures Overlay K946 9 WIRE FEEDER SETUP The Power Wave must be used with wire feeders list ed above Mount the feeder in a location suitable to your needs For most applications connect the electrode cable between the feeder and the positive connection of the power source When negative electrode polarity is required such as in some Innershield applications connect the electrode cable between the feeder and the negative connection of the
13. pairs are available on this overlay Memory 1 and Memory 2 Memory 3 and Memory 4 Memory 5 and Memory 6 Memory 7 and Memory 8 4 DISPLAY RECALL KEY 5 HIGH TEMPERATURE LIGHT 6 MEMORY LIGHTS Select a memory location PAIR for the two desired welding procedures by pressing either of the two cor responding MEMORY RECALL NUMBER keys If no procedure was saved to one of the memory pair locations the following message appears MEMORY LOCATION 1S EMPTY In this case select another memory pair Set the dual procedure switch or gun trigger to the position for PROCEDURE A or PROCEDURE B Position A activates the welding procedure from the odd numbered memory locations 1 3 5 or 7 Position B activates the welding procedure from the corresponding even numbered memory locations 2 4 6 or 8 For example if memory location 3 was selected Position A activates the procedure from memory location 3 Position B activates the proce dure from memory location 4 POWER WAVE 450 LINCOLN amp B 12 OPERATION When a pair of welding procedures are recalled from memory the display window will show the procedure description wire feed speed and the preset voltage or arc length trim of the LAST pro cedure welded with With this overlay in place the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder The new values will replace the previous values and become a perma nent part of the pr
14. setting affects the droplet transfer and allows fine tuning for different welding positions In GMAW and FCAW processes The wave control adjusts the inductance Inductance is inversely proportional to pinch Increasing the wave control setting decreases the inductance which results in the arc getting colder and pinched tighter Decreasing the wave control setting increases the inductance which results in the arc getting wider In Stick processes The wave control adjusts the arc force Increasing the wave control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the wave control setting decreases the arc force mak ing the arc softer and smoother PULSE WELDING Some people have trouble getting used to the behav ior 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 appear ance 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 lev els depends on the pulsing programs used Certain waveform characteristics are necessary to get low fume levels Unfortunately low fume procedures are harder to weld
15. show WFS Actual Arc Voltage and Actual Arc Current See Table B 5 for display summary PULSE PROCEDURES In these procedures the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual voltage 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 procedure Instead an arc length adjustment is provided The machine knows what the best arc length is at the given wire feed speed but allows the operator to change it The arc length can be adjusted between 0 5 and 1 5 on the wire feeder s Voltage display An arc length trim of 1 0 means that no adjustments will be made to the preset arc lengths An arc length trim greater than 1 0 increases the preset arc lengths An arc length trim less than 1 0 decreases the preset arc lengths The arc length adjustment is factored in at all wire feed speed settings Refer to Table B 6 for summary of arc length trim 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 GMAW Pulse process the display shows the Procedure Description WFS and Arc Length Trim Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder When the trigger is pulled
16. 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 B 9 OPERATION 10 RECALL FROM MEMORY KEY This key is used to recall an existing procedure from memory You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations Simply press the RECALL FROM MEMORY key and then the appropriate MEMORY LOCATION NUMBER key Ifyou 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 D Press the SAVE TO MEMORY key and then the RECALL FROM MEMORY key Do not press both keys at the same time A message in the display window will ask yo
17. 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 ANY INTERNAL MACHINE COMPONENT DURING THIS PROCE DURE FIGURE D 2 DISCHARGE LABEL lt mOJ gt ION 0 T13086 117 FIGURE D 3 RESISTORS WITH LEADS CONNECTED A A De C 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 Ifany 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 1 D 4 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 Remove the hex head screws from the sides and top of the machine Remove the handle bar and the machine wrap around cover Remove the two case sides There are hex head screws o
18. April 1999 INVERTEC POWER WAVE 450 For use with machines having Code Numbers 10391 10392 10405 10406 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional features may have changed ISO 9002 eg e uality P SS a CERTIFICATE NUMBER an LINCOLN World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors 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 SAFETY WARNING ARC WELDING can be hazardous Cleveland Ohio 44117 1199 PERFORMED ONLY BY QUALIFIED INDIVIDUALS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJ URY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety informa
19. G ELECTRIC SHOCK can kill e Only qualified personnel should perform this installation K e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment e Do not touch electrically hot parts e 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 subject 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 proced
20. IC VERSION X X 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 selecting a combination ofthese components from the ones that have been programmed into the Power Wave See Figure B 4 for key locations DISPLAY RECALL KEY SAVE TO MEMORY KEY MEMORY LOCATION NUMBER KEYS RECALL FROM MEMORY KEY HIGH TEMPERATURE LIGHT NOTE The following 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 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 is lit POWER WAVE 450 LINCOLN amp B 8 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 ELEC
