Lincoln Electric Invertec Power Wave 450 Im524 D Users Manual

IM524-D to the manual 1b090026-dc61-4fdc-85ca-02459b4d7100

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IM524-D

RETURN TO MAIN MENU

October, 2001

INVERTEC POWER WAVE 450
TM

For use with machines having Code Numbers:

10365
10366
10433
10434
10449

10511
10512
10520
10607
10610

Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And,
most
importantly, think before you act
and be careful.

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •
• 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

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE
powered equipment.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.

Mar ‘95

SAFETY
ELECTRIC SHOCK can kill.

ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(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 cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY
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.

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.

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.

Mar ‘95

SAFETY
PRÉCAUTIONS DE SÛRETÉ

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

Pour 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 suivantes:

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Mar. ‘93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase

_____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

TABLE OF CONTENTS
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-1
Safety Precautions......................................................................................................................A-2
Select Suitable Location .............................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting .................................................................................................................................A-2
Lifting .................................................................................................................................A-2
High Frequency Precautions.......................................................................................................A-2
Input Connections.......................................................................................................................A-2
Ground Connections...................................................................................................................A-3
Input Power Connections ...........................................................................................................A-3
Input Fuse and Supply Wire Connections ...........................................................................A-3
Input Voltage Reconnect Procedure ....................................................................................A-3
Output Connections....................................................................................................................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 Overlay................................................................B-2
General Description ....................................................................................................................B-3
Synergic Welding..................................................................................................................B-3
Recommended Processes ...................................................................................................B-3
Operational Features and Controls ......................................................................................B-3
Design Features and Advantages ........................................................................................B-3
Welding Capability................................................................................................................B-3
Limitations ............................................................................................................................B-3
Controls and Settings .................................................................................................................B-4
Case Front Controls .............................................................................................................B-4
Operating Overlays .....................................................................................................................B-5
Overview...............................................................................................................................B-5
Installing an Overlay .............................................................................................................B-5
Overlay Types .......................................................................................................................B-6
Pulse, GMAW, FCAW, Stick Overlay ....................................................................................B-7
Weld from Memory Overlay................................................................................................B-10
POWER WAVE 450

vii

vii
Weld from Memory, Dual Procedure Overlay.....................................................................B-11
Dual Wire Feeders, Dual Procedure Overlay......................................................................B-13
Limits Overlay.....................................................................................................................B-14
Setup Overlay.....................................................................................................................B-16
Wire Feeder Setup Description ..........................................................................................B-17
Overview of Welding Procedures .............................................................................................B-19
FCAW and GMAW..............................................................................................................B-19
Pulse Procedures ...............................................................................................................B-19
Stick/TIG Procedures .........................................................................................................B-19
Wave Control......................................................................................................................B-19
Pulse Welding.....................................................................................................................B-21
Overload Protection..................................................................................................................B-21
Thermal Protection .............................................................................................................B-21
Over Current Protection .....................................................................................................B-21
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-1
Wire Feeder Setup ...............................................................................................................C-1
Guns and 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 Locations ...............................................................................................................D-2
Discharge Label....................................................................................................................D-3
Resistors with Leads............................................................................................................D-3
Preventive Maintenance .............................................................................................................D-4
Recommended Tools for Installation or Service of Cooler.........................................................D-5
G3503-[ ] Installation or Service Tool Usage ..............................................................................D-5
Removing and Installing the G3503-[ ] Cooler ...........................................................................D-5
G3503-[ ] Cooler Periodic Maintenance .....................................................................................D-6
G3503-[ ] Cooler Service ............................................................................................................D-6
General Component Locations...................................................................................................D-7
Troubleshooting and Repair ................................................................................................Section E
How To Use Troubleshooting Guide ...........................................................................................E-1
Troubleshooting Guide ................................................................................................................E-2
Electrical Diagrams ..............................................................................................................Section F
Parts Manual ....................................................................................................................P-261 Series
POWER WAVE 450

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE 450
INPUT - THREE PHASE 50/60 HZ. ONLY
Input Voltages:

200

230

400

460

575

Input Currents
@ 500A/40 VDC
@ 450A/38 VDC

87
75

76
65

44
38

38
32

32
28

RATED OUTPUT
Duty Cycle

Amps

Volts at Rated Amperes

200 - 60% Duty Cycle
230/400/460 - 60% Duty Cycle
460/575 - 60% Duty Cycle
200 - 100% Duty Cycle
230/400/460 - 100% Duty Cycle
460/575 - 100% Duty Cycle

500
500
500
450
450
450

Constant Open
Circuit Voltage

Continuous
Current Range

Process
Current Ranges

75 Volts

5-540 Amps

GMAW 50-540 Amps
FCAW 40-540 Amps
STICK 30-540 Amps

40
40
40
38
38
38

VDC
VDC
VDC
VDC
VDC
VDC

OUTPUT

Pulse
Current Range

Pulse
Voltage Range

Pulse and Background
Time Range

Pulse
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
Copper Wire in
Conduit
AWG[IEC]
Sizes (MM2)

Input
Voltage/
Freqency

Duty
Cycle

Input Ampere
Rating on
Nameplate

200/50-60
230/50-60
400/50-60
460/50-60
575/50-60

60%
60%
60%
60%
60%

87
76
44
38
32

4
4
8
8
8

200/50-60
230/50-60
400/50-60
460/50-60
575/50-60

100%
100%
100%
100%
100%

75
65
38
32
28

4
4
8
8
8

Type 75°C
Ground Wire in
Conduit
AWG[IEC]
Sizes (MM2)

Type 75°C
(Super Lag)
or Breaker
Size (Amps)

(25)
(25)
(10)
(10)
(10)

8 (10)
8 (10)
10 (6)
10 (6)
10 (6)

120
100
50
50
50

(25)
(25)
(10)
(10)
(10)

8 (10)
8 (10)
10 (6)
10 (6)
10 (6)

100
100
50
50
40

PHYSICAL DIMENSIONS
Height

Width

Depth

Weight

905 mm
35.6 in.

