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Lincoln Electric IM524-D User's Manual

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1. Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturers instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAFETY 3 77 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammabl
2. relay terminals 1 and 2 minimum long relay terminals 3 and 4 2 medium slotted screwdriver two 10 inch adjustable wrenches two 7 16 open or box end wrenches 1 4 hex socket with wrench 1 4 hex socket with wrench needlenose pliers All plumbing components REMOVING AND INSTALLING THE G3503 COOLER 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine from service input power 2 Remove cooler assembly G3503 a remove gas cylinder s from tray b remove cooler access panel c Remove both fasteners from base that hold cool er in place Remove ground lead if present Carefully pull cooler assembly rearward until coolers Molex connectors are visible d disconnect cooler s connectors from the P3 and P4 harnesses Continue pulling the cooler out of the Power Wave oO If necessary perform periodic maintenance or ser vice on the cooler 4 Reinstall cooler by reversing tasks in step 2 Be sure to reattach ground lead if previously removed 5 If necessary fill cooler with selected coolant to spec ified level see Fig 1 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs O N Reconnect service input power to the Power Wave e verify that the reconnect panel setting and lead placement match the service voltage 00 Prime the cooler a Install the Set up overlay b Keep acces
3. This Troubleshooting Guide is provided to help you lo cate and correct possible machine misad justments Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting Step 2 PERFORM EXTERNAL RECOMMEND ED TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious exter nal pos sibilities that may contribute to the machine symptom Perform these tests checks in the order listed In gen eral these tests can be conducted without removing the case wraparound cover Step 3 CONSULT LOCAL AUTHORIZED FIELD SERVICE FACILITY If you have exhausted all of the recommended tests in step 2 consult your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN amp TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s are removed Machine is dead no output no fans no displays
4. e Reinstall strainer and acorn nut tightening with 75 15 in lbs of torque Wipe dry all areas wetted by coolant Dispose of towels in an environmentally responsible manner see Recommended Coolants 4 Gently rinse the reservoir s strainer under running water to thoroughly clean it 5 Remove fan shroud and inspect hoses and electrical har nesses for kinking or damage cut abrasion swelling etc Replace if necessary 6 Remove accumulated dust from cooler especially from the motor and heat exchanger by blowing it off with shop air or vacuuming it out e The heat exchanger fins are sharp but can be easily bent Treat them with care to avoid personal injury and damaging them e Remove the cooler from the machine for a more thor ough cleaning job 7 Motor lubrication is recommended once a year e Remove plug over lube port at top of motor near fan end e Add 20 drops of electric motor or SAE 10 oil then reinstall plug 8 Flush coolant from the system and replace with fresh rec ommended coolant at least once a year More frequent flushing may be necessary depending upon a user s par ticular system or its usage NOTE Never run the pump dry Always use a recommended coolant otherwise pump damage may result 9 Reinstall the G3503 cooler into the Power Wave machine G3503 COOLER SERVICE 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine fro
5. 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 ev The Power Wave is not recommended for pipe thawing POWER WAVE 450 LINCOLN amp B 4 B 4 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the Power Wave Refer to Figure B 1 and corresponding explanations FIGURE B 1 CASE FRONT CONTROLS O y LCD DISPLAY POWER SWITCH HIGH TEMPERATURE LIGHT REMOTE CONTROL AMPHENOL RECEPTACLE 5 AMP CIRCUIT BREAKER LCD DISPLAY ADJ USTMENT On 0 UN RA CASE FRONT CONTROLS Refer to Figure B 1 for the location of the following controls 1 LCD DISPLAY Provides welding procedure infor mation and parameters such as wire type gas type WFS trim etc 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 d
6. LO to HI Use the WAVE CONTROL UP or WAVE CONTROL DOWN key to change the wave control to the desired level When this scale is shown the WAVE CONTROL setting can also be changed while welding on the fly Press the DISPLAY RECALL key to exit the wave control function For a description of how the wave control setting affects the welding procedure refer to the Overview of Welding Procedures sub section of the Operation section of this manual The wire feed speed and voltage or arc length trim desired for the new procedure can be changed from the wire feeder 7 DISPLAY RECALL KEY Since not all the informa tion about the procedure can be seen on the 2 line LCD display window at the same time use the DISPLAY RECALL key to display and verify all of the selected procedure information The normal default display window shows the Procedure Description WFS and preset voltage or arc length trim values Press and hold the DISPLAY RECALL key and the window shows the procedure de scription and gas type for as long as the key is held depressed Release the DISPLAY RECALL key and the window shows wire size material type and process description After a few sec onds the window changes back to the default dis play SAVE TO MEMORY 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 memo
7. 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 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output fans run display is on Machine regularly overheats yel low light LED on the front panel glows indicating a thermal over load The fans run
8. 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 E 3 E 3 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no output no fans no display Main input fuses are open indicating excessive input current draw
9. 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 E 5 E 5 TROUBLESHOOTING TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The voltage and or wire feed speed will not adjust to user satis faction The voltage and or wire feed speed can be adjusted on the wire feeder but the changes are not shown on the Power Wave The Dual Procedure overlay is installed The user cannot change from procedure A to procedure B or vice versa The display can not be seen clear ly or can not be seen at all Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Certain limits may have been imposed on the welding parame ters Refer to the Limits Overlay section in the Operations section of this manual to change the set limits 1 When the Limits Overlay or the Setup Overlay is placed on the machine the Power Wave s and feeder s displays do not match These overlays can not be used for welding 2 If two wire feeders are connect ed to the Power Wave only one of the feeder s settings can be dis played on the Power Wave at one time Pull the trig ger of the wire feeder who
10. D 3 RESISTORS WITH LEADS CONNECTED Yes A De E 9 Check voltage across terminals 9 and 12 with a 10 DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capac itor discharge procedure Repeat discharge procedure steps 7 8 and 9 for each of the other three Switch Boards POWER WAVE 450 LINCOLN amp 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 1 Remove the hex head screws from the sides and top of the machine Remove the handle bar and the machine wrap around cover Remove the two case sides There are hex head screws on each side 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 Heat Sink Fins e Input Filter Capacitor
