Lincoln-electric IM524 INVERTEC POWER WAVE 450 Manuel d'utilisateur

IM524-DOctober, 2001For use with machines having Code Numbers: 10365 1051110366 1051210433 1052010434 1060710449 10610INVERTEC POWER WAVE 450TMOPER

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

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 PANEL4(OUT)(IN)651 WORK TERMINAL2 ELECTRODE TERMINAL3 REMOTE CONTROL AMPHENOL RECE

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

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

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

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. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press thiskey to change the present voltage sensin

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

Use the ELECTRODE SENSE LEAD KEY to selecteither the - output terminal or the electrode sense (67)lead for the positive voltage reference.The work sen

OVERVIEW OF WELDING PROCEDURESFLUX CORED ARC WELDING (FCAW) ANDGMAW PROCEDURESFor each wire feed speed, a corresponding voltage ispreprogrammed into t

OPERATIONB-20 B-20POWER WAVE 450TriggerPosition1GMAW GMAW STICK1Pulse GMAWPulse FCAW FCAWWFS DISPLAY: WFS DISPLAY:Wire Feed Speed Wire Feed SpeedWFS a

PULSE WELDINGSome people have trouble getting used to the behaviorof the pulsing arc. The parameters programmed intothe Power Wave have been thoroughl

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 c

There are two water connections on the rear of thePower Wave. See Figure C.1. Connect the water linesbetween these connectors and those on the wire fe

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn the input power OFF at thedisconnect swi

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.

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

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

MAINTENANCED-5 D-5POWER WAVE 450RECOMMENDED TOOLS FOR INSTAL-LATION OR SERVICE OF COOLER:• absorbent towels• alcohol wipe• 3 mm allen wrench (G3503 on

MAINTENANCED-6 D-6G3503-[ ] COOLER PERIODIC MAINTENANCE1. Preparation:• Always switch off the Power Wave machine power.• Always disconnect the Power W

MAINTENANCED-7 D-7POWER 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

Major physical or electrical dam-age is evident when the sheetmetal cover(s) are removed.Machine is dead – no output – nofans – no displays.Machine ha

Machine has no output – no fans –no display. Main input fuses areopen, indicating excessive inputcurrent draw.Machine has no output – no dis-play – fa

Machine has no output – fans run– display is on.Machine regularly overheats – yel-low light (LED) on the front panelglows, indicating a thermal over-l

The voltage and/or wire feedspeed will not adjust to user satis-faction.The voltage and/or wire feedspeed can be adjusted on the wirefeeder but the ch

Machine does not respond to keysbeing pressed, or the machine hasimproper displays.Machine display reads “ErrorInvalid Overlay,” or it displays aninco

The Beeper (Piezoelectric Buzzer) cannot beheard – machine operating normally.The welding parameters that weresaved in memory are differentwhen recall

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

Machine loses output while weld-ing. Fans and display are function-ing properly.For no apparent reason the weldcharacteristics have changed.Machine of

WIRING DIAGRAMSF-1 F-1POWER WAVE 450KEYPADRS232CONNECTOR1234567820LCDDISPLAYRECEPTACLE5ACIRCUITBREAKER+-+-+-+-CURRENTTRANSFORMERBCDEFAGHIJKLMN102D106A

WIRING DIAGRAMSF-2 F-2POWER WAVE 450KEYPADRS232CONNECTOR1234567820LCDDISPLAYRECEPTACLE5ACIRCUITBREAKER+-+-+-+-CURRENTTRANSFORMERBCDEFAGHIJKLMN102D106A

WIRING DIAGRAMSF-3 F-3POWER WAVE 450KEYPADRS232CONNECTOR1234567820LCDDISPLAY5ACIRCUITBREAKER+-+-+-+-CURRENTTRANSFORMERBCDEFAGHIJKLMN102D106A2752762772

NOTES

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

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TABLE OF CONTENTSvi viPOWER WAVE 450PageSafety...

vii viiPOWER WAVE 450Weld from Memory, Dual Procedure Overlay......B-11Dual Wire Feeder

POWER WAVE 450TECHNICAL SPECIFICATIONS - POWER WAVE 450INPUT - THREE PHASE 50/60 HZ. ONLYInput Voltages: 200 230 400 460 575Input Currents@ 500A/40 VD