515 mm
20.3 in.

1010 mm
39.8 in.

138 kg
304 lbs.

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
0° to 40°C

-50° to 85°C

POWER WAVE 450

A-2

INSTALLATION

Read this entire installation section before you
start installation.

HIGH FREQUENCY PRECAUTIONS
If possible, locate the Power Wave away from radio
controlled machinery. The normal operation of the
Power Wave may adversely affect the operation of RF
controlled equipment, which may result in bodily injury
or damage to the equipment.

SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on
the rear of the machine. See Figure A.1 for the location of the rating plate.
FIGURE A.1 - RATING PLATE LOCATION

• Do not touch electrically hot parts.
• Always connect the Power Wave grounding terminal
(located inside the reconnect input access doors).

SELECT SUITABLE LOCATION
Place the welder where clean cooling air can circulate
in through the rear louvers and out through the side
and front louvers. Dirt, dust, or any foreign material
that can be drawn into the welder should be kept at a
minimum. Using filters on the air intake to prevent dirt
from building up restricts air flow. Do not use such filters. Failure to observe these precautions can result in
excessive operating temperatures and nuisance shutdowns.
The Power Wave may be used outdoors. Power Wave
power sources carry an IP23 enclosure rating. They
are rated for use in damp, dirty environments subject
to occasional falling water such as rain. However, the
best practice is to keep the machine in a dry, sheltered
area, since a wet environment speeds corrosion of
parts. Do not place the machine in puddles or otherwise submerge parts of the machine in water. This
may cause improper operation and is a possible safety hazard.

STACKING
Power Wave machines cannot be stacked.

TILTING
Each machine must be placed on a secure, level surface. The machine may topple over if this procedure
is not followed.

LIFTING
Lift the machine by the lift bail only. Do not attempt to
lift the machine by the push handle.

1. RATING PLATE
2. RECONNECT/INPUT ACCESS DOOR
3. INPUT CORD ACCESS HOLE

POWER WAVE 450

A-3

INSTALLATION
CAUTION

Failure to follow these instructions can cause immediate 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 grounding methods. See example Figure A.2 for the location
of the reconnect/input access door and your specific
connection diagram.

INPUT POWER CONNECTIONS
Connect L1, L2, L3 according to the Input Supply
Connection Diagram decal located on your reconnect/input access door. See example Figure A.2.

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and

wire sizes. Fuse the input circuit with the recommended super lag fuses or delay type circuit breakers.
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.

INPUT VOLTAGE RECONNECT
PROCEDURE

WARNING
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be made
in accordance with all local and national electrical
codes and the connection diagram located on the
inside of the reconnect/input access door of the
machine. Failure to do so may result in bodily injury or
death.
-----------------------------------------------------------------------Welders are shipped connected for the highest input
voltage listed on the rating plate. To change this connection for a different input voltage, refer to reconnect
instructions which follow and to the reconnect diagram supplied with your machine, located inside your
reconnect access door. See example Figure A.2.

FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR

LY
N R
O U AM
E YO GR
PL O A
M R T DI
SA E IC
EF F
R CI
E
SP

NOTE: Turn main input power to
mthe machine OFF before performing reconnect procedure. Failure to
do so will result in damage to the
machine. DO NOT switch the reconnect bar with machine power
ON.

Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the magnitude of the current increases.

POWER WAVE 450

A-4

INSTALLATION
FIGURE A.3 – FRONTPANEL/BACK PANEL

6
5

(IN)
(OUT)

4
1

1 WORK TERMINAL
2 ELECTRODE TERMINAL
3 REMOTE CONTROL AMPHENOL RECEPTACLE

4 WATER COOLING FITTINGS (ON ACCESS PANEL)
5 WIRE FEEDER CONNECTIONS (ON BACK PANEL)
6 ELECTRODE TERMINAL

To reconnect your machine for the proper input voltage, see the reconnect instructions on your input
access door and:
1. Move the large input voltage switch to the
proper position according to your input voltage, and the labels near the switch.

2. Move the auxiliary “A” lead to the appropriate
terminal, according to your input voltage and
the labels near the terminals.

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 does not require it. When pulsing,
the pulse current often exceeds 650 amps with the
Power Wave 450. Voltage drops can become excessive if undersized welding cables are used.

Routing
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly. Avoid excessive lengths, bundle the
electrode and ground cables together where practical,
and do not coil excess cable.

OUTPUT CONNECTIONS
See Figure A.3 for the location of the work terminal,
electrode terminal, remote control amphenol receptacle, water cooler fittings and wire feeder connections.

WATER COOLER CONNECTIONS
The water cooler fittings are a quick-connect type.
Refer to the Accessories and Maintenance sections of
this manual for water cooler operation and recommended coolants.

WIRE FEEDER CONNECTIONS
Refer to the Accessories section for Wire Feeder Connections.
Refer to Setup overlay in Operation section for Wire
Feeder Configuration.

POWER WAVE 450

B-1

OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.

SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• 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 explosion.
• Keep flammable material away.
• Do not weld on containers that have held combustibles.

ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines
detailed in the beginning of this manual.

HOT COOLANT can burn skin
• Always be sure coolant is not hot before
doing any work on cooler parts.

POWER WAVE 450

B-1

B-2

OPERATION

QUICK START REFERENCE FOR
USING THE PROCESS SELECTION
OVERLAY

Step 2: Adjust the wire feed to speed “WFS” and
voltage “V” or arc length “T” (if necessary).
a. Press the DISPLAY RECALL key
view additional procedure information.