11. Funds only l Credit Card band e Telephone gei Signature as it appears on Charge Card E No LILI LL ee ate ll LU 7 Si 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 Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 5 00 L Spa formation Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H ES Weg E E Incentive Management IM EE ae A New Approach to Industrial Economics 5 00 NA TT Educational Video Information ED 93 Lames F Lincoln Arc Welding Foundation Book Information JFLF 515 Welding Preheat Calculator m _wc 8 Pipe Welding Chars sso eos I SUB TOTAL Oooo ona Shipping Costs tam TOTAL COST Liette Geen Saal mm mm mm mm mm mm l WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is 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 m
12. ai AAA AAA dE A D 4 Recommended Tools for Installation or Service of Cooler D 5 G3503 Installation or Service Tool Usage D 5 Removing and Installing the G3503 Cooler nnnon nn ncrano nos D 5 G3503 Cooler Periodic Maintenance D 6 G3503 Cole SNC iii A a D 6 General Component Location sb D 7 Troubleshooting and Repair Section E How To Use Troubleshooting Guide E 1 Troubleshooting GUd ea teeraa A Moi anata E 2 Electrical Diagrams seriinin dais Section F Parts Manual da iain ania Ala aid lite P 261 Series POWER WAVE 450 LINCOLN amp vii A 1 A 1 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 450 INPUT THREE PHASE 50 60 HZ ONLY Input Voltages Input Currents 5004 40 VDC O 450A 38 VDC RATED OUTPUT Duty Cycle Volts at Rated Amperes 200 60 Duty Cycle 40 VDC 230 400 460 60 Duty Cycle 40 VDC 460 575 60 Duty Cycle 40 VDC 200 100 Duty Cycle 38 VDC 230 400 460 100 Duty Cycle 38 VDC 460 575 100 Duty Cycle 38 VDC OUTPUT Constant Open Continuous Process Circuit Voltage Current Range Current Ranges 75 Volts 5 540 Amps GMAW 50 540 Amps FCAW 40 540 Amps STICK 30 540 Amps Pulse Pulse Pulse and Background Pulse Current Range Voltage Range Time Range Frequency 5 750 Amps 5 55 Volts 100 Microsec 3 3 Sec 0 15 1000 Hz RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 Input Input Ampere Copper Wire in Ground Wire in Super Lag Voltage Rating on Condu
13. and the display is on Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure that the machine was powered up with a properly installed overlay With no overlay on the machine or an invalid over lay the machine will have no out put 2 Check to see if the Limits or Setup overlay is installed on the front panel These two overlays can not be used for welding 3 Check for proper input voltage per machine nameplate 4 Make certain the reconnect panel is configured properly 5 Check that when the trigger is pulled on the wire feeder the wire feeder s voltage display changes to indicate arc voltage If this does not happen feeder may be faulty 6 Check feeder control cable for loose or faulty connections 7 If the machine is connected for 380 VAC or higher and has not been used for a long period of time the capacitors may require conditioning Let the machine run at an idle state no load for 30 minutes 1 Welding application may exceed recommended duty cycle 2 Dirt and dust may have clogged the cooling channels inside the machine Refer to the Maintenance Section of this man ual 3 Air intake and exhaust louvers may be blocked due to inade quate clearance around machine RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per
14. 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 A lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4 th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add I 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 America invoiced orders over 50 00 A 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 SC CHECK ONE Address I Please Invoice only if order is over 50 00 i I Check or Money Order Enclosed U S
15. kill 0 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 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 CAUTION TO PREVENT DAMAGE TO MACHINE AVOID UNNECESSARY MOVEMENT OF FRONT PANEL 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure D 3 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE POWER WAVE 450 LINCOLN amp D 1 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 a
16. le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PRECAUTIONS DE SURETE POUR LES MACHINES A SOUDER A TRANSFORMATEUR ET A REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branch a une bonne mise a la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l in
17. observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dess
18. of overlays can be used with the Power Wave 1 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 B7 procedures that have been stored in the memory of the Power Wave 2 DUAL FEEDER DUAL ei PROCEDURE MEMORY 3 Setup Overlays These overlays provide specific SELECTION OVERLAY machine setup information such as operating lim its for the welding procedures stored in memory 3 LIMITS OVERLAY B 8 4 Special Purpose Overlays These are custom overlays for specific customer applications 3 SETUP OVERLAY B 9 4 TEST amp CALIB OVERLAY Detailed information on how to use currently available Power Wave overlays follows These overlays are optional See Accessories Section for Order Numbers POWER WAVE 450 LINCOLN amp B 7 OPERATION PULSE GMAW FCAW AND STICK TIG PROCESS SELECTION OVERLAY An operator can use this overlay to create a new welding procedure save a newly created welding procedure view an ex
19. 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 Overvoltage protection Digital signal processor and microprocessor control e RS232 interface for future welding application updates Simple reliable reconnection for various input volt ages New accessories and wire feeders communicate using a digital current loop to transfer information 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 500 amps 40 volts at
20. switch is in the ON position the output ter minals of the Power Wave 450 are electrically hot When the switch is in the OFF position the output ter minals of the Power Wave 450 are electrically cold and the machine cannot produce an output In the Stick Pro cess the LCD display shows Procedure Description and Pre set Current SET The Current Trim is always equal to 1 T 1 00 When the trigger is pulled the Preset Current Ac tual Arc Voltage and Actual Arc Current are displayed See Tables B 3 and B 4 for a summary of the informa tion discussed above WAVE CONTROL The wave control settings of all procedures can be changed on the Power Wave 450 GMAW Pulse GMAW and FCAW Stick Process Selection Overlay The wave control is a setup parameter that may be adjusted when the welding procedures are set This feature pro vides an easy way to change the arc behavior without creating a new procedure The wave control setting of a procedure limits the speed at which the current waveform of that procedure can change Typically each procedure is programmed to have aver age wave con trol at the center of the scale POWER WAVE 450 LINCOLN amp B 20 B 20 OPERATION In Pulse processes The wave control adjustment allows the frequency setting to vary Increasing the wave control allows the frequency setting to increase and decreasing the wave control allows the frequency setting to decrease Varying the wave control settin
21. voltage settings In the MIG MAG Pulse Modes check the arc length trim setting These con trols are on the wire feeder 2 Check for proper shielding gas and gas flow 3 Check for loose or faulty weld ing cables 1 The machine may be trying to deliver too much power When the average output current exceeds a maximum limit the peak current is drastically cut back Lower the welding parameter settings and or increase the stickout length to eliminate this problem RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors eng
22. ECTRODE 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 Control Cable includes 67 lead Electrode Sense Lead Gg Wire Feeder E Block Electrode Cable Work Cable FIGURE B 11 NEGATIVE VOLTAGE SENSING POLARITY Control Cable includes 67 lead Electrode Sense Lead CE Wire Feeder E Block 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 is preprogrammed into the machine by welding experts This preprogrammed voltage is the best average volt age for the procedure at the given wire feed speed If the wire feed speed is changed on the wire feeder the voltage automatically changes with it In some cases the operator may want to change the preprogrammed voltages for example to compensate for cable and fixture voltage drop
