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 Page Safety .................................................................................................................................................i-iv Installation ........................................................................................................
Page 11 - 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 12 - 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 13 - 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 14 - 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 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 the proper input ...
Page 15 - POWER WAVE 450 ROBOTIC DIMENSIONS
INSTALLATION A-5 A-5 POWER WAVE 450 POWER WAVE 450 ROBOTIC DIMENSIONS 18.76 19.50 15.50 35.82 A 16.08 29.49 32.26 35.00 38.82 M17793
Page 16 - POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT
INSTALLATION A-6 A-6 POWER WAVE 450 POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM K680K681CONTROL TO WIRE DRIVE CABLES CUSTOMER MUST PROVIDE WIRE DEREELING METHOD SYNERGIC 7F WIRE DRIVE K679-1 (LOW SPEED)K679-2 (...
Page 17 - 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 19 - 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 20 - 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 21 - 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 22 - 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 23 - 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 24 - 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 25 - 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 26 - ROBOTIC INTERFACE WELD FROM MEMORY, DUAL PROCEDURE 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 = 10 This message is then replaced by the followi...
Page 28 - FIGURE B.6 – 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 30 - SETUP OVERLAY; FIGURE B.7 – 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 31 - WIRE FEEDER SETUP DESCRIPTION; Table B.1: Positive Voltage Sensing Options; Table B.2: Negative 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 32 - or; PULSE PROCEDURES; knows; WAVE CONTROL; In GMAW and FCAW processes:
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 34 - 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 35 - INTERFACE DESCRIPTION; trim; WIRE BURNBACK FUNCTION; ROBOT SIGNAL DESCRIPTIONS; WIRE FEED SPEED COMMAND
1. INTERFACE DESCRIPTION This interface is designed for a Power Wave 450 and aFanuc robot using ArcTool software (V1.30P) withtouch sensing and through arc tracking. The interfaceresponds to all of the ArcTool welding inputs and out-puts except wire fault and wire stick alarm. All of thecircuitry fo...
Page 37 - TIONS; ROBOT CONTROLLER ELECTRICAL; POWER WAVE CIRCUITS; VOLTAGE COMMAND
2.17 DUAL PROCEDURE SWITCH COM- MAND This is an active low output from the robot con-troller used to activate the dual procedure switch.When the Power Wave is running a dual proce-dure overlay this output is used to switchbetween procedures. If the output is held highby the robot controller then pro...
Page 39 - ROBOT CONTROLLER SETUP; WELD SYSTEM SETUP
5. ROBOT CONTROLLER SETUP 5.1 WELD SYSTEM SETUP MONITORING FUNCTIONS1 Arc loss ENABLED 2 Gas shortage DISABLED 3 Wire shortage DISABLED 4 Wire stick ENABLED 5 Power supply failure ENABLED 6 Coolant shortage ENABLED WELD RESTART FUNCTION7 Return to path DISABLED 8 Overlap distance 0mm 9 Return to pat...
Page 40 - ARCTOOL WELDING INPUTS AND
ROBOTIC INTERFACE C-6 C-6 POWER WAVE 450 6. CONNECTIONS 6.2 ARCTOOL WELDING INPUTS AND OUTPUTS J101-1 +Serial loop CTRL J27-1 J101-2 High speed sense 1 P83-K J101-3 High speed sense 2 P83-L J101-4 -Serial loop CTRL J27-4 J104-1 Voltage signal CTRL J21-4 J104-2 Current signal CTRL J21-7 J104-3 Water ...
Page 41 - ACCESSORIES; FIGURE D.1 – WIRE FEEDER AND
WATER COOLER USAGE The Power Wave is equipped with an optional internalwater cooler. We recommend using the water coolerwhen welding above 300 amps with argon blends on aregular basis. The gun heating from pulsing above 300amps average current is often excessive and leads toreduced consumable life, ...