Read and understand the “Controls and Settings” and
“Operating Overlays” sections of this manual before
using the following Quick Start Reference procedure
to operate the Power Wave.
NOTE: Selection of certain options may limit the
selection of subsequent options.

b. Adjust wire feed speed and voltage or arc
length trim through the controls on your wire
feeder. The new values appear on both the
wire feeder and the Power Wave display.
Step 3: Save process information (if desired).

Step 1: Select your process information:

a. Press the SAVE TO MEMORY key

a. Install the desired PROCESS OVERLAY.

SAVE

b. Press one of the MEMORY LOCATION keys
(1-8).

b. Turn the machine ON.
c. Select the desired welding
PROCESS1.

You can recall your procedure later by pressing the
RECALL FROM MEMORY key

RECALL

and the appro-

priate MEMORY LOCATION key.
1

The electrode class, electrode size, and electrode/
gas type you can select for your process will be
limited to the machine’s programmed recommendations. Therefore, selecting certain options may limit
other option selections.

The wave control scale displayed shows the default
setting. (The higher the setting, the softer the arc.) If
you change the setting, your new setting will be displayed.

d. Select ELECTRODE CLASS.

e. Select ELECTRODE SIZE.

Select ELECTRODE/GAS TYPE.

g. Press the WAVE CONTROL
UP or DOWN keys to see
the present setting. Press
the WAVE CONTROL UP or
WAVE CONTROL DOWN
keys to adjust2.
POWER WAVE 450

B-3

OPERATION

B-3

GENERAL DESCRIPTION

DESIGN FEATURES AND ADVANTAGES

The INVERTEC Power Wave power source is a high
performance, digitally controlled inverter welding
power source capable of complex, high-speed waveform control. It uses three-phase input power only.
The Power Wave is designed to be used as a synergic
welding system in conjunction with a wire feeder.

• Designed to NEMA Standards.

SYNERGIC WELDING

• Modular construction for easy servicing.

The Power Wave system is designed primarily as a
synergic welding system. The word “synergic” comes
from the word “synergism,” which means “two or more
things working together to achieve an effect which neither can achieve individually.”

• Thermostatically protected.

The Power Wave and wire feeder operate as a team.
Each “knows” what the other is doing at all times.
They each also know what process, wire type, wire
size, and gas combination are being used. In a synergic system, the wire feeder and power source must
“talk” together. This means that only certain wire feeders can work in a synergic setup. A synergic feeder
has special circuitry to “talk” with and “listen” to the
Power Wave power source.
Welding experts have preprogrammed the system for
the best range of process settings according to wire
type, wire size, and gas combination. When the wire
feed speed is changed, the system automatically
adjusts the current and voltage waveforms to give the
best weld characteristics. This improves the soundness, appearance, and repeatability of welds.

• Multiple process output ranges 5 - 540 amps.
• 2-line LCD display.
• Easy access for input connections. Connections
are simple strip and clamp (no lugs required).

• Electronic overcurrent protection.
• Overvoltage protection.
• Digital signal processor and microprocessor control.
• RS232 interface for future welding application
updates.
• Simple, reliable reconnection for various input voltages.
• New accessories and wire feeders communicate
using a digital current loop to transfer information.
• Auto device recognition simplifies accessory cable
connections.
• Direct support of two wire feeders.
• Auto-configurable for either metric or English mode.
• Multiprocess control: Stick, short arc, GMAW spray,
GMAW pulse, and flux cored arc welding (FCAW).

Refer to the Accessories section of this manual for
available wire feeders.

• Simple control through use of overlays that limit
access to only those keys required for a given application.

RECOMMENDED PROCESSES

WELDING CAPABILITY

The Power Wave is designed to be used as a multiple
process machine. It comes preprogrammed with
GMAW pulse, GMAW (short arc and spray) FCAW
(Innershield™ and Outershield™), and stick procedures.

The Power Wave 450 is rated at 500 amps, 40 volts at
60% duty cycle based on a ten minute time period. It
is capable of higher duty cycles at lower output currents. If the duty cycles are exceeded, a thermostat
will shut off the output until the machine cools to a reasonable operating temperature.

OPERATIONAL FEATURES AND
CONTROLS

LIMITATIONS

The Power Wave, through use of a keypad overlay
system, provides various options and controls such as
Multiple Process/Procedure Selection; Memory
Storage of Procedures; Weld from Memory Only operation; Dual Process/Dual Feeder capability.

• The Power Wave is not recommended for processes other than those specified by available overlays.
• The Power Wave is not recommended for pipe
thawing.

POWER WAVE 450

B-4

OPERATION

CONTROLS AND SETTINGS

CASE FRONT CONTROLS

All operator controls and adjustments are located on
the case front of the Power Wave. Refer to Figure B.1
and corresponding explanations.

Refer to Figure B.1 for the location of the following
controls:

FIGURE B.1 – CASE FRONT CONTROLS
6

3
1

1. LCD DISPLAY: Provides welding procedure information and parameters such as wire type, gas
type, WFS, trim, etc.
2. POWER SWITCH: Controls input power to the
Power Wave. When the switch is turned to the ON
position, the connected wire feeder meters light
up and the LCD display on the Power Wave shows
the following:
LINCOLN ELECTRIC
Version X.X

This display is shown for a few seconds followed
by another display that depends on the overlay
placed on the machine. At this point, the machine
is ready for operation.

4
1
2
3
4
5
6

LCD DISPLAY
POWER SWITCH
HIGH TEMPERATURE LIGHT
REMOTE CONTROL AMPHENOL RECEPTACLE
5 AMP CIRCUIT BREAKER
LCD DISPLAY ADJUSTMENT

3. HIGH TEMPERATURE LIGHT (thermal overload): A
yellow light that comes on when an over temperature situation occurs. Output is disabled until the
machine cools down. At that point the light goes
out and output is enabled again.
4. REMOTE CONTROL AMPHENOL RECEPTACLE:
Allows remote current control during stick welding
via a hand or foot Amptrol accessory.
5. 5 AMP CIRCUIT BREAKER: Protects two auxiliary
power circuits: the 24V supply used by the trigger
circuits and the 42V supply used by the internal
machine circuits and the wire feeders.
6. LCD DISPLAY ADJUSTMENT: Use a small flat
blade screw driver to adjust the viewing angle of
the LCD display.