23. IM524 D October 2001 INVERTEC POWER WAVE 450 For use with machines having Code Numbers 10365 10511 10366 10512 10433 10520 10434 10607 10449 10610 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your SSSR overall safety can be increased by tide proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN UAL AND THE SAFETY PRE CAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased ELLE e RA OPERATOR S MANUAL _ Am pq O EOEEEEOOC mm EL ISO 9001 Led ts DS Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright 2001 Lincoln Global Inc LINCOLN LELECTRIC e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 44 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California t
24. LAY memi O mem2 mm O weus O weu ouai PROCEDURE A O mima O mes PROCEDURE A O 6 She Aa aa ER POWER WAVE 450 G PANEL 3 WELD FROM MEMORY DUAL PROCEDURE 19169 3 N THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 e E 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 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 SIS 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
25. 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 Un 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 PULSE WELDING Some people have trouble getting used to the behavior of the pulsing arc The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appearance There are however a few things to keep in mind when pulse welding Spatter levels are often very low with the pulse welding process Pulsing is often used to eliminate cleaning operations necessary when using other weld ing processes Fume levels are sometimes lower with the pulsing process Whether or not you will get lower fume levels depends on the pulsing programs used Certain wave form characteristics are necessary to get low fume lev els Unfortunately low fume procedures are harder to weld with than procedures designed to optimize the welding process The pulsing process is not slower than other pro cesses The process i
26. NNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE WARNING Disconnect input power before inspecting or servicing machine Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install use or service this equipment a 200 208V 200 2080 200 208V e 220 230V Sy 220 230V Sp 220 2304 ee d 4 380415 e 380 415V e o 380 415V e 440 4600 440 4504 440 460V SIRED INPUT VOLTAGE RANGE breakers have a delay in tripping action that decreases as the mag POWER WAVE 450 LINCOLN amp A 4 A 4 INSTALLATION FIGURE A 3 FRONTPANEL BACK PANEL 3 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To reconnect your machine for the proper input volt age see the reconnect instructions on your input access door and 1 Move the large input voltage switch to the proper position according to your input volt age and the labels near the switch 2 Move the auxiliary A lead to the appropriate terminal according to your input voltage and the labels near the terminals OUTPUT CONNECTIONS See Figure A 3 for the location of the work terminal electrode terminal remote control amphenol recepta cle water cooler fi
27. ON X X This display is followed by OVERLAY ID NUMBER 9 2 WIRE FEEDERS MEMORY CHART The active welding procedure is determined by the active wire feeder and its gun switch position The weld ing procedure recall from memory is as follows Active Gun Trigger Memory Location Wire Feeder Position of Procedure 1 A 1 1 B 2 2 A 3 2 B 4 Pull the trigger on either wire feeder Depending on the gun switch position the corre sponding memory location is automatically recalled The wire feeders memory chart has no keys it is simply a chart The display window will show the procedure description wire feed speed and the preset volt age or arc length trim of the last active welding procedure With this overlay in place the wire feed speed and the preset voltage or arc length trim can be changed from the wire feeder The new values replace the previous values and become a perma nent part of the procedure 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 DISPLAY RECALL KEY To view other information about the active welding procedure press the DISPLAY RECALL key The display window will show the procedure description and gas type of the last active procedure for as long as the key is held depressed When the key is released the wire size material type an
28. TY 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 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 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 Esr APSMERTLICULT F n RBAPHECTIHIEBLTIA D ECETIA OF Bit ADAN A ARE eya 37128 else e S XACOER E 2743 MAS AH 7AA H4 587E ARBSHAIS a os Land dl CA al hia Ja d 4942 Jaial O L is Al AA ge Cal sag st e Turn power off before servicing e Desconectar el cable de ali mentaci n de p
29. VELAND OHIO USA CM NVERTEC POWER WAVE ea HIGH TEMP 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 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 E Type Name No Four types
30. and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et
31. aptive behavior is pro grammed to support a stickout range from 0 5 to 1 25 1 3 to 3 2 cm In the low and high end of the wire feed speed ranges of most processes the adaptive behav ior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process It is possible to achieve adaptive behavior for longer stickout lengths However shielding gas is often lost when the stickout is too long A longer electrical stickout is often used with the puls ing process at higher deposition rates A long stickout will increase the melt off rate of the wire In pulse welding like other wire welding processes the arc length is determined by the voltage setting This voltage is programmed at the factory for each process and wire feed speed It may be changed using the Voltage setting on the wire feeder When adaptive processes are used the voltage will vary with stickout The machine must change the volt age to keep a stable arc It is very important to recog nize this Actual arc voltage when welding will vary because the stickout will seldom be held at the nominal 0 75 1 9 cm value OVERLOAD PROTECTION Thermal Protection The Power Wave has thermostatic protection from excessive duty cycles overloads loss of cooling and high ambient temperatures When the power source is subjected to any of the conditions mentioned above a thermostat will open The yellow high temperature l
32. by ry location the following message appears OVERLAY ID EE NUMBER A This message is then replaced by the following SEET locaton message SET LIMIT KEY SELECT A MEMORY AND POCA NON LIMIT UP DOWN KEYS 2 RECALL FROM MEMORY KEY The SET LIMIT key and LIMIT UP LIMIT DOWN AND keys are used to set the maximum and minimum 3 MEMORY LOCATION NUMBERS allowed wire feed speed and voltage trim or arc The RECALL FROM MEMORY key is used to recall a welding procedure from memory length trim values of the procedure that was recalled from memory POWER WAVE 450 LINCOLN amp 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 LIMIT DOWN keys to change the minimum wire feed speed to the desired value Press the SET LIMIT key The present maximum and minimum voltage trim or arc length trim will be displayed Refer to Table B 3 to see how voltage trim affects preset voltage Refer to Table B 6 to see how arc length trim affects preset arc length Use the LIMIT UP and LIMIT DOWN keys to change the maximum value The maximum for either type is 1 5 Press the SET LIMIT key The new maximum and old minimum voltage trim or arc length trim will be displayed Use the LIMIT UP and LIMIT DOWN keys to change the minimum value The minimu
33. d 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 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 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 OVER
34. d process descriptions will be displayed 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 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 setthe 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 FROM MEMORY KEY 3 MEMORY LOCATION NUMBER KEYS 5 LIMIT UP DOWN KEYS 6 SAVE TO MEMORY KEY 7 DISPLAY RECALL KEY 4 SET LIMIT 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