21. IMIT DOWN keys to change the minimum wire feed speed to the desired value Press the SET LIMIT key The present maximum and minimum voltage trim or arc length trim will be displayed Refer to Table B 3 to see how voltage trim affects preset voltage Refer to Table B 6 to see how arc length trim affects preset arc length Use the LIMIT UP and LIMIT DOWN keys to change the maximum value The maximum for either type is 1 5 Press the SET LIMIT key The new maximum and old minimum voltage trim or arc length trim will be displayed Use the LIMIT UP and LIMIT DOWN keys to change the minimum value The minimum for either type is 0 5 SAVE TO MEMORY KEY The SAVE TO MEMO RY KEY is used to save the procedure with the newly set limits to memory Press the SAVE TO MEMORY key followed by the MEMORY LOCATION NUMBER key of the desired memory location This does not have to be the original location from which the procedure was recalled Step 6 can be performed any time during the 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 desc
22. INES ARE SHIPPED FROM FACTORY e Disconnect pur poworpergre inspecting mune macnne Crore PERDIO CONNECTED FOR 440 OR 460 VOLTS AAN ing reconnect procedure Failure to INPUT LINES e Do not operate with covers removed R 1 CONNECT L1 L2 8 L3 INPUT EAU o Do not touch electrically live parts do so will result in damage to the SUPPLY LINES TO THEINPUT py ri SHOCK a i 8 S SIDE OF CR1 CONTACTOR AS CAN KILL Only qualified persons should install use machine DO NOT switch the re SHOWN Se l l l Et tie equipment connect bar with machine power GC E 2 CONNECT LEAD MARKED REPLACE WITH A 5 AMP SLOW BLOW ONLY ON D TO GROUND PER NATIONAL CRI ELECTRICAL CODE el el e 3 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 208 230V 208 230V 208 230V 380 415V ER A 380 415V eo A 380 415V S gt A 440 460V 440 460V 440 460V 4 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE o T Lo o o o L Be VOLTAGE 208 230V VOLTAGE 380 415V VOLTAGE 440 460V XD RW THE LINCOLN ELECTRIC CO CLEVELAND OHIO USA 20363 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 A 4 A 4 INS
23. M MEMORY KEY 3 MEMORY LOCATION NUMBER KEYS 4 SET LIMIT KEY 5 LIMIT UP DOWN KEYS 6 SAVE TO MEMORY KEY 7 DISPLAY RECALL KEY 8 MEMORY LIGHTS 1 LCD DISPLAY WINDOW Power up the machine Determine the memory location number of the with this overlay in place 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 RE NUMBER 4 This message is then replaced by the following a la Al message SET LIMIT KEY SELECT A MEMORY AND SEET LIMIT UP DOWN KEYS a RECALL PROM 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 B 15 B 15 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 L
24. OLER 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 whether enough water 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 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 OPERATION When the WATER COOLER PRESSURE light turns on release the key If this key has been pressed for 30 seconds and the WATER COOLER PRESSURE light still did not turn on check the water cooler for adequate fluid level 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 thi
25. SPLAY 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 We Feeder Poston qt Procedure size material type and process descriptions will 1 A 1 be displayed for a few seconds e i HIGH TEMPERATURE LIGHT The high tempera 4 B 4 ture light comes on when the internal machine Pull the trigger on either wire feeder Depending on the gun switch position the corre sponding memory location is automatically recalled The wire feeders memory chart has no keys it is simply a chart The display window will show the procedure description wire feed speed and the preset volt age or arc length trim of the last active welding procedure temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out MEMORY LIGHTS A memory light is on when its corresponding memory is slected This tells you what memory location is active at any given time POWER WAVE 450 LINCOLN amp B 14 B 14 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 8 FIGURE B 8 LIMITS OVERLAY POWER WAVE 450 LINCOLN E ELECTRIC WELDING PROCEDURE LIMITS 1 LCD DISPLAY WINDOW 2 RECALL FRO
26. TALLATION FIGURE A 3 FRONTPANEL BACK PANEL 3 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To operate at 208 230 VAC 1 Open the reconnect input access door 2 Move the input voltage switch to voltage 208 230V position 3 Move A lead to the 208 230V terminal To operate at 440 460 VAC No setup required The machine is factory connected to operate at 440 volts To verify do the following 1 Open the reconnect input access door 2 Check that the input voltage switch is set to Voltage 440 460V position 3 Check that the A lead is at the 440 460V 4 WATER COOLING FITTINGS ON BACK PANEL 5 WIRE FEEDER CONNECTIONS ON BACK PANEL 6 ELECTRODE TERMINAL 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 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 u
27. TOTAL COST LA mm m 2 ee WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O Japanese it ie BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da O Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e solez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra CO EFOEREMR RABE ELE het EE LATE OHLMPT APYORAPHRBS NTWSHRELTFSU o RREAN DEBREREAR SR O HATCHA d TH e Sal Siss HS aa s iss gu BAA ole e Su AXE HZA ole Je L Gre gi el ai wal je el ai ay ASI d o El ell Aal aal All E dg e die tg e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e RIVTOEODMTOREFE MBMICU THEN EA ep UB R ML TER LS Y Aal He Ad d s s S dall pis O Wear eye e
28. TRODE 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 ELECTRODE 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 exitthe 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 1 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 win
29. UCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ie BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HA OHBRBEE lt K RA ES TEMULT FE TLTRHOREMEN gt TFS EE eS A EA DS Ss co o AlSoll AE SAS HAY Set MAPAS EPIA HECH Aal veel Gl d illai aul y Llana d AAL all oig Gail call lala ag ls Gras L el El El an eed ee ed fed LIMITED WARRANTY STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company Lincoln warrants to the end user purchaser of all new welding and cutting equipment electrode and flux collectively called the Goods that it will be free of defects in workmanship and material This warranty is void if Lincoln or its Authorized Service Facility finds that the equipment has been subjected to improper installation improper care or abnormal opera tions WARRANTY PERIOD Lincoln will assume both the parts and labor expense of correcting defects during the full warranty period All war ranty periods date from the date of purchase to the original end user or from the date of manufacture if the original invoice cannot be provided and are as follows 7 Years e Main power rectifiers on all non inverter low frequency 50 and 60 Hz type welders 3 Years e All Lincoln welding machines wirefeeders and plasma cutting machines unless