POWER WAVE 450

B-5

OPERATION

OPERATING OVERLAYS

INSTALLING AN OVERLAY

OVERVIEW

1. Open the ACCESS DOOR by grasping the provided indent on the door and pulling the door forward. See Figure B.3 for door location.

The Power Wave is controlled by a panel of keys (keypad) located on the front of the machine. The operator can access controls by placing an overlay over the
keys.

FIGURE B.3 – OVERLAY ACCESS DOOR

An OVERLAY 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. The printed keys allow the operator to communicate with the
machine for a specific set of functions. The bar code
allows the machine to identify the overlay.

2
4

FIGURE B.2 – TYPICAL POWER WAVE OVERLAY
C COPYRIGHT 1994

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
L9361-2 WELD FROM MEMORY

™
TM

INVERTEC POWER WAVE 350

WARNING

HIGH TEMP.

PROGRAM LIST

MEMORY RECALL

2
4

DISPLAY
RECALL

Before the Power Wave is turned ON, the operator
selects the desired overlay and mounts it in the overlay frame on the front of the machine. Then, when the
machine is turned ON, it reads the overlay bar code
and configures the machine accordingly, allowing the
operator to access only certain keys. The machine
must be powered up each time an overlay is
changed.

1
2
3
4
5

OVERLAY ACCESS DOOR
OVERLAY FRAME
ACCESS DOOR INDENT
TRACKS
LOCATING PINS

2. Select the desired overlay from the storage compartment located behind the access door.
3. Remove any overlay already in the overlay frame
and place it in the storage compartment.
4. Slide the new overlay into the overlay frame. Align
the overlay with the two tracks on the sides of the
frame. Be sure the overlay is seated in the bottom
lip of the frame and on the top two locating pins.
Close the access door securely.

POWER WAVE 450

B-6

OPERATION

OVERLAY TYPES
Four types of overlays can be used with the Power
Wave.
1. Process Overlays. These overlays are used to
create, save and recall specific welding procedures by selecting and adjusting the various welding settings that have been programmed into the
Power Wave at the factory.
2. Weld From Memory Overlays. These overlays
(also called Shop Overlays) provide a simple way
for operators to recall and use any of the welding
procedures that have been stored in the memory
of the Power Wave.
3. Setup Overlays. These overlays provide specific
machine setup information, such as operating limits for the welding procedures stored in memory.
4. Special Purpose Overlays. These are custom
overlays for specific customer applications.
Detailed information on how to use currently available
Power Wave overlays follows.

Overlay
Type
1

2
2
2
2

Overlay
Name

Figure
No.

PULSE, GMAW,
FCAW, STICK PROCESS
SELECTION OVERLAY

B.4

WELD FROM MEMORY
OVERLAY

B.5

WELD FROM MEMORY, DUAL
PROCEDURE OVERLAY

B.6

*DUAL WIRE FEEDERS, DUAL
PROCEDURES OVERLAY

B.7

*DUAL FEEDER, DUAL
PROCEDURE, MEMORY
SELECTION OVERLAY

*LIMITS OVERLAY

B.8

SETUP OVERLAY

B.9

*TEST & CALIB. OVERLAY

*These overlays are optional. See Accessories
Section for Order Numbers.

POWER WAVE 450

B-7

OPERATION

PULSE, GMAW, FCAW, AND STICK/TIG
PROCESS SELECTION OVERLAY
An operator can use this overlay to create a new welding procedure, save a newly created welding procedure,
view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See
Figure B.4. The steps for performing each of these functions are given below.
FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY

3
1
2
3
4
5
6

LCD DISPLAY WINDOW
PROCESS SELECT KEY
ELECTRODE CLASS UP/DOWN KEYS
ELECTRODE SIZE UP/DOWN KEYS
ELECTRODE/GAS TYPE UP/DOWN KEYS
WAVE CONTROL UP/DOWN KEYS

1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears on
the display for a few seconds:
LINCOLN ELECTRIC
VERSION X.X
This display is followed by:
OVERLAY ID
NUMBER = 1
A welding procedure is made up of seven components: process, material type, wire diameter, program,
wire feed speed, voltage or arc length trim, and wave
control. A new welding procedure is created by
selecting a combination of these components from the
ones that have been programmed into the Power
Wave. See Figure B.4 for key locations.

7
8
9
10
11

DISPLAY RECALL KEY
SAVE TO MEMORY KEY
MEMORY LOCATION NUMBER KEYS
RECALL FROM MEMORY KEY
HIGH TEMPERATURE LIGHT

NOTE: The following four selections should
always be performed in this order: process, electrode class, electrode size, electrode/gas type.
Selecting a setting for one component narrows
your choice of available settings in remaining components. This is why the order of performing the
steps is important. However, if you make component selections out of order, the machine will
prompt you to make a new selection for any settings that do not apply.
2. PROCESS SELECT KEY: Use the PROCESS
SELECT key to select from the processes available in the machine. Press the PROCESS
SELECT key until the light by the desired process
is lit.

