Lincoln Electric IM524-D - Manuals

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....

Page 3 - ii; ELECTRIC SHOCK can kill.

ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...

Page 4 - iii

FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...

Page 7 - TABLE OF CONTENTS; Page; Operation

TABLE OF CONTENTS vi vi POWER WAVE 450 Page Safety .................................................................................................................................................i-iv Installation .........................................................................................

Page 9 - TECHNICAL SPECIFICATIONS - POWER WAVE 450; Input Currents; RATED OUTPUT; INSTALLATION

POWER WAVE 450 TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE 50/60 HZ. ONLY Input Voltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 200 - 60% Duty Cycle 500 40 VDC 230/400/460 - 6...

Page 10 - SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; STACKING; HIGH FREQUENCY PRECAUTIONS

Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse boxbefore working on this equipment. • Do not touch electrically ho...

Page 11 - FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR; 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 symbolis located inside the reconnect/inputaccess door for this purpose. See your local and national electr...

Page 12 - Move the large input voltage switch to the; OUTPUT CONNECTIONS; Size

INSTALLATION A-4 A-4 POWER WAVE 450 2 3 1 FIGURE A.3 – FRONTPANEL/BACK PANEL 4 (OUT) (IN) 6 5 1 WORK TERMINAL2 ELECTRODE TERMINAL3 REMOTE CONTROL AMPHENOL RECEPTACLE 4 WATER COOLING FITTINGS (ON ACCESS PANEL)5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)6 ELECTRODE TERMINAL To reconnect your machine for ...

Page 13 - OPERATION; OPERATING INSTRUCTIONS; • Always be sure coolant is not hot before

OPERATION B-1 B-1 POWER WAVE 450 OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth-ing. • Insulate yoursel...

Page 15 - GENERAL DESCRIPTION; SYNERGIC WELDING

GENERAL DESCRIPTION The INVERTEC Power Wave power source is a highperformance, digitally controlled inverter weldingpower source capable of complex, high-speed wave-form control. It uses three-phase input power only.The Power Wave is designed to be used as a synergicwelding system in conjunction wit...

Page 16 - CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS; CASE FRONT CONTROLS; POWER SWITCH: Controls input power to the

CONTROLS AND SETTINGS All operator controls and adjustments are located onthe case front of the Power Wave. Refer to Figure B.1and corresponding explanations. FIGURE B.1 – CASE FRONT CONTROLS CASE FRONT CONTROLS Refer to Figure B.1 for the location of the followingcontrols: 1. LCD DISPLAY: Provides ...

Page 17 - OPERATING OVERLAYS; OVERVIEW; FIGURE B.2 – TYPICAL POWER WAVE OVERLAY; INSTALLING AN OVERLAY; FIGURE B.3 – OVERLAY ACCESS DOOR; INVERTEC POWER WAVE 350

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 thekeys. An OVERLAY is a special plastic sheet with a numberof keys and symbols printed on one side and a barcode pr...

Page 18 - OVERLAY TYPES; Overlay

OVERLAY TYPES Four types of overlays can be used with the PowerWave. 1. Process Overlays. These overlays are used to create, save and recall specific welding proce-dures by selecting and adjusting the various weld-ing settings that have been programmed into thePower Wave at the factory. 2. Weld From...

Page 19 - LCD DISPLAY WINDOW: Power up the machine; LINCOLN ELECTRIC

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

Page 20 - SAVE TO MEMORY KEY: This key is used to save

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 ELECTRODE CLASS UP orDOWN key until the desired material type is dis-played. 4. ELECTRODE SIZE UP/DOWN: Use the ELEC- TRODE SIZE UP or DOWN keys to sele...

Page 21 - RECALL FROM MEMORY KEY: This key is used

10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. Youcan recall and use any of the previously createdwelding procedures that are stored in one of theeight memory locations. Simply press theRECALL FROM MEMORY key and then theappropriate MEMORY LOCATION NUMBER k...

Page 22 - WELD FROM MEMORY OVERLAY; FIGURE B.5 – WELD FROM MEMORY OVERLAY

1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID NUMBER = 2 This message is then replaced by the followin...

Page 23 - WELD FROM MEMORY, DUAL PROCEDURE OVERLAY; FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY

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

Page 26 - FIGURE B.8 – LIMITS OVERLAY

1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID NUMBER = 4 This message is then replaced by the followin...