Page 42 - L9777 WIRE FEED UNIT DIMENSION PRINT; Any prepacked welding industry coolant; DO NOT USE OIL-BASED COOLANTS OF ANY; FOR THE LATEST
ACCESSORIES D-2 D-2 POWER WAVE 450 1 . 0 0 6 . 2 5 6 . 7 5 4 . 6 7 R E M O T E A 6 . 6 7 7 . 1 6 7 . 5 0 1 . 7 2 3 . 1 8 . 2 5 . 2 5 . 2 8 1 7 . 0 0 1 1 . 2 5 1 . 4 4 T Y P . O U T L E T 1 . 3 1 . 8 1 1 . 0 0 8 . 0 6 . 8 7 I N L E T I N P U T 3 . 3 6 6 . 2 1 G A S F I T T I N G M O U N T I N G W I R...
Page 43 - MOUNTING THE WIRE FEED UNIT
ACCESSORIES D-3 D-3 POWER WAVE 450 MOUNTING THE WIRE FEED UNIT Mount the wire feed unit by means of the insulatedmounting bracket attached to the bottom of the gear-box. See L9777 Dimension Print following, to find thesize and location of the mounting holes. The gearboxassembly is electrically “ hot...
Page 44 - DRIVE ROLL AND GUIDE TUBE KITS:
ACCESSORIES D-4 D-4 POWER WAVE 450 Standard 4-Roll Kits (KP655 and KP656) 1) Turn off welding power source. 2) Release both quick release levers by sliding the levers sideways into the open positions. 3) Remove clamping screw & clamping collar from the drive shaft closest to the incoming side of...
Page 45 - Idle Roll Pressure Setting
ACCESSORIES D-5 D-5 POWER WAVE 450 Idle Roll Pressure Setting The idle roll pressure is set at the factory, backed outthree turns from full pressure on 4-roll feeders. This isan approximate setting. For small wire sizes and alu-minum wire up to 9 or 10 turns out may be required tominimize “ birdnest...
Page 46 - REQUIRES INSTALLATION OF 2; Feeding Electrode and Brake Adjustment
ACCESSORIES D-6 D-6 POWER WAVE 450 7) To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling theReadi-Reel cage from the molded adapter with bothhands. Do not remove adapter from the spindle. To Mount 10 to 44 lb (4.5-20kg) Spool(12 ” /300mm Diameter): (For 8 ” (200...
Page 47 - DO NOT; Feeding Electrode
ACCESSORIES D-7 D-7 POWER WAVE 450 4) Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms. 5) Cut and remove only the tie wire holding the free end of the coil. Insert the free end into one of theholes in the cover and secure it by bending it back.Cut and remove the ...
Page 48 - Drive Rolls and Guide Tubes; Avoiding Wire Feeding Problems; Wire Drive Motor and Gearbox
ACCESSORIES D-8 D-8 POWER WAVE 450 Routine Maintenance of Wire FeedUnit Drive Rolls and Guide Tubes After feeding every coil of wire, inspect the drive rollsection. Clean it as necessary. Do not use a solventfor cleaning the idle roll because it may wash the lubri-cant out of the bearing. The driver...
Page 49 - Diameter Hole; Switch Requirements
ACCESSORIES D-9 D-9 POWER WAVE 450 Gun Cable Connector Requirementsto Permit Proper Connection to WireFeed Units Connector must beinsulated in this area Style "A" 1.25 max (31.7) 2.00 (51.0) 1.25 (31.7) 1.00 (25.4) .252 (6.40) .260 (6.60) .295 (7.49).290 (7.36) "A" DIA HOLE .062R (1....
Page 50 - 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 51 - 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 52 - 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 53 - 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 54 - VICE TOOL USAGE
MAINTENANCE E-5 E-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 56 - FIGURE D.4 – GENERAL COMPONENT LOCATIONS
MAINTENANCE E-7 E-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 57 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING F-1 F-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 58 - 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 65 - 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 66 - 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...