POWER WAVE 450

B-8

OPERATION

3. ELECTRODE CLASS UP/DOWN: Use the ELECTRODE CLASS UP or DOWN keys to select from
the material types available for the selected
process. Press the ELECTRODE CLASS UP or
DOWN key until the desired material type is displayed.
4. ELECTRODE SIZE UP/DOWN: Use the ELECTRODE SIZE UP or DOWN keys to select from the
wire diameters available for the selected process
and material type. Press the ELECTRODE SIZE
UP or DOWN key until the desired wire diameter is
displayed.
5. ELECTRODE/GAS TYPE UP/DOWN KEYS: Use
the ELECTRODE/GAS TYPE UP or DOWN keys to
select from the programs available for the selected process, material type, and wire diameter.
Press the ELECTRODE/GAS TYPE UP or DOWN
Key until the desired program is displayed.
6. WAVE CONTROL UP/DOWN KEYS: Press one of
the two WAVE CONTROL keys to display the present wave control. This is shown on a scale from
LO to HI. Use the WAVE CONTROL UP or WAVE
CONTROL DOWN key to change the wave control
to the desired level. When this scale is shown, the
WAVE CONTROL setting can also be changed
while welding (on the fly). Press the DISPLAY
RECALL key to exit the wave control function. For
a description of how the wave control setting
affects the welding procedure, refer to the
Overview of Welding Procedures sub-section of
the Operation section of this manual.
The wire feed speed and voltage or arc length
trim desired for the new procedure can be
changed from the wire feeder.

B-8

7. DISPLAY RECALL KEY: Since not all the information about the procedure can be seen on the 2-line
LCD display window at the same time, use the
DISPLAY RECALL key to display and verify all of
the selected 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 the procedure description and gas type for as long as the key is
held depressed. Release the DISPLAY RECALL
key, and the window shows wire size, material
type, and process description. After a few seconds, the window changes back to the default display.
8. SAVE TO MEMORY KEY: This key is used to save
a newly created welding procedure. The Power
Wave has eight memory locations which can be
used to store all the settings of up to eight welding
procedures. Once stored in a memory location, a
procedure can be recalled for later use with the
RECALL FROM MEMORY key. To save a newly
created welding procedure:
Press the SAVE TO MEMORY key SAVE and then
one of the MEMORY LOCATION NUMBER keys.
Keep a record of this number for future reference.
Any previously created welding procedure stored
in that location will be erased.
If you press the SAVE TO MEMORY key but
decide not to save the procedure, you can exit this
function by pressing the DISPLAY RECALL key.
9. MEMORY LOCATION NUMBER KEYS: To view
information about any stored welding procedure,
simply press its MEMORY LOCATION NUMBER
key.
As you hold down the selected key, the procedure
description and gas type of the procedure appear
in the display window. The process type is shown
by the indicating light opposite the appropriate
process symbol.
When you release the selected key, the wire size,
material type and process description appear for a
few seconds.
This function does not display the wire feed speed
and voltage or arc length trim settings. To view
these, you must recall the procedure from memory with the RECALL FROM MEMORY key.

POWER WAVE 450

B-9

OPERATION

10. RECALL FROM MEMORY KEY: This key is used
to recall an existing procedure from memory. You
can recall and use any of the previously created
welding procedures that are stored in one of the
eight memory locations.
Simply press the
RECALL FROM MEMORY key RECALL and then the
appropriate MEMORY LOCATION NUMBER key.
If you press the RECALL FROM MEMORY key and
then change your mind, you can exit this function
by pressing the DISPLAY RECALL key. If the
memory location you select does not contain a
stored welding procedure, this will be indicated in
the display window. Select another memory location. It is not necessary to save a procedure back
to memory after it is recalled from memory. When
a 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 be used to clear a memory
location.
SAVE

Press the SAVE TO MEMORY key
and then
the RECALL FROM MEMORY key RECALL . (Do not
press both keys at the same time.) A message in
the display window will ask you to press the MEMORY LOCATION NUMBER key of the memory
location you want to clear.
If you press the SAVE TO MEMORY and RECALL
FROM MEMORY keys and then change your
mind, you can exit this function by pressing the
DISPLAY RECALL key.
11. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.

POWER WAVE 450

B-9

B-10

OPERATION

WELD FROM MEMORY OVERLAY
The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight memory locations. See Figure B.5.
FIGURE B.5 – WELD FROM MEMORY OVERLAY

1
1
2
3
4
5
6

LCD DISPLAY WINDOW
MEMORY RECALL KEYS
PROGRAM LIST
DISPLAY RECALL KEY
HIGH TEMPERATURE LIGHT
MEMORY LIGHTS

3
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears in the
display window for a few seconds:
LINCOLN ELECTRIC
Version X.X

With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values will
replace the previous values and become a permanent part of the procedure.
If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedure,
these limits will be active when this overlay is in
place. They cannot be overridden from this overlay.

This display is followed by:
OVERLAY ID
NUMBER = 2
This message is then replaced by the following
message:
SELECT A MEMORY
LOCATION
2. MEMORY RECALL NUMBERS: Select the memory location of the desired welding procedure by
pressing the appropriate MEMORY RECALL
NUMBER key.
If no procedure was saved in the selected memory location, the following message appears:
MEMORY LOCATION
# IS EMPTY
Select another memory location.
When a welding procedure is recalled from memory, the display window will show the procedure
description, wire feed speed, and arc length trim
or preset voltage.

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
procedure stored in memory. A “Dry Erase” marker should be used for this purpose.
4. DISPLAY RECALL KEY: To view other information
about the selected procedure, press the DISPLAY
RECALL key. The display window will show the
procedure description and gas type of the selected procedure for as long as the key is held
depressed. When the key is released, material
type, wire size, and process descriptions will be
displayed for a few seconds.
5. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory is active at any given time.

