Lincoln-electric IM579 POWER WAVE 450 User Manual

OPERATOR’S MANUALIM579April, 1999For use with machines having Code Numbers: 10391103921040510406INVERTEC POWER WAVE 450TMSafety Depends on YouLinco

Failure to follow these instructions can cause immedi-ate failure of components within the welder.GROUND CONNECTIONSThe frame of the welder must be gr

INSTALLATIONA-4 A-4POWER WAVE 450231FIGURE A.3 – FRONTPANEL/BACK PANEL1 WORK TERMINAL2 ELECTRODE TERMINAL3 REMOTE CONTROL AMPHENOL RECEPTACLE4 WAT

OPERATIONB-1 B-1POWER WAVE 450OPERATING INSTRUCTIONSRead and understand this entire section of operatinginstructions before operating the machine.SAFE

QUICK START REFERENCE FORUSING THE PROCESS SELECTIONOVERLAYRead and understand the “Controls and Settings” and“Operating Overlays” sections of this ma

GENERAL DESCRIPTIONThe INVERTEC Power Wave power source is a highperformance, digitally controlled inverter weldingpower source capable of complex, hi

CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe case front of the Power Wave. Refer to Figure B.1and corresponding expla

OPERATING OVERLAYSOVERVIEWThe Power Wave is controlled by a panel of keys (key-pad) located on the front of the machine. The opera-tor can access con

OVERLAY TYPES Four types of overlays can be used with the PowerWave.1. Process Overlays. These overlays are used tocreate, save and recall specific we

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears onthe display f

3. ELECTRODE CLASS UP/DOWN: Use the ELEC-TRODE CLASS UP or DOWN keys to select fromthe material types available for the selectedprocess. Press the EL

SAFETYi iPOWER WAVE 450WARNINGPROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT

10. RECALL FROM MEMORY KEY: This key is usedto recall an existing procedure from memory. Youcan recall and use any of the previously createdwelding p

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay wi

When a pair of welding procedures are recalledfrom memory, the display window will show theprocedure description, wire feed speed, and thepreset volta

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay wi

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay w

Use the LIMIT UP and LIMIT DOWN keys tochange the maximum wire feed speed to thedesired value.Press the SET LIMIT key again. The new maximumand old mi

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

When the “WATER COOLER PRESSURE” lightturns on, release the key. If this key has beenpressed for 30 seconds and the ‘WATER COOLERPRESSURE’ light stil

OPERATIONB-18 B-18POWER WAVE 450Use the ELECTRODE SENSE LEAD KEY to selecteither the - output terminal or the electrode sense (67)lead for the positiv

SAFETYii iiPOWER WAVE 450WELDING SPARKS cancause fire or explosion.4.a. Remove fire hazards from the weld-ing area. If this is not possible,cover the

OVERVIEW OF WELDING PROCEDURESFLUX CORED ARC WELDING (FCAW)AND GMAW PROCEDURESFor each wire feed speed, a corresponding voltagehas been preprogrammed

OPERATIONB-20 B-20POWER WAVE 450TriggerPosition1GMAW GMAW STICK1GMAW GMAWPulse FCAW Pulse FCAWWFS DISPLAY: WFS DISPLAY:Wire Feed Speed Wire Feed Speed

In Pulse processes:The wave control adjustment allows the frequency set-ting to vary. Increasing the wave control allows the fre-quency setting to inc

OVERLOAD PROTECTIONTHERMAL PROTECTIONThe Power Wave has thermostatic protection fromexcessive duty cycles, overloads, loss of cooling, andhigh ambient

OPTIONS/ACCESSORIES• Synergic 7 wire feeder (K632-1) standard speed,or(K632-2) high speed• MAGNUM 400 gun (K471-2) or 550 gun (K598)• Remote control (

WATER COOLER USAGE The Power Wave is equipped with an optional internalwater cooler. We recommend using the water coolerwhen welding above 300 amps wi

MAINTENANCED-1 D-1POWER WAVE 450WARNINGWARNINGCAUTIONSAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this mainten

MAINTENANCED-2 D-2POWER WAVE 450FIGURE D.1 – RESISTOR LOCATIONSWARNING5. Locate two sets of two resistors on the left side ofthe machine and three set

6. Locate the #9 and #12 terminals, identified by the“Discharge” labels, on each of the four SwitchBoards. See Figure D.2.7. Using insulated, needle

PREVENTIVE MAINTENANCEPerform the following preventive maintenance proce-dures at least once every six months. It is good prac-tice to keep a prevent

SAFETYiii iiiPOWER WAVE 450FOR ENGINEpowered equipment.7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work

MAINTENANCED-5 D-5POWER WAVE 450FIGURE D.4 – GENERAL COMPONENT LOCATIONS1 DISPLAY BOARD (BACK OF PANEL)2 POWER SWITCH3 MAIN TRANSFORMER4 AUXILIARY

TROUBLESHOOTINGE-1 E-1POWER WAVE 450HOW TO USE TROUBLESHOOTING GUIDEThis Troubleshooting Guide is designed to be used by the machine Owner/Operator. U

TROUBLESHOOTINGE-2 E-2POWER WAVE 450Major physical or electrical dam-age is evident when the sheetmetal cover(s) are removed.Machine is dead – no outp

TROUBLESHOOTINGE-3 E-3POWER WAVE 450Machine has no output – no fans –no display. Main input fuses areopen, indicating excessive inputcurrent draw.Mach

TROUBLESHOOTINGE-4 E-4POWER WAVE 450Machine has no output – fans run– display is on.Machine regularly overheats – yel-low light (LED) on the front pan

TROUBLESHOOTINGE-5 E-5POWER WAVE 450The voltage and/or wire feedspeed will not adjust to user satis-faction.The voltage and/or wire feedspeed can be a

TROUBLESHOOTINGE-6 E-6POWER WAVE 450Machine does not respond to keysbeing pressed, or the machine hasimproper displays.Machine display reads “ErrorInv

TROUBLESHOOTINGE-7 E-7POWER WAVE 450The Beeper (Piezoelectric Buzzer) cannot beheard – machine operating normally.The welding parameters that weresave

TROUBLESHOOTINGE-8 E-8POWER WAVE 450Machine loses output while weld-ing. Fans and display are function-ing properly.For no apparent reason the weldcha

WIRING DIAGRAMSF-1 F-1POWER WAVE 450NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The spe

SAFETYiv ivPOWER WAVE 450PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specif

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POWER WAVE 450Thank Youfor selecting a QUALITY product by Lincoln Electric.We want youto take pride in operating this Lincoln Electric Company product

TABLE OF CONTENTSvi viPOWER WAVE 450PageSafety...

TECHNICAL SPECIFICATIONS - POWER WAVE 450Input Voltages: 230 460Input Currents@ 500A/40 VDC 76 38@ 450A/38 VDC 65 32Duty Cycle Amps Volts at Rated Amp

Read this entire installation section before youstart installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qualified personnel shouldperform