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IM579
April, 1999
TM
INVERTEC POWER WAVE 450
For use with machines having Code Numbers: 10391
10392
10405
10406
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before y
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i i SAFETY WARNING 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 recom- mended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2
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ii ii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the weld- 5.a. Use only compressed gas cylin- ing area. If this is not possible, ders containing the correct shield- cover them to prevent the welding ing gas for the process used and sparks from starting a fire. properly operating regulators Remember that welding designed for the gas and sparks and hot materials from welding can easily go through small pressure used. A
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iii iii SAFETY FOR ENGINE ELECTRIC AND MAGNETIC powered equipment. FIELDS may be dangerous 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 8.a. Electric current flowing through any conductor causes local- ized Electric and Magnetic Fields (EMF). Welding current cre- 7.b.Operate engines in open, well-ventilated ates EMF fields around welding cables and welding areas or vent the engine exhaust fumes machines. outdoors. 8.
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iv iv SAFETY 7. Quand on ne soude pas, poser la pince à une endroit isolé PRÉCAUTIONS DE SÛRETÉ de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 8. S’assurer que la masse est connectée le plus prés possible manuel aussi bien que les précautions de sûreté générales suiv- de la zone de travail qu’il est pratique de l
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• Thank You 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
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vi vi TABLE OF CONTENTS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications .............................................................................................................A-1 Safety Precautions...........
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE ONLY Input Voltages: 230 460 Input Currents @ 500A/40 VDC 76 38 @ 450A/38 VDC 65 32 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 230/400/460 - 60% Duty Cycle 450 38 VDC 230/400/460 - 100% Duty Cycle 400 38 VDC RATED OUTPUT Constant Open Continuous Process Circuit Voltage Current Range Current Ranges 75 Volts 5-520 Amps GMAW 50-520 Amps FCAW 40-520 Amps STICK 30-520 Amps Pulse Pulse Pulse and Background Puls
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A-2 A-2 INSTALLATION Read this entire installation section before you LIFTING start installation. Lift the machine by the lift bail only. Do not attempt to lift the machine by the push handle. SAFETY PRECAUTIONS HIGH FREQUENCY PRECAUTIONS If possible, locate the Power Wave away from radio WARNING controlled machinery. The normal operation of the ELECTRIC SHOCK can kill. Power Wave may adversely affect the operation of RF controlled equipment, which may result in bodily injury • Only qualifie
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A-3 A-3 INSTALLATION wire sizes. Fuse the input circuit with the recom- CAUTION mended super lag fuses or delay type circuit breakers. Choose an input and grounding wire size according to Failure to follow these instructions can cause immedi- local or national electrical codes. Using fuses or cir- ate failure of components within the welder. cuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high curre
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A-4 A-4 INSTALLATION FIGURE A.3 – FRONTPANEL/BACK PANEL 6 (IN) 5 4 (OUT) 2 1 3 1 WORK TERMINAL 4 WATER COOLING FITTINGS (ON BACK PANEL) 2 ELECTRODE TERMINAL 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL) 3 REMOTE CONTROL AMPHENOL RECEPTACLE 6 ELECTRODE TERMINAL To operate at 208-230 VAC: OUTPUT CONNECTIONS 1. Open the reconnect/input access door. See Figure A.3 for the location of the work terminal, electrode terminal, remote control amphenol recepta- 2. Move the input voltage switch to voltag
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING
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B-2 B-2 OPERATION Step 2: Adjust the wire feed to speed “WFS” and QUICK START REFERENCE FOR voltage “V” or arc length “T” (if necessary). USING THE PROCESS SELECTION a. Press the DISPLAY RECALL key to OVERLAY view additional procedure information. Read and understand the “Controls and Settings” and b. Adjust wire feed speed and voltage or arc “Operating Overlays” sections of this manual before length trim through the controls on your wire using the following Quick Start Reference p
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B-3 B-3 OPERATION DESIGN FEATURES AND ADVANTAGES GENERAL DESCRIPTION • Designed to NEMA Standards. The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding • Multiple process output ranges 5 - 540 amps. power source capable of complex, high-speed wave- • 2-line LCD display. form control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic • Easy access for input connections. Connections welding system in conjun
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B-4 B-4 OPERATION CASE FRONT CONTROLS CONTROLS AND SETTINGS Refer to Figure B.1 for the location of the following All operator controls and adjustments are located on controls: the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations. 1. LCD DISPLAY: Provides welding procedure infor- mation and parameters such as wire type, gas FIGURE B.1 – CASE FRONT CONTROLS type, WFS, trim, etc. 6 2. POWER SWITCH: Controls input power to the Power Wave. When the switch is turned
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B-5 B-5 OPERATION INSTALLING AN OVERLAY OPERATING OVERLAYS 1. Open the ACCESS DOOR by grasping the provid- OVERVIEW ed indent on the door and pulling the door for- The Power Wave is controlled by a panel of keys (key- ward. See Figure B.3 for door location. pad) located on the front of the machine. The opera- tor can access controls by placing an overlay over the keys. FIGURE B.3 – OVERLAY ACCESS DOOR An OVERLAY is a special plastic sheet with a number of keys and symbols printed on one side
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B-6 B-6 OPERATION Overlay Overlay Figure OVERLAY TYPES Type Name No. Four types of overlays can be used with the Power 1 GMAW PULSE, GMAW Wave. FCAW, STICK PROCESS 1. Process Overlays. These overlays are used to SELECTION OVERLAY B.4 create, save and recall specific welding proce- 2 WELD FROM MEMORY dures by selecting and adjusting the various weld- OVERLAY B.5 ing settings that have been programmed into the Power Wave at the factory. 2 WELD FROM MEMORY, DUAL PROCEDURE OVERLAY B.6 2. Weld From
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B-7 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 existing welding procedure, recall an existing welding procedure, and clear a memory location. See Figure B.4. The steps for performing each of these functions are given below. FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY 1 11 10 2 8 6 9 34 5 7 1 LCD DISPLAY WINDOW 7 DISPLAY RECA
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B-8 B-8 OPERATION 3. ELECTRODE CLASS UP/DOWN: Use the ELEC- 7. DISPLAY RECALL KEY: Since not all the informa- TRODE CLASS UP or DOWN keys to select from tion about the procedure can be seen on the 2-line the material types available for the selected LCD display window at the same time, use the process. Press the ELECTRODE CLASS UP or DISPLAY RECALL key to display and verify all of DOWN key until the desired material type is dis- the selected procedure information. The normal played. default di
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B-9 B-9 OPERATION 10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations. Simply press the RECALL RECALL FROM MEMORY key and then the appropriate MEMORY LOCATION NUMBER key. If you press the RECALL FROM MEMORY key and then change your mind, you can exit this function by pressing the DISPLAY RECALL key. If the memory location y