POWER WAVE 450

B-11

OPERATION

WELD FROM MEMORY, DUAL PROCEDURE OVERLAY
The Weld From Memory, Dual Procedure Overlay lets an operator recall and use dual welding procedures stored
in memory. The overlay must be used with a separate dual procedure switch or a gun that has a two position
trigger. The switch or trigger selects which procedure will be active. See Figure B.6

FIGURE B.6 – WELD FROM MEMORY, DUAL PROCEDURE OVERLAY

1
5

3
1 LCD DISPLAY WINDOW
2 MEMORY RECALL KEYS
3 PROGRAM LIST

4 DISPLAY RECALL KEY
5 HIGH TEMPERATURE LIGHT
6 MEMORY LIGHTS

1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave is
turned on, the following message appears in the
display window for a few seconds:
LINCOLN ELECTRIC
Version X.X

Select a memory location PAIR for the two desired
welding procedures by pressing either of the two corresponding MEMORY RECALL NUMBER keys.
If no procedure was saved to one of the memory pair
locations, the following message appears:
MEMORY LOCATION
# IS EMPTY

This display is followed by:
OVERLAY ID
NUMBER = 3

In this case select another memory pair.

This message is then replaced by the following
message:
SELECT A MEMORY
LOCATION
2. MEMORY RECALL KEYS: The following four
memory pairs are available on this overlay:
Memory 1 and Memory 2
Memory 3 and Memory 4
Memory 5 and Memory 6
Memory 7 and Memory 8

Set the 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 the welding procedure from the
corresponding even numbered memory locations (2, 4,
6 or 8). For example, if memory location 3 was
selected, Position A activates the procedure from
memory location 3; Position B activates the procedure from memory location 4.

POWER WAVE 450

B-12

OPERATION

When a pair of welding procedures are recalled
from memory, the display window will show the
procedure description, wire feed speed, and the
preset voltage or arc length trim of the LAST procedure welded with.
With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values will
replace the previous values and become a permanent part of the procedure.
If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedures,
these limits will be active when this overlay is in
place. They cannot be overridden from this overlay.
3. THE PROGRAM LIST: The PROGRAM LIST block
in the center of this overlay provides a convenient
place to record a brief description of each welding
procedure stored in memory. A “Dry Erase” marker should be used for this purpose.
4. DISPLAY RECALL KEY: To view other information
about the active procedure, press the DISPLAY
RECALL key. The display window will show the
procedure description and gas type of the active
procedure for as long as the key is held
depressed. When the key is released, the wire
size, material type, and process descriptions display for a few seconds.
5. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory location is active at any given time.

POWER WAVE 450

B-12

B-13

OPERATION

DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY (OPTIONAL)
The Dual Wire Feeders, Dual Procedures Overlay is used when the Power Wave is equipped with two wire feeders and two guns with two position switches. Any welding procedure stored in memory locations 1, 2, 3, or 4
can be automatically recalled and used. See Figure B.7.
FIGURE B.7 – DUAL WIRE FEEDERS, DUAL PROCEDURE OVERLAY

1
2
3
4
5

LCD DISPLAY WINDOW
WIRE FEEDERS MEMORY CHART
DISPLAY RECALL KEY
HIGH TEMPERATURE LIGHT
MEMORY LIGHTS

1
5

2
1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave is
turned on, the following message appears in the
display window for a few seconds:
LINCOLN ELECTRIC
VERSION X.X

OVERLAY ID
NUMBER = 9
2. WIRE FEEDERS MEMORY CHART: The active
welding procedure is determined by the active
wire feeder and its gun switch position. The welding procedure recall from memory is as follows:

#1
#1
#2
#2

Gun Trigger Memory Location
Position
of Procedure
A
B
A
B

With this overlay in place, the wire feed speed and
the preset voltage or arc length trim can be
changed from the wire feeder. The new values
replace the previous values and become a permanent part of the procedure.
If limits have been set on the wire feed speed, voltage or arc length trim of the selected procedures,
these limits will be active when this overlay is in
place. They cannot be overridden from this overlay.

This display is followed by:

Active
Wire Feeder

1
2
3
4

Pull the trigger on either wire feeder.
Depending on the gun switch position, the corresponding memory location is automatically
recalled. The wire feeders memory chart has no
keys; it is simply a chart.

3. DISPLAY RECALL KEY:To view other information
about the active welding procedure, press the
DISPLAY RECALL key. The display window will
show the procedure description and gas type of
the last active procedure for as long as the key is
held depressed. When the key is released, the wire
size, material type, and process descriptions will
be displayed for a few seconds.
4. HIGH TEMPERATURE LIGHT: The high temperature light comes on when the internal machine
temperature exceeds the allowed limit. Output is
disabled until the machine cools down and the
high temperature light goes out.
5. MEMORY LIGHTS: A memory light is on when its
corresponding memory is slected. This tells you
what memory location is active at any given time.

The display window will show the procedure
description, wire feed speed, and the preset voltage or arc length trim of the last active welding
procedure.
POWER WAVE 450

B-14

OPERATION

LIMITS OVERLAY (OPTIONAL)
The Limits Overlay is used to set the maximum and minimum limits of the wire feed speed and voltage or arc length
trim for any welding procedure stored in memory. See Figure B.8.

FIGURE B.8 – LIMITS OVERLAY

1
8
2
6
3

4
1
2
3
4

LCD DISPLAY WINDOW
RECALL FROM MEMORY KEY
MEMORY LOCATION NUMBER KEYS
SET LIMIT KEY

5
6
7
8

LIMIT UP/DOWN KEYS
SAVE TO MEMORY KEY
DISPLAY RECALL KEY
MEMORY LIGHTS

Determine the memory location number of the
welding procedure for which you want to set limits.Then press the RECALL FROM MEMORY key
RECALL followed by the MEMORY LOCATION NUMBER key for the selected procedure.
If no procedure was saved in the selected memory location, the following message appears:

This display is followed by:

MEMORY LOCATION
# IS EMPTY

OVERLAY ID
NUMBER = 4
This message is then replaced by the following
message:
SELECT A MEMORY
LOCATION

Select another memory location.
4. SET LIMIT KEY:
AND
5. LIMIT UP / DOWN KEYS:

2. RECALL FROM MEMORY KEY:
AND
3. MEMORY LOCATION NUMBERS:
The RECALL FROM MEMORY key RECALL is used
to recall a welding procedure from memory.