30. a mixture of 50 water and 50 pure ethylene glycol or any commercial water alcohol mixture 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 substances are virtually impossible to purge from the system DO NOT USE OIL BASED COOLANTS OF ANY TYPE POWER WAVE 450 LINCOLN amp MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill a e Only Qualified personnel should perform this maintenance e 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 A 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 on each side A CAUTION TO PREVENT DAMAGE TO MACHINE AVOID UNNECESSARY MOVEMENT OF FRONT PANEL 4 Obtain a high resistan
31. anged 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 amp E 7 E 7 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Beeper Piezoelectric Buzzer cannot be heard machine operating normally The welding parameters that were saved
32. ar and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo 08 HRUSBCRBRELTE iD RR HRARGHRBAR ex 19 Sal HSE HSSHAR Adi y due de Lily lan Al o A ag 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute
33. ari C 2 Maintenance TEEN Section D SCHENTEN D 1 Routine and Periodic Maintenance ins D 1 Input Filter Capacitor Discharge Procedure D 1 Preventive Maintenance 32m a av EE EENS D 4 General Component Locations D 5 Troubleshooting and Repair Section E Electrical Diagrams nnc rd Section F Parts Manual cours a a ai aa E aeaa E Appendix POWER WAVE 450 LINCOLN amp vi A 1 A 1 INSTALLATION Input Voltages Input Currents 5004 40 VDC O 450A 38 VDC RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 230 400 460 60 Duty Cycle 450 38 VDC 230 400 460 100 Duty Cycle 400 38 VDC RATED OUTPUT Constant Open Continuous Process Circuit Voltage Current Range Current Ranges 75 Volts 5 520 Amps GMAW 50 520 Amps FCAW 40 520 Amps STICK 30 520 Amps Pulse Pulse Pulse and Background Pulse Current Range Voltage Range Time Range Frequency RECOMMEN INPUT WIRE AND FUSE SI Type 75 C Type 75 C Type 75 C Input Input Ampere Copper Wire in Ground Wire in Super Lag Voltage Rating on Conduit Conduit or Breaker Fregency Nameplate AWG IEC AWG IEC Size Amps Sizes MM Sizes MM 230 50 60 60 460 50 60 60 230 50 60 100 460 50 60 100 Weig 137 9 kg 303 5 lbs OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 to 40 C 50 to 85 C POWER WAVE 450 LINCOLN amp INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNIN
34. bon et s r tat 2 z defonctionnement PRECAUTIONS DE SURETE POUR LES d Ne jamais plonger le porte lectrode dans l eau pour le MACHINES A SOUDER A TRANSFOR ES MATEUR ET A REDRESSEUR e Ne jamais toucher simultan ment les parties sous ten EC sion des porte lectrodes connect s deux machines 1 Relier la terre le chassis du poste conformement au code souder parce que la tension entre les deux pinces peut de l lectricit et aux recommendations du fabricant Le dis tre le total de la tension vide des deux machines positif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Dans le cas de travail au dessus du niveau du sol se prot ger f contre les chutes dans le cas ou on recoit un choc Ne jamais 2 Autant que possible l installation et l entretien du poste enroule le c ble lectrode autour de n importe quelle partie seront effectu s par un lectricien qualifi du corps 3 Avant de faires des travaux l interieur de poste la 3 Un coup d arc peut tre plus s v re qu un coup de soliel debrancher l interrupteur la boite de fusibles donc 4 Garder tous les couvercles et dispostifis de s ret leur a Utiliser un bon masque avec un verre filtrant appropri place ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement 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 d
35. ca invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or 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 IMETHOD OF PAYMENT Sorry No C O D Orders Nana CHECK ONE EEN Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only I Credit Card o Telephone Si Signature as it appears on Charge Card A A e i l 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 Lincoln Welding School times Price Code Quantity Cost I ED 80 New Lessons in Arc Welding L Seminar Information Procedure Handbook Twelfth Edition 15 00 PH J ED 45 How to Read Shop Drawings 5450 H T Educational Video Information Incentive Management 5 00 IM etree A New Approach to Industrial Economics 500 NA Lames F Lincoln Arc Welding The American Century of John C meom 5 00 AC Y Foundation Book Information Welding Preheat Caloulator__________ 3 00 wcs __ _ SE Pipe Welding Oe 450 ED89 I SUB TOTAL OOOO Additional Shipping Costs if any I
36. call 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 2 The wave control scale displayed shows the default setting The higher the setting the softer the arc If you change the setting your new setting will be dis played POWER WAVE 450 LINCOLN amp B 3 OPERATION GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance digitally controlled inverter welding power source capable of complex high speed wave form control lt 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
37. ce 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 D 1 D 2 D 2 MAINTENANCE FIGURE D 1 RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5 Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine 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 is present be careful not to touch these resistors WARNING e ELECTRIC SHOCK can kill e Proceed with caution being care ful not to touch any internal machine components during the discharge procedure POWER WAVE 450 LINCOLN amp D 3 D 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
38. d 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 amp TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines 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 detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Each time an overlay is ch
39. dow 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 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 A Press the SAVE TO MEMORY key SAVE 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
40. e soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir Dout risque d incendie d tincelles POWER WAVE 450 LINCOLN amp V vV for selecting a QUALITY product by Lincoln Electric We want you J kont You to take pride in operating this Lincoln Electric Company product se 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 Number Code amp Serial Number Date of Purchase Whenever
41. ecure 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 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 D 5 D 5 MAINTENANCE FIGURE D 4 GENERAL COMPONENT LOCATIONS 1 DISPLAY BOARD BACK OF PANEL 2 POWER SWITCH 8 OVERLAY BAR CODE SENSORS 9 TERMINAL STRIP LOCATION 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 3 MAIN TRANSFORMER 6 HEAT SINK FINS 7 OUTPUT TERMINALS a Vin lt 7 e SEA POWER WAVE 450 LINCOLN amp TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE AA 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 detailed in the Safety Section of this manual to avoid electr