35. d the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line The Power Wave has a 1 375 35 mm access hole for the input cord but the input cord is not supplied POWER WAVE 450 LINCOLN amp INSTALL CAUTION Failure to follow these instructions can cause immedi ate failure of components within the welder GROUND CONNECTIONS The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper ground ing methods See example Figure A 2 for the location of the reconnect input access door and your specific connection diagram INPUT POWER CONNECTIONS Connect L1 L2 L3 according to the Input Supply Connection Diagram decal located on your recon nect input access door See example Figure A 2 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and A 3 ATION 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 weld
36. duce the size of the gun and improve parts life The Power Wave comes with a standard internal water cooler However an external cooler may also be used TABLE C 1 RECOMMENDED GUNS FOR USE WITH POWER WAVE 450 Gun Application Cooling Product No MAGNUM 400 GMAW Gas K471 2 MAGNUM 550 GMAW Gas K598 WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler We recommend using the water cooler when welding above 300 amps with argon blends 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 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 POWER WAVE 450 LINCOLN amp ACCESSORIES 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 flow switch which is closed when there is adequate coolant circulating in the system If this flow rate drops below the switch manufacturers set p
37. e Power Wave See Figure B 9 FIGURE B 9 SETUP OVERLAY e O E a A ERAS o N 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 Se ae G ES WATER COOLER SETUP S LCD DISPLAY WINDOW Power up the machine with this overlay in place When the Power Wave is turned on the following message appears in the display window for a few seconds LINCOLN ELECTRIC Version X X This display is followed by OVERLAY ID NUMBER 0 This message is then replaced by the following message POWER WAVE SETUP WATER COOLER ON OFF KEY Press this key to toggle the water cooler between being enabled and disabled The present status of the water cooler is indicated by the WATER COOLER ON light 5 WIRE FEEDER 1 POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY WATER COOLER PRESSURE LIGHT This light indicates whether or not the coolant flow rate is high enough for normal water cooler operation If the water cooler loses the required flow rate it will shut down within a couple of seconds the water cooler pressure light will turn off and the machine sounds a buzzer PRIME WATER COOLER KEY The water cooler may have to be primed if there is not enough coolant in the system for proper operation Make sure t
38. e fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure In some cases it may be necessary to remove safety them with tape when possible 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 wo
39. e or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode SL s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application
40. een 0 5 and 1 5 on the wire feeder s Voltage display An arc length trim of 1 0 means that no adjustments will be made to the pre set arc lengths An arc length trim greater than 1 0 increases the preset arc lengths An arc length trim less than 1 0 decreases the pre set arc lengths The arc length adjustment is factored in at all wire feed speed settings Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length set tings of the procedure by 10 percent In the Pulse process the display shows the Procedure Description WFS and Arc Length Trim Arc length trim is pro grammed to a default at the factory and may be adjust ed on the wire feeder When the trigger is pulled the WES Actual Arc Voltage and Actual Arc Current are dis played Stick TIG PROCEDURES Stick welding can be performed with the Power Wave 450 by attaching a remote control kit to the 6 pin amphenol on the front of the machine The K941 1 remote control kit is recom mended Select the Stick Process from either the Pulse GMAW and FCAW Stick process selection overlay or recall it from a previ ously stored memory location with a Weld From Memory overlay When this process is selected the Power Wave 450 reads the current amps setting from the remote control kit It also controls the output of the machine based on the position of the Output Terminals switch which is also located on the remote control kit When this
41. er inrush currents even if the machine is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Welders are shipped connected for the highest input voltage listed on the rating plate To change this con nection for a different input voltage refer to reconnect instructions which follow and to the reconnect dia gram supplied with your machine located inside your reconnect access door See example Figure A 2 FIGURE A 2 CONNECTION DIAGRAM ON RECONNECT INPUT ACCESS DOOR NOTE Turn main input power to mthe machine OFF before perform ing reconnect procedure Failure to do so will result in damage to the machine DO NOT switch the re connect bar with machine power ON SHOWN 2 CONNECT LEAD MARKED ELECTRICAL CODE 4 POSITION SWITCH TO DE Also called inverse time or thermal magnetic circuit breakers These nitude of the current increases INPUT SUPPLY CONNECTION DIAGRAM NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 440 OR 460 VOLTS 1 CONNECT Lt L2 amp L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF CRI CONTACTOR AS TO GROUND PER NATIONAL 3 CO
42. erminal 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 terminal and the work cable is connected to the output terminal of the power source This is negative polarity voltage sensing illustrated by Figure B 11 When the Power Wave and the wire feeder s are connected in this manner the arc voltage can be measured in one of four ways These four ways are shown in Table B 2 Table B 2 Negative Voltage Sensing Options Positive Voltage Reference Negative Voltage Reference Output Terminal Output Terminal Output Terminal Work Sense 21 Lead Electrode Sense 67 Lead Output Terminal Electrode Sense 67 Lead Work Sense 21 Lead Consult the factory before using this option POWER WAVE 450 LINCOLN amp B 18 B 18 OPERATION Use the EL
43. essed detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Background noise may be too loud for user to hear beeper 1 Make certain that a remote control unit is not connected When a remote control unit is used the weld parameters are set by the remote control potentiometers 1 Make sure that the water cooler has been enabled Refer to the Setup Overlay descrip tion in the Operation Section of this manual 2 The cooler s circuit breaker may have tripped 3 If the water cooler is enabled but generates insufficient coolant flow rate the machine will beep loudly and the water cooler will shut down In this case prime the water cooler Refer to the Setup Overlay description in the Operation Section of this manual If the water cooler is enabled and the flow switch inside the water cooler opens due to inadequate coolant flow rate the machine indicates this by beeping This happens regardless of the overlay placed on the machine In this case do the following 1 Turn the machine off and on a couple of times and see if the beeping continues If the flow rate dropped momentarily then turning the machine off and on eliminates the beep ing A momentary drop in flow rate could be due to someone stepping on the water cooler hose for example 2 Check the water cooler and accessory hoses for kinks internal obstructions or block age or ruptures If such problems were fou
