Lincoln Electric IM579 manual

OPERA TOR’S MANUAL IM579 April, 1999 For use with machines having Code Numbers: 10391 10392 10405 10406 INVER TEC PO WER W A VE 450 TM 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 pr oper installation . . . and thoughtful operation on [...]

SAFETY i i PO WER W A VE 450 W ARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN AW A Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety information, it is strongly r ecom- mended that you purchase a copy of ?[...]

SAFETY ii ii PO WER W A VE 450 WELDING SP ARKS can cause fire or explosion. 4.a. Remove fire hazar ds from the weld- ing area. If this is not possible, cover them to prevent the welding sparks from starting a fir e. Remember that welding sparks and hot materials from welding can easily go thr ough small cracks and openings to adjacent areas. A void[...]

SAFETY iii iii PO WER W A VE 450 FOR ENGINE powered equipment. 7.a. T ur n the engine off befor e troubleshooting and maintenance work unless the maintenance work requir es it to be running. 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 7.c. Do not add the fuel near an open flame welding arc or when [...]

SAFETY iv iv PO WER W A VE 450 PRÉCA UTIONS DE SÛRETÉ Pour votre pr opr e pr otection 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. Pr otegez-vous contre la secousse élect[...]

PO WER W A VE 450 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 ha ve in bringing this product to y ou! Read this Operators Man ual completely bef ore attempting to use this equipment. Sav e this manual and k eep it handy f[...]

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

TECHNICAL SPECIFICA TIONS - POWER W A VE 450 Input V olta g es: 230 460 Input Currents @ 500A/40 VDC 76 38 @ 450A/38 VDC 65 32 Duty Cyc le Amps V olts 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 Cir cuit V olta ge Current Rang e Current Rang es 75 V olts 5-520 Am[...]

Read this entire installation section before y ou start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T urn 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 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPT ACLE 4 WA TER COOLING FITTINGS (ON BACK P ANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK P ANEL) 6 ELECTRODE TERMINAL T o operate at 208-230 V AC: 1. Open the reconnect/input access door . 2. Move the[...]

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 AR T 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: Se[...]

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 procedur e 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 Wa v e . 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 (al[...]

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 from memory . Y ou can recall and use any of the pr eviously created welding procedur es that are stored 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 M[...]

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 recalled 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 . If this key has been pressed for 30 seconds and the ‘W A TER COOLER PRESSURE’ light still did not turn on, check the water cooler for adequate fluid level. 5. WIRE FEEDER 1 +/- POLARITY KEY : Press this key to change the present voltage sensing polari- ty of wire feeder 1. [...]

OPERA TION B-18 B-18 PO WER W A VE 450 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 volt[...]

OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCA W) AND GMA W PROCEDURES For each wire feed speed, a corr esponding voltage has been prepr ogrammed into the machine by welding experts. This prepr ogrammed voltage is the best average voltage for the procedur e at the given wire feed speed. If the wire feed speed is changed on the wire feed[...]

OPERA TION B-20 B-20 PO WER W A VE 450 T rigger Position 1 GMAW GMAW STICK 1 GMA W GMAW Pulse FCAW Pulse 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 DISPL[...]

In Pulse processes: The wave control adjustment allows the fr equency set- ting to vary . Increasing the wave control allows the fr e- quency setting to increase, and decr easing the wave control allows the fr equency setting to decrease. V arying the wave control setting af fects the droplet transfer and allows fine-tuning for differ ent welding p[...]

OVERLOAD PROTECTION THERMAL PRO TECTION The Power W ave has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and high ambient temperatures. When the power sour ce is subjected to any of these conditions or any of the con- ditions mentioned above, a thermostat will open. The yellow high temperature light on the case fr[...]

OPTIONS/ACCESSORIES • Syner gic 7 wir e feeder (K632-1) standar d 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 Wir e Feeders, Dual Procedur es Overlay (K946-9) WIRE FEEDER SETUP The Power W ave must be used with wire feeders list- ed above[...]

W A TER COOLER USA GE The Power W ave is equipped with an optional inter nal water cooler . W e recommend using the water cooler when welding above 300 amps with ar gon blends on a regular basis. The gun heating fr om pulsing above 300 amps average current is often excessive and leads to reduced consumable life, r educed gun life, and opera- tor di[...]

MAINTENANCE D-1 D-1 PO WER W A VE 450 W ARNING W ARNING CAUTION 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 Perf[...]

MAINTENANCE D-2 D-2 PO WER W A VE 450 FIGURE D.1 – RESISTOR LOCA TIONS W ARNING 5. Locate two sets of two resistors 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 t[...]

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. Carefull[...]

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 screws fr om 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 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 ormed on this equipment may result in danger to the technician and machine operator and will inv alidate your f actor y warranty . For y our saf ety , please observ[...]

TROUBLESHOOTING E-2 E-2 PO WER W A VE 450 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 authorize[...]

TROUBLESHOOTING E-3 E-3 PO WER W A VE 450 Machine has no output – no f ans – no displa y . Main input fuses are open, indicating e xcessiv e input current dra w . Machine has no output – no dis- pla y – f ans run. Machine has no output – no dis- pla y – f ans run – circuit breaker (5-amp) repeatedly trips. 1. Check f or proper input v[...]

TROUBLESHOOTING E-4 E-4 PO WER W A VE 450 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 [...]

TROUBLESHOOTING E-5 E-5 PO WER W A VE 450 The v oltage and/or wire f eed speed will not adjust to user satis- f action. The v oltage and/or wire f eed speed can be adjusted on the wire f eeder but the changes are not shown on the P ow er Wa ve . The Dual Procedure ov er lay is installed. The user cannot change from procedure “A” to procedure ?[...]

TROUBLESHOOTING E-6 E-6 PO WER W A VE 450 Machine does not respond to ke ys being pressed, or the machine has improper displa ys. Machine displa y reads “Error Inv alid Overla y , ” or it displa ys an incorrect ov er lay ID n umber on pow er-up . Machine displa ys “ERROR: S.L. NO T INITIALIZED” on pow er-up . 1. Each time an overla y is cha[...]

TROUBLESHOOTING E-7 E-7 PO WER W A VE 450 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 for user to hear beep[...]

TROUBLESHOOTING E-8 E-8 PO WER W A VE 450 Machine loses output while weld- ing. F ans and displa y 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[...]

WIRING DIAGRAMS F-1 F-1 POWER W A VE 450 NOTE: This diagram is for reference only . It may not be accurate for all machines co v ered by this manual. The specific diag r am for a particular code is pasted inside the machine on one of the enclosure panels. WIRING DIAGRAM[...]

Now A v ailable...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of previous editions published 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 hardbound book[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese 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 PARA EL[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• Sales and Ser vice through Subsidiaries and Distr ibutors Worldwide • Cle v eland, Ohio 44117-1199 U .S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com W orld's Leader in W elding and Cutting Products Premier Manuf acturer of Industr ial Motors ST A TEMENT OF LIMITED W ARRANTY The Lincoln Electric Company (Lin[...]