42. educe the size of the gun and improve parts life The Power Wave comes with a standard internal water cooler However an external cooler may also be used TABLE C 1 RECOMMENDED GUNS FOR USE WITH POWER WAVE 450 Gun Application Cooling Product No MAGNUM 400 GMAW Gas K471 2 MAGNUM 550 GMAW Gas K598 Use of the Synergic 7 wire feeder requires appropriate input cable assembly wire stand and drive roll kit Refer to Synergic 7 Operator s Manual for available options 11 96 POWER WAVE 450 LINCOLN amp C 2 ACCESSORIES 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 ona 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 C 1 Connect the water lines between these connectors and those on the wire feed er The water is fed through the feeder into the gun When a water cooler is used the water cooler must be enabled by using the Setup Overlay 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
43. er flow If such problems were found then correct them and turn the machine off and on to check if the beeping has been eliminated 3 Check the water cooler fluid level Low fluid 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 amp TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines 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 detailed in the beginning of this manual 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 poor connec tions 1 Check for proper wire feed speed setting In the MIG MAG and FCAW Modes chec
44. exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out MEMORY 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 B 11 OPERATION WELD FROM MEMORY DUAL PROCEDURE OVERLAY The Weld From Memory Dual Procedure Overlay lets an operator recall and use dual welding procedures stored in memory The overlay must be used with a separate dual procedure switch or a gun that has a two position trigger The switch or trigger selects which procedure will be active See Figure B 6 FIGURE B 6 WELD FROM MEMORY DUAL PROCEDURE OVERLAY memi mem2 O mm O weus O weu Er DUAL PROCEDURE A O mima O mme PROCEDURE A O E O O O POWER WAVE 450 a PANEL 3 WELD FROM MEMORY DUAL PROCEDURE us1652 gt LECTRIC COMP CLEVELAND OHIO USA e D THERMAL PROCEDURE B 1 LCD DISPLAY WINDOW 2 MEMORY RECALL KEYS 3 PROGRAM LIST 1 LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 3 This message is then replaced by the following message SELECT A MEMORY LOCATION 2 MEMORY RECALL KEYS The following four memory
45. flame welding arc or when the engine is run ning Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands air clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 7 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 7 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 7 g To prevent accidentally starting gasoline engines while turn ing the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 7 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC neos N may be dangerous Ee hb 8 a Electric current flowing through any conductor causes local ized Electric and Magnetic Fields EMF We
46. g or cutting operations and any other source of heat sparks or flame 5 d Never allow the electrode electrode holder or any other elec trically hot parts to touch a cylinder 5 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 5 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 5 g Read and follow the instructions on compressed gas cylin ders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 J efferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY pow ered equipment 6 a Turn off input power using the dis connect switch at the fuse box before working on the equipment 6 b Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations 6 c Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations POWER WAVE 450 LINCOLN amp SAFETY FOR ENGINE powered equipment 7 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 7 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Do not add the fuel near an open
47. ic Company is subject to the warranty period of the original manufacturer 2 All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty SAE400 WELD N AIR compressor is warranted by the compressor manu facturer and not covered by this warranty 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 Premier Manufacturer of Industrial Motors a Aaa El March 99
48. ical 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 E 2 E 2 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s
49. ically measured between the Power Wave s output studs L Select arc voltage sensing polarity first POLARITY KEY A Positive Polarity Voltage Sensing In most welding applications the electrode cable is connected to the output terminal and the work cable is connected to the output terminal of the power source This is positive polarity voltage sensing illustrated by Figure B 10 When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of four ways These four ways are shown in Table B 1 Table B 1 Positive Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Output Terminal Work Sense 21 Lead Electrode Sense 67 Lead Output Terminal Electrode Sense 67 Lead Work Sense 21 Lead Consult the factory before using this option Use the ELECTRODE SENSE LEAD KEY to select either the output terminal or the electrode sense 67 lead for the positive voltage reference The work sense 21 lead is used only in rare cir cumstances For most installations use the WORK SENSE LEAD KEY to select the output terminal for the negative voltage reference Consult the factory if use of the work sense 21 lead is desired B Negative Polarity Voltage Sensing In some welding applications such as Inner shield the electrode cable is connected to the output termina
50. in memory are different when recalled The water cooler does not turn on The machine beeps without the keys being pressed 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 If the water cooler is enabled but there is insufficient pressure in the water cooler hose 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 pressure in the water cooler hose 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 the water cooler hose for kinks and other places of reduced wat