44. fe CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page LC EE LIN Installation cacon NEE EENG ENEE ged Section A Technical Specifications caricia gedeelter A 1 Safety Precauciones lan dista A 2 Sel ct Suitable OCIO A ie ian last A 2 Stacking ita ei A 2 TAMOS A te E A a eel A 2 LIN Ri A a A dan NEE A 2 High Frequency Precautions ss A 2 lite Ee el A 2 Ground gel le LEE A 3 Input Power Connections acii a a a diia A 3 Input Fuse and Supply Wire Connections VV A 3 Input Voltage Reconnect brocedumg si A 3 Output gell e EE A 4 Work and Electrode Cable Connections 444 A 4 Water Cooler Connections iii ria A 4 Wire Feeder Connections sienne A 4 OPTOMA baled tapas pda ans Ni adds Section B Safety lge el EE EE B 1 Quick Start Reference for Process Selection Overlay crac B 2 General Deepen ca is ina nat da ann ir ne ee B 3 Synergic Welding iii pa B 3 Recommended Processes usines B 3 Operational Features and Controls ss B 3 Design Features and Advantages oooocinccninccnoniconccnonccnn nono nanannn nana nan aran nin rra B 3 Welding Capabiliby EE B 3 Limitation Ss e ti ieee B 3 Controls nd S Et Siennine ido B 4 Case Front COntO Simi ENEE EE B 4 is clsitefle UC B 5 OVGIVIGW rei disci detach ihe uhh uk AT ale iid Sadia ade RO APT PE dd and B 5 Install
45. g affects the droplet trans fer 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 induc tance which results in the arc getting wider In Stick processes The wave control adjusts the arc force Increasing the wave control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the wave control setting decreases the arc force making the arc softer and smoother TABLE B 3 ADJ USTBLE PARAMETERS Adjustable Parameters GMAW Pulse Wire Feed Speed Arc Length Trim Wire Feeder WES Displa Wire Feeder Voltage Displa Power Wave 450 Display with GMAW Pulse Wave GMAW FCAW Stick Control Process Selection Overlay Frequency GMAW FCAW Wire Feed Speed Wave Control Arc Force Wave Control Inductance TABLE B 4 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 Pulse GMAW Pulse FCAW FCAW WFS DISPLAY WFS DISPLAY Wire Feed Speed Wire Feed Speed WFS and WFS and Preset VOLTAGE VOLTAGE Open Arc
46. h 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 3 77 WELDING SPARKS can cause mt ES fire or explosion e Keep flammable material away e Do not weld on containers that have held com bustibles ARC RAYS can burn RL e Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual HOT COOLANT can burn skin e Se e Always be sure coolant is not hot before doing any work on cooler parts POWER WAVE 450 LINCOLN amp OPERATION QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the Controls and Settings and Operating Overlays sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave NOTE Selection of certain options may limit the selection of subsequent options Step 1 Select your process information a Install the desired PROCESS OVERLAY b Turn the machine ON c Select the desired welding PROCESS PULSE GMAW e ee o bebe E S o STICK SELECT PROCESS olo ELECTRODE CLASS A ES d Select ELECTRODE CLASS o o ELECTRODE SIZE S MM IN e Select ELECTRODE SIZE JP i Ww of ELECTRODE GAS TYPE f Se
47. hat the water cooler has been turned on before it is primed The WATER COOLER ON light should be turned on Check reservoir for proper coolant level See Water Cooler informa tion in ACCESSORIES section To prime the water cooler hold the PRIME WATER COOLER key down While this key is pressed the display will show PRIME WATER COOLER POWER WAVE 450 LINCOLN amp OPERATION When the WATER COOLER PRESSURE light turns on release the key WIRE FEEDER 1 POLARITY KEY Press this key to change the present voltage sensing polari ty of wire feeder 1 The present polarity of wire feeder 1 is indicated by the WIRE FEEDER 1 POLARITY light If wire feeder 1 is set for positive voltage sensing polarity this light is turned on WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY Press this key to enable or disable the elec trode sense lead lead 67 of wire feeder 1 When enabled voltage sensing is done by the electrode sense lead When 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 wil
48. ight on the case front comes on See Figure B 1 for loca tion Machine output is disabled and welding is not possible until the machine is allowed to cool and the High Temperature Light goes out Current Protection The Power Wave is limited to producing 750 amps peak current If the average current exceeds 540 amps the peak current will automatically be cut back to 100 amps until the average current decreases to 50 amps POWER WAVE 450 LINCOLN amp C 1 ACCESSORIES OPTIONS ACCESSORIES e Synergic 7 wire feeder K632 1 standard speed or K632 2 high speed MAGNUM 400 gun K471 2 or 550 gun K598 Internal water cooler Undercarriages Single K961 1 Jor Dual K962 1 Gas Cylinders Remote control stick welding K941 1 e Amptrols Hand K963 1 or 2 Foot K870 e Limits Overlay K946 4 Dual Wire Feeders Dual Procedures Overlay K946 9 e Dual Feeder Dual Procedure Memory Selection Overlay K946 12 e Test and Calibration Overlay 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 power source See Figure C 1 Connect the c
49. ineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters
50. ing ary Overlay siesta aaa aan ott Gl Anar asta a B 5 Overlay DOS ada oia B 6 Pulse GMAW FCAW Stick Overlay siens B 7 Weld from Memory Overlay sise B 10 POWER WAVE 450 LINCOLN amp vii Weld from Memory Dual Procedure Overlay cacon nc narco nanaranncninn B 11 Dual Wire Feeders Dual Procedure Overlay ss B 13 Limits Overlay een ania A Ua AAA tated nn tt ace B 14 Setup Overlays tactic aan A nanan Aa Tam nen eae B 16 Wire Feeder Setup Description ss B 17 Overview of Welding Procedures iii B 19 FG AW ahd GMAW nn nine need dE B 19 Pulse Procedures ne nn titre eel nausea B 19 StiCk TIG Proc dures nace ois ede A ME ade Rei oh B 19 Wave PERL uge det cesarean A A otanatincesauanarintteaieees B 19 Pulse Welding iii ia B 21 Overload PLONE A AA dr nn eae B 21 Thermal Protection da B 21 Over Current Protec uenia a ina minimale B 21 EE EE o E ee Section C Options Accessories ii na et een oldie ain C 1 Wire FeederSetup snc rent ir AE ane MA C 1 GUNS ANG Cables A MN es da een net end RE C 1 Water Cooler Usada C 2 Under IMA iia da at es cn rente Ant C 2 MAINTENANCE is Section D Safety Pr cautions sens site E a An EATA D 1 Routine and Periodic Maintenance ins D 1 Input Filter Capacitor Discharge Procedure D 1 R sistor LOCATIONS isis en dt ane era ia D 2 Discharge Label deeg ase ia ot D 3 Resistors WILL Sica td ibi D 3 Preventive MAMENANCE
51. ings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover LE plates to protect your eyes from sparks and the rays of the arc when welding or
52. isplay is shown for a few seconds followed by another display that depends on the overlay placed on the machine At this point the machine is ready for operation HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tempera ture situation occurs Output is disabled until the machine cools down At that point the light goes out and output is enabled again REMOTE CONTROL AMPHENOL RECEPTACLE Allows remote current control during stick welding via a hand or foot Amptrol accessory 5 AMP CIRCUIT BREAKER Protects two auxiliary power circuits the 24V supply used by the trigger circuits and the 42V supply used by the internal machine circuits and the wire feeders LCD DISPLAY ADJUSTMENT Use a small flat blade screw driver to adjust the viewing angle of the LCD display POWER WAVE 450 LINCOLN amp 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 a Semer THE LINCOLN ELECTRIC COMPANY CLE
53. isting 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 ojo ELECTRODE CLASS a o PANEL 1 PULSE GMAW FCAW STICK TIG PROCESS SELECTION ie O N THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 ojo ojo ff ELECTRODE SIZE ELECTRODE GAS TYPE LCD DISPLAY WINDOW PROCESS SELECT KEY ELECTRODE CLASS UP DOWN KEYS ELECTRODE SIZE UP DOWN KEYS ELECTRODE GAS TYPE UP DOWN KEYS WAVE CONTROL UP DOWN KEYS O 0 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 ELECTRIC 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 7 DISPLAY RECALL KEY 8 SAVE TO MEMORY KEY 9 MEMORY LOCATION NUMBER KEYS 10 RECALL FROM MEMORY KEY 11 HIGH TEMPERATURE LIGHT NOTE The 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
54. it Conduit or Breaker Fregency Nameplate AWG IEC AWG IEC Size Amps Sizes MM Sizes MM 200 50 60 60 230 50 60 60 400 50 60 60 460 50 60 60 575 50 60 60 200 50 60 100 230 50 60 100 400 50 60 100 460 50 60 100 575 50 60 100 Weight 138 kg 304 lbs OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 to 40 C 50 to 85 C POWER WAVE 450 LINCOLN amp A 2 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS AA WARNING 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
