Lincoln Electric INVERTEC POWER WAVE 450 IM524-D Operator'S Manual Download Page 4

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can
cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.
Remember that welding sparks and hot

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

Summary of Contents for INVERTEC POWER WAVE 450 IM524-D

Page 1: ...tion and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN UAL AND THE SAFETY PRE CAUTIONS CONTAINED THROUGHOUT And most importantly think bef...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy o...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic...

Page 5: ...ri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...onnections A 4 Work and Electrode Cable Connections A 4 Water Cooler Connections A 4 Wire Feeder Connections A 4 Operation Section B Safety Instructions B 1 Quick Start Reference for Process Selection...

Page 8: ...nd Cables C 1 Water Cooler Usage C 2 Undercarriages C 2 Maintenance Section D Safety Precautions D 1 Routine and Periodic Maintenance D 1 Input Filter Capacitor Discharge Procedure D 1 Resistor Locati...

Page 9: ...Range Voltage Range Time Range Frequency 5 750 Amps 5 55 Volts 100 Microsec 3 3 Sec 0 15 1000 Hz RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 C Type 75 C Type 75 C Input Duty Input Ampere Copper Wir...

Page 10: ...rts of the machine in water This may cause improper operation and is a possible safe ty hazard STACKING Power Wave machines cannot be stacked TILTING Each machine must be placed on a secure level sur...

Page 11: ...rrents even if the machine is not being used at high currents INPUT VOLTAGE RECONNECT PROCEDURE Only a qualified electrician should connect the input leads to the Power Wave Connections should be made...

Page 12: ...ittings and wire feeder connections WORK AND ELECTRODE CABLE CONNECTIONS Size Use the largest welding electrode and ground cables possible at least 70mm2 2 0 copper wire even if the output current doe...

Page 13: ...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 SPARKS can cause fire or explosio...

Page 14: ...ngth T if necessary a Press the DISPLAY RECALL key to view additional procedure information b Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder The new val...

Page 15: ...nershield and Outershield and stick proce dures OPERATIONAL FEATURES AND CONTROLS The Power Wave through use of a keypad overlay system provides various options and controls such as Multiple Process P...

Page 16: ...rlay placed on the machine At this point the machine is ready for operation 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over tempera ture situation occurs Output is...

Page 17: ...ys The machine must be powered up each time an overlay is changed INSTALLING AN OVERLAY 1 Open the ACCESS DOOR by grasping the provid ed indent on the door and pulling the door for ward See Figure B 3...

Page 18: ...ys provide specific machine setup information such as operating lim its for the welding procedures stored in memory 4 Special Purpose Overlays These are custom overlays for specific customer applicati...

Page 19: ...However if you make compo nent selections out of order the machine will prompt you to make a new selection for any set tings that do not apply 2 PROCESS SELECT KEY Use the PROCESS SELECT key to select...

Page 20: ...ed procedure information The normal default display window shows the Procedure Description WFS and preset voltage or arc length trim values Press and hold the DISPLAY RECALL key and the window shows t...

Page 21: ...procedure is saved into a memory location it can be recalled from there until another procedure is stored in that location or the location is cleared The RECALL FROM MEMORY and SAVE TO MEMORY keys can...

Page 22: ...in place They cannot be overridden from this over lay 3 PROGRAM LIST The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding proc...

Page 23: ...e dual procedure switch or gun trigger to the position for PROCEDURE A or PROCEDURE B Position A activates the welding procedure from the odd numbered memory locations 1 3 5 or 7 Position B activates...

Page 24: ...overlay provides a convenient place to record a brief description of each welding procedure stored in memory A Dry Erase mark er should be used for this purpose 4 DISPLAY RECALL KEY To view other inf...

Page 25: ...the selected procedures these limits will be active when this overlay is in place They cannot be overridden from this over lay 3 DISPLAY RECALL KEY To view other information about the active welding p...

Page 26: ...ocedure If no procedure was saved in the selected memo ry location the following message appears MEMORY LOCATION IS EMPTY Select another memory location 4 SET LIMIT KEY AND 5 LIMIT UP DOWN KEYS The SE...

Page 27: ...cedure with the newly set limits to memory Press the SAVE TO MEMORY key followed by the MEMORY LOCATION NUMBER key of the desired memory location This does not have to be the original location from wh...

Page 28: ...proper coolant level See Water Cooler informa tion in ACCESSORIES section To prime the water cooler hold the PRIME WATER COOLER key down While this key is pressed the display will show PRIME WATER CO...