51. ines detailed in the beginning of this manual POWER WAVE 450 LINCOLN amp B 2 OPERATION QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the Controls and Settings and Operating Overlays sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave NOTE Selection of certain options may limit the selection of subsequent options Step 1 Select your process information a Install the desired PROCESS OVERLAY b Turn the machine ON c Select the desired welding PROCESS d Select ELECTRODE CLASS olo ELECTRODE CLASS o o ELECTRODE SIZE MM IN e Select ELECTRODE SIZE EIS vw Le ofo f ELECTRODE GAS TYPE f Select ELECTRODE GAS TYPE EIS 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 EIS Step 2 Adjust the wire feed to speed WFS and voltage V or arc length T if necessary a Press the DISPLAY RECALL key to view additional procedure information b Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder The new values appear on both the wire feeder and the Power Wave display Step 3 Save process information if desired a Press the SAVE TO MEMORY key Save b Press one of the MEMORY LOCATION keys 1 8 You can re
52. ion 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 Electric 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 is hands on 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 4th 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 l 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 l For North Ameri
53. ion ou d autres S ret Pour Soudage A L Arc endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines 1 Protegez vous contre la secousse lectrique de levage c bles de grue ou atres circuits Cela peut a Les circuits l lectrode et la pi ce sont sous tension rose qe S ee S elas G SE des quand la machine souder est en marche Eviter tou ines Jusqu Au pent jours tout contact entre les parties sous tension et la 9 Assurer une ventilation suffisante dans la zone de soudage peau nue ou les v tements mouill s Porter des gants Ceci est particuli rement important pour le soudage de t les secs et sans trous pour isoler les mains galvanis es plomb es ou cadmi es ou tout autre m tal qui b Faire tr s attention de bien s isoler de la masse quand produit des fum es toxiques on soude dans des endroits humides ou sur un planch 10 Ne pas souder en pr sence de vapeurs de chlore provenant er metallique ou des grilles metalliques principalement d op erations de d graissage nettoyage ou pistolage La dans les positions assis ou couch pour lesquelles une chaleur ou les rayons de l arc peuvent r agir avec les grande partie du corps peut tre en contact avec la vapeurs du solvant pour produire du phosg ne gas forte masse ment roxique ou autres produits irritants c Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en
54. k 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 amp F 1 WIRING DIAGRAMS WIRING DIAGRAM f a JU L jist anion CAE 1 il 1 CA ba tal D I Edda DH DH DH DH k H DH pret Mantel cl or Drees NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels POWER WAVE 450 LINCOLN amp A Hr Hr ee WIRING DIAGRA Now Available 12th Edition The Procedure Handbook of Arc Welding
55. l and the work cable is connected to the output terminal of the power source This is negative polarity voltage sensing illustrated by Figure B 11 When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of four ways These four ways are shown in Table B 2 Table B 2 Negative Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Output Terminal Work Sense 21 Lead Electrode Sense 67 Lead Output Terminal Electrode Sense 67 Lead Work Sense 21 Lead Consult the factory before using this option POWER WAVE 450 LINCOLN amp B 18 B 18 OPERATION Use the ELECTRODE SENSE LEAD KEY to select either the output terminal or the electrode sense 67 e The two wire feeders can only be connected in the lead for the positive voltage reference same manner either by the Positive Polarity or the The work sense 21 lead is used only in rare circum Negative Polarity setup stances For most installations use the WORK SENSE LEAD KEY to select the output terminal for the negative voltage reference Consult the factory if use of the work sense 21 lead is desired FIGURE B 10 POSITIVE VOLTAGE SENSING POLARITY ee Wire Feeder D Block eg Cable Work Cable FIGURE B 11 NEGATIVE VOLTAGE SENSING POLARITY Control Cable includes 67 lead
56. lade screw driver to adjust the viewing angle of the LCD display POWER WAVE 450 LINCOLN B 5 B 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 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 fa Sc THELINGOLN El LINCOLN BIS INVERTEC POWER WAVE Before the 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
57. lding current cre ates EMF fields around welding cables and welding machines 8 b EMF fields may interfere with some pacemakers and welders have a pacemaker should consult their physician before welding 8 c Exposure to EMF fields in welding may have other health effects which are now not known 8 d All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 8 d 1 Route the electrode and work cables together Secure them with tape when possible 8 d 2 Never coil the electrode lead around your body 8 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 8 d 5 Do not work next to welding power source POWER WAVE 450 LINCOLN amp SAFETY PR CAUTIONS DE S RET 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un P our votre propre protection lire et observer toutes les instructions chauffement et un risque d incendie En EE de SC Ge a Sn 8 S assurer que la masse est connect e le plus pr s possible o AUSSI DIN QUE lee PleCauuons Ge EIS ENER ES de la zone de travail qu il est pratique de la faire Si on place antes la masse sur la charpente de la construct
58. ltage protection Digital signal processor and microprocessor control e RS232 interface for future welding application updates Simple reliable reconnection for various input volt ages e New accessories and wire feeders communicate using a digital current loop to transfer information e Auto device recognition simplifies accessory cable connections Direct support of two wire feeders e Auto configurable for either metric or English mode e Multiprocess control Stick short arc GMAW spray GMAW pulse and flux cored arc welding FCAW e 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 450 amps 38 volts at 60 duty cycle based on a ten minute time period It is capable of higher duty cycles at lower output 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 e The Power Wave is not recommended for process es other than those specified by available overlays e The Power Wave is not recommended for pipe thawing POWER WAVE 450 LINCOLN amp BA B 4 OPERATION CASE FRONT CONTROLS Refer to Figure B 1 for the location of the following controls CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the Power Wave Refer to Figure B 1 and c