55. l 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 automatically 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 T
56. lect ELECTRODE GAS TYPE JP g Press the WAVE CONTROL UP or DOWN keys to see the present setting Press the WAVE CONTROL UP or WAVE CONTROL DOWN keys to adjust WAVE CONTROL JP Step 2 Adjust the wire feed to speed WFS and voltage V or arc length T if necessary a Press the DISPLAY RECALL key view additional procedure information DISPLAY RECALL to b Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder The new values appear on both the wire feeder and the Power Wave display Step 3 Save process information if desired a Press the SAVE TO MEMORY key b Press one of the MEMORY LOCATION keys 1 8 You can recall your procedure later by pressing the RECALL FROM MEMORY key and the appro priate MEMORY LOCATION key The electrode class electrode size and electrode gas type you can select for your process will be limited to the machine s programmed recommenda tions Therefore selecting certain options may limit other option selections The wave control scale displayed shows the default setting The higher the setting the softer the arc If you change the setting your new setting will be dis played POWER WAVE 450 LINCOLN amp OPERATION GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance digitally controlled inverter welding power source capable of complex high speed wave form contr
57. ler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level c Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated e Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 4 Check coolant level Add more if required Rear Panel of Power Wave Reservoir Screen Zen Visible Coolant Level E 0 25 to 0 50 inches A Figure C 2 Do Not Use Any prepacked welding industry coolant mixture such as those offered by Miller OKI Bernhard or Dynaflux These coolants contain 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 K961 1 Single Cylinder Undercarriage Designed for quick installation in the field Consists of a front caster assembly a rear platform assembly a handle and an upper cylinder support K962 1 Dual Cylinder Undercarriage Designed for quick installation in the field Consists of a front caster assembly a dual bottle rear platform assembly a handle and a dual bottle upper cylinder support POWER WAVE 450 LINCOLN amp MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can
58. 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 procedure 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 ke
59. m service input power e Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine whenever e replacing major cooler components i e pump motor heat exchanger etc e replacing hoses and electrical harnesses that are kinked or damaged cut abraded deteriorated or swollen etc e investigating suspect coolant leakage 3 Pump replacement a Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants b Remove fan shroud c Place absorbent towels underneath pump head and wherever coolant system is opened d Carefully pull pump inlet hose and its elbow from reservoir bottom e Loosen pump outlet hose clamp at QD then carefully remove from fitting f Disconnect v band clamp from motor and remove pump e Do not drop or lose drive coupling between pump and motor e Do not discard old pump Remove both fittings Keep v clamp Seal old pump in a waterproof bag Package into protective container and Return to nearest Lincoln Electric FSS center g Install new pump and v band clamp e Do not apply any lubricant to pump s drive coupling e Pump body is properly oriented with its strainer at the 6 00 position e Tighten v clamp with 15 to 30 in lbs of torque h Attach coolant lines to QD and reservoir i Wipe dry all areas wetted by coolant Di
60. m 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 description and gas type of the last active procedure for as long as the key is held depressed When the key is released the wire size material type and process descriptions will be displayed for a few seconds MEMORY 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 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 of the machine and wire feeder s connected to th
61. nd then correct them and turn the machine off and on to check if the beeping has been elimi nated 3 Check the water cooler fluid level Low coolant level could cause the flow rate 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 E 8 E 8 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Machine loses output while weld ing Fans and display are function ing properly For no apparent reason the weld characteristics have changed Machine often noodle welds with a particular procedure POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check for proper input voltages per machine nameplate 2 Check for balanced three phase input supply voltage 3 Check electrode and work cables for loose or poor connec tions 1 Check for proper wire feed speed setting In the MIG MAG and FCAW Modes check for prop er
62. nd 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 MAINTENANCE Locate the 9 and 12 terminals identified by the Discharge labels on each of the four Switch Boards See Figure D 2 Using insulated needle nose type jumper leads and insulated gloves connect one jumper lead to one end of the resistor obtained in step 4 Connect the other jumper lead to the other end of the resistor Carefully connect the needle nose end of one of the jumper leads to terminal 9 See Figure D 3 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave resistor connected for 10 seconds DO NOT TOUCH TER MINALS RESISTORS OR ANY INTERNAL MACHINE COMPONENT DURING THIS PROCE DURE FIGURE D 2 DISCHARGE LABEL lt T13086 117 FIGURE
63. o cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding 8 Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 hy h 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 9 MAGNETIC FIELDS i may be dangerous 1 c Do not add th
64. observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products
65. oder 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 O Desligue a corrente antes de fazer servi o e N o toque as partes el tricas nuas FILA H ERIRUD PSB ETRRAT FE BETTE OMR egal HS xt et AIR Aa AL k NM y Je lo e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e 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 e N o opere com os paineis abertos ou guardas removidas O0NFAMPIN ADNVALEZE CRMBIFELEWTE EU CRRRIARRARS SHR Ro exo wel HAE AA DRAS AREY Gals 13 yal D Gada ve Aale Cut Al ll Apa WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ie BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR HORM PBMOX A NHRBEE lt RA ESEMLTFEN tULTHHORAMEI HOT F SU HAMAD SUCER HN RD RES AMEN RRR ST R D A B A R ECKE o HZ SEE oc ZHAXIAINE nie elt HA zeit ot jo Xx AS ET SAIT BEHE Aal veel Gl d ala
66. of eight mem ory locations See Figure B 5 FIGURE B 5 WELD FROM MEMORY OVERLAY PANEL 2 WELD FROM MEMORY 19169 2 POWER WAVE 450 LINCOLN GO ELECTRIC Om E UNA LCD DISPLAY WINDOW 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 Version X X If limits have been set on the wire feed speed volt DEE f age or arc length trim of the selected procedure EES EE 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 SELECT A MEMORY place to record a brief description of each welding LOCATION 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 save
67. oint the flow switch opens A cou ple of seconds after the flow switch opens the water cooler shuts down If the water cooler is enabled and the flow switch opens the machine beeps loudly indi cating that there is a problem with the water cooler operation RECOMMENDED COOLANTS 1 The following coolants have been determined to be compatible with the wetted materials used in the G3503 cooler assembly e Distilled or deionized water e Potable tap water e Sediment free mixtures containing a maxi mum of 50 ethylene glycol or automotive grade antifreeze and the balance of distilled or deionized water 2 Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water 3 Consult gun torch and wire feeder manuals for coolant recommendations and select one from the above list 4 Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphazard ly discarded especially by pouring liquids down the drain Contact the local EPA office for responsible disposal methods or for recycling information 5 The cooler s reservoir has a nominal liquid capacity of 1 6 gallons PRIMING THE COOLER 1 Select a recommended coolant and fill cooler to specified level see Fig C 2 2 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs 3 Prime the coo