The SET LIMIT key and LIMIT UP / LIMIT DOWN
keys are used to set the maximum and minimum
allowed wire feed speed, and voltage trim or arc
length trim values of the procedure that was
recalled from memory.

POWER WAVE 450

B-15

OPERATION

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 displayed.
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 minimum voltage trim or arc length trim will be
displayed. (Refer to Table B.3 to see how voltage
trim affects preset voltage. Refer to Table B.6 to
see how arc length trim affects preset arc length.)

B-15

7. DISPLAY RECALL KEY: To view other information
about the active welding procedure, press the
DISPLAY RECALL key. The display window will
show the procedure description and gas type of
the last active procedure for as long as the key is
held depressed. When the key is released, the wire
size, material type, and process descriptions will
be displayed for a few seconds.
6. MEMORY LIGHTS: A memory light is on when its
corresponding memory is selected. This tells you
what memory is active at any given time.

Use the LIMIT UP and LIMIT DOWN keys to
change the maximum value. The maximum for
either type is 1.5.
Press the SET LIMIT key. The new maximum and
old minimum voltage trim or arc length trim will be
displayed.
Use the LIMIT UP and LIMIT DOWN keys to
change the minimum value. The minimum for
either type is 0.5.
6. SAVE TO MEMORY KEY: The SAVE TO MEMORY KEY is used to save the procedure with the
newly set limits to memory. Press the SAVE TO
MEMORY key SAVE followed by the MEMORY
LOCATION NUMBER key of the desired memory
location. This does not have to be the original
location from which the procedure was recalled.
Step 6 can be performed any time during the limitsetting process. You do not have to set all the
available limits. When you have set all the desired
limits, save the procedure to memory.
To clear any previously set limits, recall the procedure from memory and change the limits to the
maximum range available. Then save the procedure to memory.

POWER WAVE 450

B-16

OPERATION

SETUP OVERLAY
The Setup Overlay is used to control the water cooler operation (on/off and prime the water cooler), and to set
up the voltage sensing configuration of the machine and wire feeder(s) connected to the Power Wave. See Figure
B.9.
FIGURE B.9 – SETUP OVERLAY
C COPYRIGHT 1994

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9660 SETUP OVERLAY

WARNING

+POLARITY

ELECTRODE
SENSE LEAD
ENABLED

WORK SENSE
LEAD ENABLED

WATER COOLER ENABLED

WATER COOLER PRESSURE

+/ POLARITY

WATER
COOLER
ENABLE

ELECTRODE
SENSE
LEAD

PRIME
WATER
COOLER

WORK
SENSE
LEAD

WIRE
FEEDER 1

WIRE
FEEDER 2

6
7

WATER COOLER CAN ONLY BE
PRIMED WHEN IT IS ENABLED.

3
2
4

PRIME THE WATER COOLER
UNTIL WATER COOLER PRESSURE
LIGHT TURNS ON.

WATER COOLER SETUP

1
2
3
4

LCD DISPLAY WINDOW
WATER COOLER ON/OFF KEY
WATER COOLER PRESSURE LIGHT
PRIME WATER COOLER KEY

5 WIRE FEEDER 1+/- POLARITY KEY
6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY
7 WIRE FEEDER 1 WORK SENSE LEAD KEY

1. LCD DISPLAY WINDOW: Power up the machine
with this overlay in place. When the Power Wave
is turned on, the following message appears in the
display window for a few seconds:
LINCOLN ELECTRIC
Version X.X

3. WATER COOLER PRESSURE LIGHT: This light
indicates whether or not the coolant flow rate is
high enough for normal water cooler operation. If
the water cooler loses the required flow rate it will
shut down within a couple of seconds, the water
cooler pressure light will turn off,and the machine
sounds a buzzer.

This display is followed by:
OVERLAY ID
NUMBER = 0
This message is then replaced by the following
message:
POWER WAVE
SETUP
2. WATER COOLER ON/OFF KEY: Press this key to
toggle the water cooler between being enabled
and disabled. The present status of the water
cooler is indicated by the “WATER COOLER ON”
light.

4. PRIME WATER COOLER KEY: The water cooler
may have to be primed if there is not enough
coolant in the system for proper operation. Make
sure that the water cooler has been turned on
before it is primed. (The “WATER COOLER ON”
light should be turned on.) Check reservoir for
proper coolant level - See Water Cooler information in ACCESSORIES section. To prime the water
cooler, hold the PRIME WATER COOLER key
down. While this key is pressed, the display will
show:

POWER WAVE 450

PRIME WATER
COOLER

B-17

OPERATION

When the “WATER COOLER PRESSURE” light
turns on, release the key.
5. WIRE FEEDER 1 +/- POLARITY KEY: Press this
key to change the present voltage sensing polarity of wire feeder 1. The present 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, this light is turned on.
6. WIRE FEEDER 1 ELECTRODE SENSE LEAD
KEY: Press this key to enable or disable the electrode sense lead (lead #67) of wire feeder 1. When
enabled, voltage sensing is done by the electrode
sense lead. When disabled, voltage sensing is
done at the Power Wave output terminal. When
enabled, the “WIRE FEEDER 1 ELECTRODE
SENSE LEAD ENABLED” light will be illuminated.
7. WIRE FEEDER 1 WORK SENSE LEAD KEY:
Press this key to enable or disable the work sense
lead (lead #21) of wire feeder 1. When enabled,
voltage sensing is done by the work sense lead.
When disabled, voltage sensing is done at the
Power Wave output terminal. When enabled, the
“WIRE FEEDER 1 WORK SENSE LEAD
ENABLED” light will be illuminated.