59. memory locations 1 2 3 or 4 can be automatically recalled and used See Figure B 7 FIGURE B 7 DUAL WIRE FEEDERS DUAL PROCEDURE OVERLAY IE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 POWER WAVE 450 LINCOLN amp ELECTRIC meni O mm2 1 LCD DISPLAY WINDOW 2 WIRE FEEDERS MEMORY CHART 3 DISPLAY RECALL KEY 4 HIGH TEMPERATURE LIGHT 5 MEMORY LIGHTS F em ef PROCEDURE B PROCEDURE 1 alo 26 E GER 1 LCD DISPLAY WINDOW Power up the machine With this overlay in place the wire feed speed and with this overlay in place When the Power Wave is the preset voltage or arc length trim can be turned on the following message appears in the changed from the wire feeder The new values display window for a few seconds replace the previous values and become a perma LINCOLN ELECTRIC nent part of the procedure VERSION X X If limits have been set on the wire feed speed volt es y age or arc length trim of the selected procedures a ad these limits will be active when this overlay is in OVERLAY ID place They cannot be overridden from this over NUMBER 9 lay 2 WIRE FEEDERS MEMORY CHART The active DISPLAY RECALL KEY To view other information welding procedure is determined by the active wire feeder and its gun switch position The weld ing procedure recall from memory is as follows Active Gun Trigger Memory Location about the active welding procedure press the DI
60. mmended 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 amp TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines PROBLEMS SYMPTOMS The voltage and or wire feed speed will not adjust to user satis faction The voltage and or wire feed 1 When the Limits Overlay or the speed can be adjusted on the wire feeder but the changes are not shown on the Power Wave The Dual Procedure overlay is installed The user cannot change from procedure A to procedure B or vice versa The display can not be seen clear ly or can not be seen at all 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 Setup Overlay is placed on the machine the Power Wave s and feeder s displays do not match These overlays can not be used for welding 2 If two wire feeders are connect ed to the Power Wave only one of the feeder s settings can be dis playe
61. n X X If limits have been set on the wire feed speed volt ae f age or arc length trim of the selected procedure a eS these limits will be active when this overlay is in OVERLAY ID place They cannot be overridden from this over NUMBER 2 lay This message is then replaced by the following PROGRAM LIST The PROGRAM LIST block in message the center of this overlay provides a convenient place to record a brief description of each welding es E procedure stored in memory A Dry Erase mark er should be used for this purpose 2 MEMORY RECALL NUMBERS Select the mem ory location of the desired welding procedure by pressing the appropriate MEMORY RECALL NUMBER key If no procedure was saved in the selected memo ry location the following message appears MEMORY LOCATION 1S EMPTY Select another memory location When a welding procedure is recalled from mem ory the display window will show the procedure description wire feed speed and arc length trim or preset voltage DISPLAY RECALL KEY To view other information about the selected procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the 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 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature
62. n 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 e Display Snubber and Shunt printed circuit boards e Power Switch e Main Transformer e Auxiliary Transformers e Input Rectifier e Heat Sink Fins e Input Filter Capacitors e Output Terminals e 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 s
63. ndersized welding cables are used Routing To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly Avoid excessive lengths bundle the electrode and ground cables together where practical and do not coil excess cable WATER COOLER CONNECTIONS The water cooler fittings are a quick connect type Refer to the Accessories section of this manual for water cooler operation and antifreeze mixtures WIRE FEEDER CONNECTIONS Refer to the Accessories section for Wire Feeder Con nections Refer to Setup overlay in Operation section for Wire Feeder Configuration POWER WAVE 450 LINCOLN amp B 1 B 1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS A WARNING e ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be 9 dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone 7 WELDING SPARKS can cause fire or explosion e Keep flammable material away Do not weld on containers that have held com bustibles ARC RAYS can burn RE e Wear eye ear and body protection Observe additional Safety Guidel
64. nput 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 amp EA TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output fans run display is on Machine regularly overheats yel low light LED on the front panel
65. ocedure If limits have been set on the wire feed speed volt age or arc length trim of the selected procedures these limits will be active when this overlay is in place They cannot be overridden from this over lay THE PROGRAM LIST The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory A Dry Erase mark er should be used for this purpose DISPLAY RECALL KEY To view other information about the active procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions dis play for a few seconds 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 MEMORY LIGHTS A memory light is on when its corresponding memory is selected This tells you what memory location is active at any given time POWER WAVE 450 LINCOLN amp B 13 B 13 OPERATION DUAL WIRE FEEDERS DUAL PROCEDURE OVERLAY OPTIONAL The Dual Wire Feeders Dual Procedures Overlay is used when the Power Wave is equipped with two wire feed ers and two guns with two position switches Any welding procedure stored in
66. ode reel welding head nozzle or semiautomatic weld ing gun are also electrically hot 1 d Always be sure the work cable makes a good electrical con nection with the metal being welded The connection should be as close as possible to the area being welded Le Ground the work or metal to be welded to a good electrical earth ground 1 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 1 g Never dip the electrode in water for cooling 1 h Never simultaneously touch electrically hot parts of elec trode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders Li When working above floor level use a safety belt to protect yourself from a fall should you get a shock 1j Also see items Ac and 6 ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 1 standards L 2 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose FUMES AND GASES can be dangero
67. 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 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 e Designed to NEMA Standards e Multiple process output ranges 5 540 amps e 2 line LCD display e Easy access for input connections Connections are simple strip and clamp no lugs required e Modular construction for easy servicing e Thermostatically protected Electronic overcurrent protection e Overvo