68. ol It uses three phase input power only The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder SYNERGIC WELDING The Power Wave system is designed primarily as a synergic welding system The word synergic comes from the word synergism which means two or more things working together to achieve an effect which nei ther can achieve individually The Power Wave and wire feeder operate as a team Each knows what the other is doing at all times They each also know what process wire type wire size and gas combination are being used In a syner gic system the wire feeder and power source must talk together This means that only certain wire feed ers can work in a synergic setup A synergic feeder has special circuitry to talk with and listen to the Power Wave power source Welding experts have preprogrammed the system for the best range of process settings according to wire type wire size and gas combination When the wire feed speed is changed the system automatically adjusts the current and voltage waveforms to give the best weld 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
69. ontrol 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 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 FIGURE C 1 WIRE FEEDER AND WATER COOLER CONNECTIONS 1 WIRE FEEDER CONNECTIONS LOCATION 2 WATER COOLER LINE IN 3 WATER COOLER LINE OUT 4 CIRCUIT BREAKER WATER COOLER 5 FILL SPOUT WATER COOLER Using a water cooled gun is recommended to re
70. or another one Inspect gun and cables for good condition POWER WAVE 450 LINCOLN amp D 5 D 5 MAINTENANCE RECOMMENDED TOOLS FOR INSTAL LATION OR SERVICE OF COOLER e absorbent towels e alcohol wipe e 3 mm allen wrench G3503 only e socket wrench e 4 inch long minimum socket extension e 1 4 5 16 and 3 8 hex standard depth sockets e 5 32 allen socket e medium blade slotted screwdriver e large blade slotted screwdriver 8 inches long minimum e two 7 16 open or box end wrenches e one 7 8 open or box end wrench e needlenose pliers e two 10 inch long adjustable wrenches e wire cutter e molex pin removal tools e tape measure e small mechanic s mirror e flashlight e dental pick e digital multimeter DMM G3503 INSTALLATION OR SER VICE TOOL USAGE Fastener Usage all use 5 16 hex screw and 3 8 hex nut Relay may require large blade slotted screwdriver 8 in long min Shroud to cooler base Quick Disconnect QD bracket Heat exchanger to cooler base Relay to cooler base Screw to fasten reservoir to cooler base Hose Clamp Fan set screw 3 mm allen wrench G3503 only 5 16 Hex Socket G3503 1 only 4 2 2 2 1 4 hex or medium slotted screwdriver 1 5 32 allen socket with wrench and 4 in min extension 1 2 Pump carbonator clamp screw 5 16 hex socket with ratchet wrench Motor mounting bolts Motor harness ground at motor terminals large blade slotted screwdriver 8 in
71. ouill 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 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 Ey s qe gu BAA ole e Su AXE HZA ole Je L Gre gi el ai wal je ll ai AN o Laly Aal ay All Ji dua yl die tg e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos RATE U DORMTORRIER HN LU THEN EA ep ES SST IF AT LS AS Aal He Ad d s s UE dall pis O Wear eye ear 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 Gl ysl o A ag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFE
72. remaining com ponents This is why the order of performing the steps is important However if you make compo nent selections out of order the machine will prompt you to make a new Selection for any set tings that do not apply 2 PROCESS SELECT KEY Use the PROCESS SELECT key to select from the processes avail able in the machine Press the PROCESS SELECT key until the light by the desired process selecting a combination of these components from the SE ones that have been programmed into the Power Wave See Figure B 4 for key locations POWER WAVE 450 LINCOLN amp OPERATION ELECTRODE CLASS UP DOWN Use the ELEC TRODE CLASS UP or DOWN keys to select from the material types available for the selected process Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis played ELECTRODE SIZE UP DOWN Use the ELEC TRODE SIZE UP or DOWN keys to select from the wire diameters available for the selected process and material type Press the ELECTRODE SIZE UP or DOWN key until the desired wire diameter is displayed ELECTRODE GAS TYPE UP DOWN KEYS Use the ELECTRODE GAS TYPE UP or DOWN keys to select from the programs available for the select ed process material type and wire diameter Press the 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
73. riate MEMORY LOCATION NUMBER key If you press the RECALL FROM MEMORY key and then change your mind you can exit this function by pressing the DISPLAY RECALL key If the memory location you select does not contain a stored welding procedure this will be indicated in the display window Select another memory loca tion It is not necessary to save a procedure back to memory after it is recalled from memory When a procedure is saved into a memory location it can be recalled from there until another procedure is stored in that location or the location is cleared The RECALL FROM MEMORY and SAVE TO MEMORY keys can be used to clear a memory location Press the SAVE TO MEMORY E and then the RECALL FROM MEMORY key secan Do not press both keys at the same time message in the display window will ask you to press the MEM ORY LOCATION NUMBER key of the memory location you want to clear If you press the SAVE TO MEMORY and RECALL FROM MEMORY keys and then change your mind you can exit this function by pressing the DISPLAY RECALL key 11 HIGH TEMPERATURE LIGHT The high tempera ture light comes on when the internal machine temperature exceeds the allowed limit Output is disabled until the machine cools down and the high temperature light goes out POWER WAVE 450 LINCOLN amp 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
74. rking near moving parts 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN SAFETY d ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors grat
75. ry location a procedure can be recalled for later use with the RECALL FROM MEMORY key To save a newly created welding procedure Press the SAVE TO MEMORY key Se and then one of the MEMORY LOCATION NUMBER keys Keep a record of this number for future reference Any previously created welding procedure stored in that location will be erased If you press the SAVE TO MEMORY key but decide not to save the procedure you can exit this function by pressing the DISPLAY RECALL key MEMORY LOCATION NUMBER KEYS To view information about any stored welding procedure simply press its MEMORY LOCATION NUMBER key As you hold down the selected key the procedure description and gas type of the procedure appear in the display window The process type is shown by the indicating light opposite the appropriate process symbol When you release the selected key the wire size material type and process description appear for a few seconds This function does not display the wire feed speed and voltage or arc length trim settings To view these you must recall the procedure from memo ry with the RECALL FROM MEMORY key POWER WAVE 450 LINCOLN amp OPERATION 10 RECALL FROM MEMORY KEY This key is used to recall an existing 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 approp
76. s 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 secure the machine covers and han dle bar Remove the overlay from the front panel of the machine Clean the plastic case with a low pres Sure airstream Wipe the sensors Fig D 4 Item 8 with a clean soft cloth Make sure the sensors are not scratched in the process Check the back of the overlays If the bar code black square s on the back of the overlay is scratched apply a dull black spray finish to the 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 f