Page 29: ...Power Wave s output studs I Select arc voltage sensing polarity first POLARITY KEY A Positive Polarity Voltage Sensing In most welding applications the electrode cable is connected to the output term...

Page 30: ...if use of the work sense 21 lead is desired The two wire feeders can only be connected in the same manner either by the Positive Polarity or the Negative Polarity setup OPERATION B 18 B 18 POWER WAVE...

Page 31: ...ength trim less than 1 0 decreases the pre set arc lengths The arc length adjustment is factored in at all wire feed speed settings Increasing the arc length by 10 percent at a given wire feed speed a...

Page 32: ...ying the wave control setting affects the droplet trans fer and allows fine tuning for different welding positions In GMAW and FCAW processes The wave control adjusts the inductance Inductance is inve...

Page 33: ...dures have been checked for their ability to deliver a sound weld However the fusion of the weld metal into the workpiece may be affected It is the responsibility of the user to determine if the welds...

Page 34: ...plications connect the work cable between the work and the positive connec tion of the power source See Figure C 1 Connect the feeder to a welding gas supply Load the wire into the feeder and gun Conf...

Page 35: ...liquids down the drain Contact the local EPA office for responsible disposal methods or for recycling information 5 The cooler s reservoir has a nominal liquid capacity of 1 6 gallons PRIMING THE COOL...

Page 36: ...TER CAPACITOR DIS CHARGE PROCEDURE 1 Turn off input power and disconnect input power lines 2 Remove the hex head screws from the top and the sides of the machine Remove the handle bar and the wrap aro...

Page 37: ...esent across the termi nals of each resistor and from each resistor to case ground 20 measurements in all If a voltage is present be careful not to touch these resistors ELECTRIC SHOCK can kill Procee...

Page 38: ...inals 9 and 12 are indicated by the Discharge label Leave resistor connected for 10 seconds DO NOT TOUCH TER MINALS RESISTORS OR ANY INTERNAL MACHINE COMPONENT DURING THIS PROCE DURE FIGURE D 3 RESIST...

Page 39: ...needed The covers must be kept in good condition to assure that high voltage parts are protected and that cor rect spacings are maintained 7 Remove welding cables and check the electrical ground cont...

Page 40: ...8 in minimum long relay terminals 3 and 4 2 medium slotted screwdriver All plumbing components N R two 10 inch adjustable wrenches REMOVING AND INSTALLING THE G3503 COOLER 1 Preparation Always switch...

Page 41: ...e NOTE Never run the pump dry Always use a recommended coolant otherwise pump damage may result 9 Reinstall the G3503 cooler into the Power Wave machine G3503 COOLER SERVICE 1 Preparation Always switc...

Page 42: ...4 GENERAL COMPONENT LOCATIONS 1 DISPLAY BOARD BACK OF PANEL 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIARY TRANSFORMER 5 INPUT RECTIFIER 6 HEAT SINK FINS 7 OUTPUT TERMINALS 8 OVERLAY BAR CODE SENSORS...

Page 43: ...nical assistance This Troubleshooting Guide is provided to help you lo cate and correct possible machine misad justments Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPT...

Page 44: ...If faulty replace with 5 amp slow blow fuse 1 Turn power OFF immediately 2 Check for proper input voltage per machine nameplate 3 Make certain the reconnect panel is configured properly for the applie...

Page 45: ...the front panel Reset if necessary 1 Remove the feeder control cable from the machine If symptoms disappear feeder or control cable is faulty If all recommended possible areas of misadjustments have...

Page 46: ...cted for 380 VAC or higher and has not been used for a long period of time the capacitors may require conditioning Let the machine run at an idle state no load for 30 minutes 1 Welding application may...

Page 47: ...l the trig ger of the wire feeder whose settings you want displayed on the Power Wave 1 Check for proper installation of the Dual Procedure overlay 2 Check the Dual Procedure Gun Trigger or separate D...

Page 48: ...bar code sensors on the front panel Fig 17 Item 8 If they are dirty blow them out with low pressure air and clean with soft cloth 3 Inspect for damage to the Bar Code s on the back of the overlay 1 C...

Page 49: ...this case do the following 1 Turn the machine off and on a couple of times and see if the beeping continues If the flow rate dropped momentarily then turning the machine off and on eliminates the bee...

Page 50: ...ing cables 1 The machine may be trying to deliver too much power When the average output current exceeds a maximum limit the peak current is drastically cut back Lower the welding parameter settings a...

Page 51: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to...

Page 52: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 53: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 54: ...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 Pr...

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