68. orresponding explanations FIGURE B 1 CASE FRONT CONTROLS ECH LCD DISPLAY POWER SWITCH HIGH TEMPERATURE LIGHT REMOTE CONTROL AMPHENOL RECEPTACLE 5 AMP CIRCUIT BREAKER LCD DISPLAY ADJUSTMENT On una 1 LCD DISPLAY Provides welding procedure 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 b
69. ploy er s safety practices MSDS forms are available from your welding distributor or from the manufacturer 3 e Also see item 7b POWER WAVE 450 LINCOLN SAFETY WELDING SPARKS can ee cause fire or explosion vm 4 a Remove fire hazards from the weld ing area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding Sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 4 b Where compressed gases are to be used at the job site spe cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equip ment being used 4 c When not welding make certain no part of the electrode cir cuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard 4 d Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from
70. power source See Figure C 1 Connect the control cable between the feeder and power source The cable has different connectors on each end and will fit in only one way If only one feed er is used it must be connected to the Feeder 1 Amphenol located on the back panel in the upper left hand corner as you view the machine from the back If a second feeder is used it must be plugged into the Feeder 2 Amphenol receptacle located just to the right of the Feeder 1 Amphenol receptacle Connect the work cable between the work and the negative connection of the power source When negative electrode polarity is required such as in some Innershield applications connect the work cable between the work and the positive connec tion of the power source See Figure C 1 e Connect the feeder to a welding gas supply e Load the wire into the feeder and gun e Configure wire feeders Refer to Setup overlay in operation section GUNS AND CABLES Several MAGNUM guns are recommended for use with the Power Wave as shown in Table C 1 Place the proper liner in the gun and connect the gun to the feeder Consult the specific instructions sup plied with the gun for detailed operating instructions 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 Using a water cooled gun is recommended to r
71. rameter that may be adjusted when the welding procedures are set This feature provides an easy way to change the arc behavior with out creating a new procedure The wave control set ting of a procedure limits the speed at which the cur rent waveform of that procedure can change Typically each procedure is programmed to have average wave control at the center of the scale POWER WAVE 450 LINCOLN amp B 20 B 20 OPERATION TABLE B 6 RELATIONSHIP BETWEEN SELECTED ARC LENGTH TRIM AND PRESET ARC LENGTH AS INDICATED BY ARC LENGTH TABLE B 3 RELATIONSHIP BETWEEN VOLTAGE TRIM AND PRESET VOLTAGE Voltage Trim Relationship to Preset Voltage TRIM GMAW FCAW ONLY 0 6 60 of preset voltage Arc Length Trim Preset Arc Lenth 0 8 80 of preset voltage 0 6 60 of preset length 1 0 no change to preset voltage 0 8 80 of preset length 1 2 120 of preset voltage 1 0 no change to preset length 1 4 140 of preset voltage 1 2 120 of preset length Explanation of Table B 3 1 4 140 of preset length If for example the minimum voltage trim is set to 0 8 and the maximum voltage trim is set to 1 4 this means that the voltage for a given wire feed speed can be adjusted to be anywhere between 80 and 140 of the preset voltage of that wire feed speed TABLE B 4 ADJ USTBLE PARAMETERS Adjustable GMAW GMAW Parameters Pulse FCAW Stick Wire Feeder Wire Feed Wi
72. re Feed WES Display Speed Speed Wire Feeder Arc Length Preset Voltage Display Trim Voltage Power Wave 450 Display with GMAW Pulse Wave Wave Wave GMAW FCAW Stick Control Control Control Process Selection Overlay Frequency Inductance Arc Force TABLE B 5 DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS Power Wave 450 Wire Feeder Trigger Position GMAW GMAW STICK GMAW GMAW Pulse FCAW Pulse FCAW WFS DISPLAY WFS DISPLAY Wire Feed Speed Wire Feed Speed WFS and WFS and Preset VOLTAGE VOLTAGE Open Arc Length Trim Preset Voltage Current DISPLAY DISPLAY Arc Length Trim Preset Voltage WFS WFS WFS DISPLAY WFS DISPLAY Actual Arc Actual Arc Preset Current Wire Feed Speed Wire Feed Speed Closed Voltage Voltage Actual Arc VOLTAGE VOLTAGE Actual Arc Actual Arc Voltage Actual DISPLAY DISPLAY Current Current Arc Current Actual Arc Voltage Actual Arc Voltage In Stick trigger is on Remote Control Kit K941 1 2Arc Current not wire feed speed is displayed if a Remote Control Kit is attached to the wire feeder POWER WAVE 450 LINCOLN amp B 21 B 21 OPERATION 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
73. ription 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 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 B 16 B 16 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 ofthe machine and wire feeder s connected to the Power Wave See Figure B 9 FIGURE B 9 SETUP OVERLAY TR A a INVERTEC POWER WAVE 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 o a e a WATER COOLER SETUP 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 CO
74. s 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 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 Press this key to enable or disable the work sense lead lead 21 of wire feeder 1 When enabled voltage sensing is done by the work sense lead When disabled voltage sensing is done at the Power Wave output terminal When enabled the WIRE FEEDER 1 WORK SENSE LEAD ENABLED light will be illuminated WIRE FEEDER SETUP DESCRIPTION The Power Wave may be Set up for either positive or negative arc voltage sensing using any two of the following places 1 the positive output terminal of the Power Wave 2 the negative output terminal of the Power Wave 3 the electrode sense lead 67 lead of the wire feeder 4 a work sense 21 lead The SETUP Overlay allows you to select between which two places arc voltage will be sensed Once the selection is made it is not necessary to reconfirm the selection every time a new overlay is used or a wire feeder is replaced with another one The selection will remain until it is changed with the SETUP Overlay When welding with a stick procedure the arc volt age is automat
75. the American Welding Society see address above 4 e Vent hollow castings or containers before heating cutting or welding They may explode 4 f Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear eat plugs when welding out of position or in confined places Always wear Safety glasses with side shields when in a weld ing area 4 9 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c CYLINDER may explode if damaged BG 5 a Use only compressed gas cylin ders containing the correct shield ing gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 5 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 5 c Cylinders should be located e Away from areas where they may be struck or subjected to physical damage A safe distance from arc weldin