77. s The preset voltages can be adjusted on the wire feeder s Voltage display When a change is made to the voltage at one wire feed speed this change is applied to all other wire feed speed settings For example if the operator turns up the voltage by 10 percent the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent In the GMAW and FCAW process the display shows The Procedure Description WFS and Preset Voltage The preset voltage which was pro grammed at the factory may be changed on the wire feeder voltage display Note that if you change the default preset voltage up or down a respective or sign will be dis played after the preset value When the gun trigger is pulled note that the display changes to show WFS Actual Arc Volt age and Actual Arc Current See Table B 4 for display summary PULSE PROCEDURES In these procedures the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual volt age The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known In this case it is not practical to preset an actual voltage for the pro cedure Instead an arc length adjustment is provided The machine knows what the best arc length is at the given wire feed speed but allows the operator to change it The arc length can be adjusted betw
78. s 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 pro grammed into the Power Wave In all cases the Power Wave procedures have been checked for their ability to deliver a sound weld However the fusion of the weld metal into the workpiece may be affected It is the responsibility of the user to determine if the welds pro duced are suitable and sound The Power Wave is optimized for use with a 0 75 1 9 cm stickout The ad
79. se 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 E 6 E 6 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Machine does not respond to keys being pressed or the machine has improper displays Machine display reads Error Invalid Overlay or it displays an incorrect overlay ID number on power up Machine displays ERROR S L NOT INITIALIZED on power up POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Each time an overlay is changed make certain that the machine is powered up with the new o
80. sories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level Fig 1 c Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated e Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 9 Check coolant level Add more if required POWER WAVE 450 LINCOLN D 6 D 6 MAINTENANCE G3503 COOLER PERIODIC MAINTENANCE 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine from service input power e Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine 3 Clean the pump s inlet strainer e Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants e Place absorbent towels underneath pump head e Hold pump head to apply countertorque when loos ening strainer s 7 8 acorn nut Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head e Gently rinse strainer under running water to thor oughly clean it e Use the mirror to inspect inside of pump for contam ination Carefully remove hardened debris with den tal pick if necessary without scratching inside of the pump
81. spose of tow els in an environmentally responsible manner see Recommended Coolants j Reinstall cooler into machine 4 Motor removal or replacement e Do not reuse the 4 internal tooth star washers Replace with new parts 5 Installing the fan e Slide onto motor shaft until the fan is located between 0 25 to 0 50 inches from the heat exchanger e Tighten set screw with 65 to 75 in lbs of torque against motor shaft s flat e Fan rotation is counterclockwise as viewed from fan end of motor s shaft e Fan pulls air through the heat exchanger blows it over the motor then exhausts it through the reser voir D 7 D 7 MAINTENANCE FIGURE D 4 GENERAL COMPONENT LOCATIONS ALA JA Le AS AN POWER WAVE 450 LINCOLN 1 DISPLAY BOARD BACK OF PANEL 2 POWER SWITCH 8 OVERLAY BAR CODE SENSORS 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 9 TERMINAL STRIP LOCATION 3 MAIN TRANSFORMER 6 HEAT SINK FINS 7 OUTPUT TERMINALS TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE 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 electrical shock or danger while troubleshooting this equipment
82. terieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN V V for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of li
83. ttings and wire feeder connections 4 WATER COOLING FITTINGS ON ACCESS PANEL 5 WIRE FEEDER CONNECTIONS ON BACK PANEL 6 ELECTRODE TERMINAL WORK AND ELECTRODE CABLE CONNECTIONS Size Use the largest welding electrode and ground cables possible at least 70mm 2 0 copper wire even if the output current does not require it When pulsing the pulse current often exceeds 650 amps with the Power Wave 450 Voltage drops can become exces sive if undersized welding cables are used Routing To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly Avoid excessive lengths bundle the electrode and ground cables together where practical and do not coil excess cable WATER COOLER CONNECTIONS The water cooler fittings are a quick connect type Refer to the Accessories and Maintenance sections of this manual for water cooler operation and recom mended coolants WIRE FEEDER CONNECTIONS Refer to the Accessories section for Wire Feeder Con nections Refer to Setup overlay in Operation section for Wire Feeder Configuration POWER WAVE 450 LINCOLN amp B 1 B 1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING e ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes wit
84. us du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de larc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de
85. 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 procedure is not followed LIFTING Lift the machine by the lift bail only Do not attempt to lift the machine by the push handle HIGH FREQUENCY PRECAUTIONS If possible locate the Power Wave away from radio controlled machinery The normal operation of the Power Wave may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the rear of the machine See Figure A 1 for the loca tion of the rating plate FIGURE A 1 RATING PLATE LOCATION 1 RATING PLATE 2 RECONNECT INPUT ACCESS DOOR 3 INPUT CORD ACCESS HOLE WARNING Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and national electri cal codes an
86. verlay in place 2 Make certain that the correct overlay ID number is displayed on power up Refer to the Operation Section of this manual 3 In some cases some of the keys on the overlay may be locked out Refer to the Operation Section of this manual for the overlay descriptions 1 Make certain the overlay is installed properly 2 Inspect the overlay bar code sensors on the front panel Fig 17 Item 8 If they are dirty blow them out with low pressure air and clean with soft cloth 3 Inspect for damage to the Bar Code s on the back of the overlay 1 Contact your local Lincoln authorized Field Service Facility for Technical assistance RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem per sists contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 450 LINCOLN TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines PROBLEMS SYMPTOMS The Beeper Piezoelectric Buzzer cannot be heard machine operating normally The welding parameters that were saved in memory are different when recalled The water cooler does not turn on The machine beeps without the keys being pr
87. y 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 memory locations 1 2 3 or 4 can be automatically recalled and used See Figure B 7 FIGURE B 7 DUAL WIRE FEEDERS DUAL PROCEDURE OVERLAY 1 LCD DISPLAY WINDOW 2 WIRE FEEDERS MEMORY CHART 3 DISPLAY RECALL KEY 4 HIGH TEMPERATURE LIGHT 5 MEMORY LIGHTS meni O mm2 1 alo 26 2 ojo we IE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA COPYRIGHT 1994 LINCOLN ELECTRIC POWER WAVE 450 PROCEDURE PROCEDURE B 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 VERSI
88. yla 2 y Llana Qu AAL all oig Gail guet lala ay cas L LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com

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