Page 2 - SAFETY; WARNING; ARC WELDING can be hazardous.; ELECTRIC SHOCK can kill.
SAFETY i i POWER WAVE 450 WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recom-me...
Page 3 - ii
SAFETY ii ii POWER WAVE 450 WELDING SPARKS cancause fire or explosion. 4.a. Remove fire hazards from the weld-ing area. If this is not possible,cover them to prevent the weldingsparks from starting a fire.Remember that welding sparks and hot materials from welding can easily go through smallcracks a...
Page 4 - iii
SAFETY iii iii POWER WAVE 450 FOR ENGINEpowered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumesoutdoors. 7.c. Do not add the fue...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv POWER WAVE 450 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous co...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
POWER WAVE 450 Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 t...
Page 7 - TABLE OF CONTENTS; Page
TABLE OF CONTENTS vi vi POWER WAVE 450 Page Safety .................................................................................................................................................i-iv Installation .........................................................................................
Page 8 - TECHNICAL SPECIFICATIONS - POWER WAVE 450; Input Currents; INSTALLATION; OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
TECHNICAL SPECIFICATIONS - POWER WAVE 450 Input Voltages: 230 460 Input Currents @ 500A/40 VDC 76 38 @ 450A/38 VDC 65 32 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 Constant Open Continuous Process Circuit Voltage Current Ra...
Page 9 - 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 10 - FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR; INPUT SUPPLY CONNECTION DIAGRAM; 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 11 - 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 BACK PANEL)5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)6 ELECTRODE TERMINAL To operate at 208-230 VAC: 1. Open the reconnect/...
Page 12 - OPERATION; OPERATING INSTRUCTIONS
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 14 - 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 15 - CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS; CASE FRONT CONTROLS; LINCOLN ELECTRIC
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 16 - 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 17 - OVERLAY TYPES; These overlays are used to
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 20 - 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 21 - WELD FROM MEMORY OVERLAY; FIGURE B.5 – WELD FROM MEMORY OVERLAY
1. LCD DISPLAY WINDOW: Power up the machinewith 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 following...
Page 22 - WELD FROM MEMORY, DUAL PROCEDURE OVERLAY; FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY
1. LCD DISPLAY WINDOW: Power up the machinewith 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 following...
Page 24 - FIGURE B.7 – DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY
1. LCD DISPLAY WINDOW: Power up the machinewith 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 = 9 2. WIRE FEEDERS MEMORY CHART: The activeweldin...
Page 25 - FIGURE B.8 – LIMITS OVERLAY
1. LCD DISPLAY WINDOW: Power up the machinewith 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 following...
Page 27 - SETUP OVERLAY; FIGURE B.9 – SETUP OVERLAY
1. LCD DISPLAY WINDOW: Power up the machinewith 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 following...
Page 28 - WIRE FEEDER SETUP DESCRIPTION; the positive output terminal of the Power Wave; Table B.1: Positive Voltage Sensing Options; ) the electrode cable is connected to the -; Table B.2: Negative Voltage Sensing Options
When the “WATER COOLER PRESSURE” lightturns on, release the key. If this key has beenpressed for 30 seconds and the ‘WATER COOLERPRESSURE’ light still did not turn on, check thewater cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press thiskey to change the present voltage sensi...
Page 32 - In GMAW and FCAW processes:; PULSE WELDING; region between pulse and short arc.
In Pulse processes: The wave control adjustment allows the frequency set-ting to vary. Increasing the wave control allows the fre-quency setting to increase, and decreasing the wavecontrol allows the frequency setting to decrease.Varying the wave control setting affects the droplettransfer and allow...
Page 33 - OVERLOAD PROTECTION; THERMAL PROTECTION
OVERLOAD PROTECTION THERMAL PROTECTION The Power Wave has thermostatic protection fromexcessive duty cycles, overloads, loss of cooling, andhigh ambient temperatures. When the power source issubjected to any of these conditions or any of the con-ditions mentioned above, a thermostat will open. Theye...
Page 34 - WIRE FEEDER SETUP; Connect the feeder to a welding gas supply.; GUNS AND CABLES; TABLE C.1 – RECOMMENDED GUNS FOR USE; 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) • Remote control (stick welding) K941-1 • Limits Overlay (K946-4) • Dual Wire Feeders, Dual Procedures Overlay(K946-9) WIRE FEEDER SETUP The Power Wave must be used ...
Page 35 - WATER COOLER USAGE
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 36 - MAINTENANCE; • Only Qualified personnel should
MAINTENANCE D-1 D-1 POWER WAVE 450 WARNING WARNING CAUTION 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. R...
Page 37 - FIGURE D.1 – RESISTOR LOCATIONS; • Proceed with caution being care-
MAINTENANCE D-2 D-2 POWER WAVE 450 FIGURE D.1 – RESISTOR LOCATIONS WARNING 5. Locate two sets of two resistors on the left side ofthe 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 ...
Page 38 - 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 leadsand insulated gloves, connect one jumper lead toone end of the resistor obtained in step 4.Connect the other jumper lead to the ...
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 andtop of the machine. Remove the...
Page 40 - FIGURE D.4 – GENERAL COMPONENT LOCATIONS
MAINTENANCE D-5 D-5 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 41 - 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 42 - TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS
TROUBLESHOOTING E-2 E-2 POWER WAVE 450 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. Conta...
Page 47 - The water cooler does not turn on.
TROUBLESHOOTING E-7 E-7 POWER WAVE 450 The Beeper (Piezoelectric Buzzer) cannot beheard – machine operating normally. The welding parameters that weresaved in memory are differentwhen recalled. The water cooler does not turn on. The machine beeps without the keys being pressed. 1. Background noise m...
Page 49 - WIRING DIAGRAMS; WIRING DIAGRAM
WIRING DIAGRAMS F-1 F-1 POWER WAVE 450 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. WIRING DIAGRAM
Page 50 - 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 the ...
Page 53 - LIMITED WARRANTY
• 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 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors STATEMENT OF LIMITED WARRANTY The Lin...