Page 28 - SETUP OVERLAY; FIGURE B.9 – SETUP OVERLAY

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

Page 29 - WIRE FEEDER SETUP DESCRIPTION; Table B.1: Positive Voltage Sensing Options

When the “WATER COOLER PRESSURE” lightturns on, release the key. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polari-ty of wire feeder 1. The present polarity of wirefeeder 1 is indicated by the “WIRE FEEDER 1+POLARITY” light. If wire feeder 1 is set for po...

Page 31 - or; PULSE PROCEDURES; knows; WAVE CONTROL

OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) ANDGMAW PROCEDURES For each wire feed speed, a corresponding voltage ispreprogrammed into the machine by welding experts.This preprogrammed voltage is the best average volt-age for the procedure at the given wire feed speed. Ifthe wire fee...

Page 32 - In GMAW and FCAW processes:

OPERATION B-20 B-20 POWER WAVE 450 Trigger Position 1 GMAW GMAW STICK 1 Pulse GMAW Pulse FCAW FCAW WFS DISPLAY: WFS DISPLAY: Wire Feed Speed Wire Feed Speed WFS and WFS and Preset VOLTAGE VOLTAGE Open Arc Length Trim Preset Voltage Current DISPLAY: DISPLAY: Arc Length Trim Preset Voltage WFS, WFS, W...

Page 33 - PULSE WELDING; The Power Wave is optimized for use with a 0.75; OVERLOAD PROTECTION; Thermal Protection

PULSE WELDING Some people have trouble getting used to the behaviorof the pulsing arc. The parameters programmed intothe Power Wave have been thoroughly tested for theirability to deliver a sound weld with good appearance.There are, however, a few things to keep in mind whenpulse welding. Spatter le...

Page 34 - TABLE C.1 – RECOMMENDED GUNS FOR USE; WATER COOLER USAGE; ACCESSORIES; FIGURE C.1 – WIRE FEEDER AND

OPTIONS/ACCESSORIES • 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]or Dual [K962-1]Gas Cylinders) • Remote control (stick welding) K941-1 • Amptrols (Hand K963-1 or -2, Foot ...

Page 36 - MAINTENANCE

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse boxbefore working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODICMAINTENANCE Perform the following preven...

Page 37 - Locate two sets of two resistors on the left side of; • Proceed with caution being care-; FIGURE D.1 – RESISTOR LOCATIONS

5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on theright side of the machine. See Figure D.1. Do nottouch the resistors or any other internal machinecomponent. Using a DC voltmeter, check for anyDC voltage that may be present across the termi-na...

Page 38 - Carefully connect the needle nose end of one of; FIGURE D.3 – RESISTORS WITH LEADS; each of the other three Switch Boards.; FIGURE D.2 – DISCHARGE LABEL

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 nose-type jumper leads and insulated gloves, connect one jumper lead toone end of the resistor obtained in step 4.Connect the other jumper lead to th...

Page 39 - PREVENTIVE 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 recordtag attached to the machine works best. 1. Remove the hex head screws from the sides and top of the machine. Remove th...

Page 40 - VICE TOOL USAGE

MAINTENANCE D-5 D-5 POWER WAVE 450 RECOMMENDED TOOLS FOR INSTAL-LATION OR SERVICE OF COOLER: • absorbent towels • alcohol wipe • 3 mm allen wrench (G3503 only) • socket wrench • 4 inch long minimum socket extension • 1/4, 5/16, and 3/8 hex standard depth sockets • 5/32 allen socket • medium blade sl...

Page 42 - FIGURE D.4 – GENERAL COMPONENT LOCATIONS

MAINTENANCE D-7 D-7 POWER WAVE 450 FIGURE D.4 – GENERAL COMPONENT LOCATIONS 1 DISPLAY BOARD (BACK OF PANEL)2 POWER SWITCH3 MAIN TRANSFORMER4 AUXILIARY TRANSFORMER5 INPUT RECTIFIER6 HEAT SINK FINS7 OUTPUT TERMINALS8 OVERLAY BAR CODE SENSORS9 TERMINAL STRIP (LOCATION) 9 4 6 3 7 2 8 1 5

Page 43 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE

TROUBLESHOOTING E-1 E-1 POWER WAVE 450 HOW TO USE TROUBLESHOOTING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorizedrepairs per-formed on this equipment may result in danger to the technician and machine operator andwill invalidate your factory warran...

Page 44 - TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS

Major physical or electrical dam-age is evident when the sheetmetal cover(s) are removed. Machine is dead – no output – nofans – no displays. Machine has no output – fans arerunning – display is on – a “click-ing” sound is heard coming fromthe machine. 1. Contact your local authorizedLincoln Electri...

Page 51 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals

Now Available...12th EditionThe 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 ...

Page 52 - ÇÃ

WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...