76. tion it is strongly recom mended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE ELECTRIC SHOCK can kill Ke O La The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 1 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous condi tions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduce Voltage Control 1 c In semiautomatic or automatic wire welding the electrode electr
77. to determine if the welds produced are suitable and sound The Power Wave 450 is optimized for use with a 0 75 1 9 cm stickout The adaptive behavior is pro grammed to support a stickout range from 0 5 to 1 25 1 3 to 3 2 cm In the low and high end of the wire feed speed ranges of most processes the adap tive behavior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process Itis possible to achieve adap tive 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 pulsing 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 voltage to keep a stable arc It is very important to recognize this Actual arc voltage when welding will vary because the stickout will seldom be held at the nominal 1 9 cm value POWER WAVE 450 LINCOLN amp B 22 B 22 OPERATION OVERLOAD PROTECTION THERMAL PROTECTION The Power Wave has thermostatic protection from excessive duty cycles
78. u 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 temperature light goes out POWER WAVE 450 LINCOLN B 10 B 10 OPERATION WELD FROM MEMORY OVERLAY The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight mem ory locations See Figure B 5 FIGURE B 5 WELD FROM MEMORY OVERLAY Gef PANEL 2 WELD FROM MEMORY 19169 2 THEUNCOLN ELECTRIC COMPANY CLEVELAND LEVELAND OHIOUSA COPYRIGHT 1994 POWER WAVE 450 O mmz O mms O mms LCD DISPLAY WINDOW On P GA r MEMORY RECALL KEYS PROGRAM LIST DISPLAY RECALL KEY HIGH TEMPERATURE LIGHT MEMORY LIGHTS 1 LCD DISPLAY WINDOW Power up the machine With this overlay in place the wire feed speed and with this overlay in place When the Power Wave the preset voltage or arc length trim can be is turned on the following message appears in the changed from the wire feeder The new values will display window for a few seconds replace the previous values and become a perma LINCOLN ELECTRIC nent part of the procedure Versio
79. und 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 Figure A 2 for the location of the reconnect input access door and related connection diagram INPUT POWER CONNECTIONS Connect L1 L2 L3 according to the Input Supply Connection Diagram decal located on the reconnect input access door See Figure A 3 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 machine is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE 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 in Figure A 2 and proceed according to the steps that follow for the appropriate voltage FIGURE A 2 CONNECTION DIAGRAM ON RECONNECT INPUT ACCESS DOOR NOTE Turn main input power to INPUT SUPPLY CONNECTION DIAGRAM A WARNING th hi OFF b f rf NOTE MACH
80. ure 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 A 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 the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line The Power Wave has a 35 mm access hole for the input cord but the input cord is not supplied POWER WAVE 450 LINCOLN amp A 3 A 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 gro
81. us themselves to the arc rays or to hot spatter or metal 9 3 a Welding may produce flames and gases hazardous to health Avoid i 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 ventila tion such as stainless or hard facing See instructions on con tainer 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 res pirator may be required Additional precautions are also required when welding on galvanized steel 3 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying opera tions The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irri tating products 3 c Shielding gases used for arc welding can displace air and Cause injury or death Always use enough ventilation espe cially in confined areas to insure breathing air is safe 3 d Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your em
82. with than procedures designed to opti mize the welding process The pulsing process is not slower than other processes The process is sometimes less forgiving when the arc gets on or ahead of the puddle More attention must be paid to the weld to avoid losing the puddle Speed is a matter of deposition rate All things being equal regarding the joint being welded the speed will depend on the wire feed speed The travel speed is maximized by maintaining a very short arc Often the process is trimmed down until the arc crackles The spatter increases slightly but many of the advantages of pulsing are retained When welding steel the Power Wave is designed to run well in this region between pulse and short arc The pulsing process greatly affects the heat input to the workpiece This can be a valuable tool for either increasing or decreasing the heat input with a given process For instance it is possible to greatly increase the heat input when welding steel at high deposition rates On the other hand it is possible to reduce the heat input using the pulsing process For example heat input is reduced greatly with some of the low current stainless steel procedures using the processes programmed into the Power Wave In all cases the Power Wave procedures have been checked for their ability to deliver a sound weld However the fusion of the weld metal into the work piece may be affected It is the responsibility of the user
83. 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 44 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment POWER WAVE 450 LINCOLN amp vi TABLE OF CONTENTS Page Safety A RN LIN Installation a Eege ee Section A Technical Specifications iii Ai ii A 1 Safety Precautions ali ai ieee ies kin navies cies ENEE E e A 2 Select Suitable Location Stacking Tilting Lifting A 2 High Frequency Pr cautions aint EENS tt deride iba A 2 Input il E le A 2 Output CONNectiONns iii dida A 4 Opera ura ea a D US Section B Safety INsStructiONS incio dado dd dba B 1 Quick Start Referenc aria dis tia id B 2 General DesCnptiOn antenne nine andre inertie de B 3 el de ET eting EE B 4 fl lalle g UE B 5 Overview of Welding Procedures sisi B 19 Overload re re EE B 22 EE Section C Wire Feeder Seti hee tenance dedi iain nde C 1 Guns er C 1 Water Cooler USA9 iii ii es Jide at

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