Lincoln Electric IM524-D manual

IM524-D October , 2001 For use with machines having Code Numbers: 10365 10511 10366 10512 10433 10520 10434 10607 10449 10610 INVER TEC PO WER W A VE 450 TM OPERA TOR’S MANUAL Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper install[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ____________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durable flame-resistant material to protect your[...]

FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U .S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U .S. National Elec[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our 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 P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circui[...]

Thank You f or selecting a QU ALITY product by Lincoln Electric. W e want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to you! Read this Operators Man ual completely bef ore attempting to use this equipment. Sav e this manual and keep it handy f or quick ref erenc[...]

T ABLE OF CONTENTS vi vi PO WER W A VE 450 Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Sectio[...]

vii vii PO WER W A VE 450 W eld from Memory , Dual Procedur e Overlay .....................................................................B-11 Dual Wire Feeders, Dual Pr ocedure Overlay......................................................................B-13 Limits Overlay ..........................................................................[...]

PO WER W A VE 450 TECHNICAL SPECIFICA TIONS - POWER WA VE 450 INPUT - THREE PHASE 50/60 HZ. ONL Y Input V olta g es: 200 230 400 460 575 Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28 RA TED OUTPUT Duty Cyc le Amps V olts at Rated Amperes 200 - 60% Duty Cycle 500 40 VDC 230/400/460 - 60% Duty Cycle 500 40 VDC 460/575 - 60%[...]

Read this entire installation section before y ou start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. • Always connect the Power W[...]

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 symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper gr ound- ing methods. S[...]

INST ALLA TION A-4 A-4 PO WER W A VE 450 2 3 1 FIGURE A.3 – FRONTP ANEL/BACK P ANEL 4 (OUT) (IN) 6 5 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPT ACLE 4 WA TER COOLING FITTINGS (ON ACCESS P ANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK P ANEL) 6 ELECTRODE TERMINAL T o reconnect your machine for the pr oper input volt- age, see[...]

OPERA TION B-1 B-1 PO WER W A VE 450 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions 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 yourself from the work and gr ound. • Always[...]

QUICK ST ART REFERENCE FOR USING THE PROCESS SELECTION OVERLA Y Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference pr ocedure to operate the Power W ave. NOTE: Selection of certain options may limit the selection of subsequent options. Step 1: Sel[...]

GENERAL DESCRIPTION The INVERTEC Power W ave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses thr ee-phase input power only . The Power W ave is designed to be used as a synergic welding system in conjunction with a wire feeder . SYNERGIC WELDING The Po[...]

CONTROLS AND SETTINGS All operator controls and adjustments ar e located on the case front of the Power W ave. Refer to Figure B.1 and corresponding explanations. FIGURE B.1 – CASE FRONT CONTROLS CASE FRONT CONTR OLS Refer to Figure B.1 for the location of the following controls: 1. LCD DISPLA Y : Provides welding pr ocedure infor- mation and par[...]

OPERA TING OVERLA YS O VER VIEW The Power W ave 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 the keys. An OVERLA Y is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other . See Figure B.2. Th[...]

O VERLA Y TYPES Four types of overlays can be used with the Power W ave. 1. Process Overlays. These overlays are used to create, save and r ecall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power W ave at the factory . 2. W eld From Memory Overlays . These overlays (also[...]

1. LCD DISPLA Y WINDOW : Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLA Y ID NUMBER = 1 A welding procedur e is made up of seven compo- nents: process, material type, wir e diameter , [...]

3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Pr ess the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4. ELECTRODE SIZE UP/DOWN: Use the ELEC- TRODE SIZE UP or DOWN keys to select from the wire diameters available for the [...]

10. RECALL FROM MEMOR Y KEY : This key is used to recall an existing pr ocedure fr om memory . Y ou can recall and use any of the pr eviously created welding procedur es that are stor ed in one of the eight memory locations. Simply press the RECALL FROM MEMOR Y key and then the appropriate MEMOR Y LOCA TION NUMBER key . If you press the RECALL FROM[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 2 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. MEM[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 3 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. MEM[...]

When a pair of welding procedur es are r ecalled from memory , the display window will show the procedur e description, wire feed speed, and the preset voltage or ar c length trim of the LAST pro- cedure welded with. With this overlay in place, the wire feed speed and the preset voltage or ar c length trim can be changed from the wir e feeder . The[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLA Y ID NUMBER = 9 2. WIRE FEEDERS MEMOR Y CHART : The active welding procedur e is determined by the active [...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 4 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. REC[...]

Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be dis- played. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value. Press the SET LIMIT key . The present maximum and minim[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 0 This message is then replaced by the following message: POWER WA VE SETUP 2. WA TER COOLE[...]

When the “WA TER COOLER PRESSURE” light turns 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 pr esent polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY” light. If wire feeder 1 is set for positive voltage sensing polarity , [...]

Use the ELECTRODE SENSE LEAD KEY to select either the - output terminal or the electrode sense (67) lead for the positive voltage refer ence. The work sense (21) lead is used only in rare cir cum- stances. For most installations, use the WORK SENSE LEAD KEY to select the - output terminal for the negative voltage refer ence. Consult the factory if [...]

O VER VIEW OF WELDING PR OCEDURES FLUX CORED ARC WELDING (FCA W) AND GMA W PROCEDURES F or each wire feed speed, a corresponding v oltage is preprogrammed into the machine b y welding e xper ts. This preprogrammed v oltage is the best aver age volt- age f or the procedure at the given wire f eed speed. If the wire f eed speed is changed on the wire[...]

OPERA TION B-20 B-20 PO WER W A VE 450 T rigger Position 1 GMAW GMAW STICK 1 Pulse GMA W Pulse FCAW FCAW WFS DISPLA Y : WFS DISPLA Y : Wire Feed Speed Wire Feed Speed WFS and WFS and Preset VOL T AGE VOL T AGE Open Arc Length T rim Preset V oltage Current DISPLA Y : DISPLA Y : Arc Length T rim Preset V oltage WFS, WFS, WFS DISPLA Y : WFS DISPLA Y :[...]

PULSE WELDING Some people hav e trouble getting used to the behavior of the pulsing arc. The parameters progr ammed into the P ower Wa ve hav e been thoroughly tested for their ability to deliv er a sound weld with good appearance. There are, ho we ver , a f ew things to k eep in mind when pulse welding. Spatter levels are often very low with the p[...]

OPTIONS/ACCESSORIES • Syner gic 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 K870) • Limits Overlay K946-4 • D[...]

There are two w ater connections on the rear of the P ower Wa ve. See Figure C.1. Connect the water lines between these connectors and those on the wire f eed- er . The water is f ed through the f eeder into the gun. When a water cooler is used, the w ater cooler must be enabled b y using the Setup Overla y . The water cooler contains a flo w switc[...]

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least once every six[...]

5. Locate two sets of two r esistors on the left side of the machine and three sets of two r esistors on the right side of the machine. See Figure D.1. Do not touch the resistors or any other internal machine component. Using a DC voltmeter , check for any DC voltage that may be present acr oss the termi- nals of each resistor and fr om each resist[...]

6. Locate the #9 and #12 terminals, identified by the “Dischar ge” labels, on each of the four Switch Boards. See Figur e D.2. 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor . 8. Car eful[...]

PREVENTIVE MAINTENANCE Perform the following preventive maintenance pr oce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance r ecor d; a r ecord tag attached to the machine works best. 1. Remove the hex head scr ews from the sides and top of the machine. Remove the handle bar and the machine wrap-around c[...]

MAINTENANCE D-5 D-5 PO WER W A VE 450 RECOMMENDED T OOLS FOR INST AL- LA TION OR SER VICE OF COOLER: • absorbent towels • alcohol wipe • 3 mm allen wrench (G3503 only) • sock et wrench • 4 inch long minimum soc ket e xtension • 1/4, 5/16, and 3/8 he x standard depth sock ets • 5/32 allen sock et • medium blade slotted scre wdriver ?[...]

MAINTENANCE D-6 D-6 G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Alwa ys s witch off the P ower Wa ve machine po wer . • Alwa ys disconnect the P ower W av e machine from ser vice input power . • Do not remove the pump relief v alve ’ s 3/4 in. acorn he x nut or attempt to adjust the relief valv e setting. 2. Remove the G3503-[ ][...]

MAINTENANCE D-7 D-7 PO WER W A VE 450 FIGURE D.4 – GENERAL COMPONENT LOCA TIONS 1 DISPLA Y BOARD (BACK OF P ANEL) 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIAR Y TRANSFORMER 5 INPUT RECTIFIER 6 HEA T SINK FINS 7 OUTPUT TERMINALS 8 OVERLA Y BAR CODE SENSORS 9 TERMINAL STRIP (LOCA TION) 9 4 6 3 7 2 8 1 5[...]

TROUBLESHOOTING E-1 E-1 PO WER W A VE 450 HOW TO USE TROUBLESHOOTING GUIDE This T roubleshooting Guide is designed to be used by the machine Owner/Oper ator . Unauthorized repairs per-f or med on this equipment may result in danger to the technician and machine oper ator and will inv alidate your f actor y warranty . For y our safety , please obser[...]

Major physical or electrical dam- age is evident when the sheet metal cover(s) are r emoved. Machine is dead – no output – no fans – no displays. Machine has no output – fans are running – display is on – a “click- ing” sound is heard coming fr om the machine. 1. Contact your local authorized Lincoln Electric Field Service Facility [...]

Machine has no output – no f ans – no displa y . Main input fuses are open, indicating e xcessive input current dra w . Machine has no output – no dis- pla y – fans run. Machine has no output – no dis- pla y – fans run – circuit breaker (5-amp) repeatedly trips. 1. Check f or proper input voltage connections. 2. Make cer tain the reco[...]

Machine has no output – fans run – display is on. Machine regularly overheats – yel- low light (LED) on the front panel glows, indicating a thermal over- load. The fans run and the display is on. 1. Make sure that the machine was powered up with a pr operly installed overlay . (With no overlay on the machine or an invalid over- lay , the mach[...]

The voltage and/or wire f eed speed will not adjust to user satis- f action. The voltage and/or wire f eed speed can be adjusted on the wire f eeder but the changes are not shown on the P ower W av e. The Dual Procedure ov erlay is installed. The user cannot change from procedure “ A ” to procedure “ B, ” or vice versa. The displa y can not[...]

Machine does not respond to ke ys being pressed, or the machine has improper displa ys. Machine displa y reads “ Error Inv alid Overlay , ” or it displays an incorrect ov erlay ID number on pow er-up. Machine displa ys “ ERR OR: S.L. NO T INITIALIZED ” on pow er-up. 1. Each time an overla y is changed make certain that the machine is powere[...]

The Beeper (Piezoelectric Buzzer) cannot be heard – machine operating normally . The welding parameters that w ere sav ed in memor y are different when recalled. The water cooler does not turn on. The machine beeps without the ke ys being pressed. 1. Background noise ma y be too loud f or user to hear beeper . 1. Make cer tain that a remote contr[...]

Machine loses output while weld- ing. F ans and display are function- ing properly . F or no apparent reason the weld characteristics hav e changed. Machine often “ noodle welds ” with a par ticular procedure. 1. Check f or proper input voltages (per machine nameplate). 2. Check f or balanced three-phase input supply voltage . 3. Check electrod[...]

Now A vailab le ...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of previous editions pub lished since 1933, the Procedure Handbook is considered by man y to be the “ Bible ” of the arc welding industry . This printing will go fast so don ’ t dela y . Place your order now using the coupon belo w . The hardboun[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P or tuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P AR[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P or tuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fum[...]

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