WIRE FEEDER SETUP DESCRIPTION
The Power Wave may be set up for either positive
or negative arc voltage sensing using any two of
the following places:

+/- POLARITY KEY
A. Positive Polarity Voltage Sensing:
In most welding applications the electrode cable is
connected to the + output terminal and the work
cable is connected to the - output terminal of the
power source. This is positive polarity voltage
sensing illustrated by Figure B.10. When the
Power Wave and the wire feeder(s) are connected
in this manner, the arc voltage can be measured in
one of four ways. These four ways are shown in
Table B.1.
Table B.1: Positive Voltage Sensing Options
Positive Voltage Reference

Negative Voltage Reference

+ Output Terminal

- Output Terminal

+ Output Terminal

Work Sense (21) Lead*

Electrode Sense (67) Lead

- Output Terminal

Electrode Sense (67) Lead

Work Sense (21) Lead*

*Consult the factory before using this option.

Use the ELECTRODE SENSE LEAD KEY to
select either the + output terminal or the electrode
sense (67) lead for the positive voltage reference.
The work sense (21) lead is used only in rare circumstances. For most installations, use the
WORK SENSE LEAD KEY to select the - output
terminal for the negative voltage reference.
Consult the factory if use of the work sense (21)
lead is desired.

1. the positive output terminal of the Power Wave
2. the negative output terminal of the Power Wave
3. the electrode sense lead (67) lead of the wire
feeder
4. a work sense (21) lead
The SETUP Overlay allows you to select between
which two places arc voltage will be sensed.
Once the selection is made it is not necessary to
reconfirm the selection every time a new overlay is
used or a wire feeder is replaced with another one.
The selection will remain until it is changed with
the SETUP Overlay.
When welding with a stick procedure, the arc voltage is automatically measured between the Power
Wave’s output studs.
I. Select arc voltage sensing polarity first.

B. Negative Polarity Voltage Sensing:
In some welding applications (such as Innershield®) the electrode cable is connected to the output terminal and the work cable is connected
to the + output terminal of the power source. This
is negative polarity voltage sensing illustrated by
Figure B.11. When the Power Wave and the wire
feeder(s) are connected in this manner, the arc
voltage can be measured in one of four ways.
These four ways are shown in Table B.2.

Table B.2: Negative Voltage Sensing Options
Positive Voltage Reference

Negative Voltage Reference

– Output Terminal

+ Output Terminal

– Output Terminal

Work Sense (21) Lead*

Electrode Sense (67) Lead

+ Output Terminal

Electrode Sense (67) Lead

Work Sense (21) Lead*

*Consult the factory before using this option

POWER WAVE 450

B-18

OPERATION

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

FIGURE B.10

POSITIVE VOLTAGE SENSING POLARITY
Power
Wave

Control Cable (includes 67 lead)
Electrode Sense Lead
67

Wire Feeder
Block

Electrode Cable
Work Cable

FIGURE 11B
FIGURE B.11

NEGATIVE VOLTAGE SENSING POLARITY
Power
Wave

Control Cable (includes 67 lead)
Electrode Sense Lead
67

B-18

Wire Feeder
Block

Electrode
Cable
Work Cable
POWER WAVE 450

B-19

OPERATION

OVERVIEW OF WELDING
PROCEDURES
FLUX CORED ARC WELDING (FCAW) AND
GMAW PROCEDURES
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine by welding experts.
This preprogrammed voltage is the best average voltage for the procedure at the given wire feed speed. If
the wire feed speed is changed on the wire feeder, the
voltage automatically changes with it.
In some cases, the operator may want to change the
preprogrammed voltages; for example, to compensate
for cable and fixture voltage drops. The preset voltages
can be adjusted on the wire feeder’s Voltage display.
When a change is made to the voltage at one wire feed
speed, this change is applied to all other wire feed
speed settings. For example, if the operator turns up
the voltage by 10 percent, the machine automatically
increases the preset voltages at all the other wire feed
speeds by 10 percent. In the GMAW and FCAW
process, the display shows The Procedure Description,
WFS and Preset Voltage. The preset voltage which was
pro-grammed at the factory, may be changed on the
wire feeder voltage display. Note that if you change the
default preset voltage up or down a respective “ ” or “ ”
sign will be dis-played after the preset value. When the
gun trigger is pulled note that the display changes to
show WFS, Actual Arc Volt-age and Actual Arc Current.
See Table B.4 for display summary.
V

PULSE PROCEDURES
In these procedures, the actual voltage greatly
depends on the waveform used. The peak currents,
background currents, rise times, fall times, and pulse
times all affect the actual volt-age. The actual voltage
for a given wire feed speed is not directly predictable
unless the waveform is known. In this case, it is not
practical to preset an actual voltage for the pro-cedure.
Instead, an arc length adjustment is provided. The
machine “knows” what the best arc length is at the
given wire feed speed but allows the operator to
change it.
The arc length can be adjusted between 0.5 and 1.5 on
the wire feeder’s Voltage display. An arc length trim of
1.0 means that no adjustments will be made to the preset arc lengths. An arc length trim greater than 1.0
increases the preset arc lengths. An arc length trim
less than 1.0 decreases the pre-set arc lengths. The
arc length adjustment is factored in at all wire feed
speed settings.

B-19

Increasing the arc length by 10 percent at a given wire
feed speed also increases all the other arc length settings of the procedure by 10 percent. In the Pulse
process, the display shows the Procedure Description,
WFS and Arc Length Trim. Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder. When the trigger is pulled, the
WFS, Actual Arc Voltage and Actual Arc Current are
dis-played.

Stick / TIG
PROCEDURES
Stick welding can be performed with the Power Wave
450 by attaching a remote control kit to the 6-pin
amphenol on the front of the machine. The K941-1
remote control kit is recom-mended. Select the Stick
Process from either the Pulse, GMAW and FCAW,
Stick process selection overlay, or recall it from a previously stored memory location with a Weld From
Memory overlay. When this process is selected, the
Power Wave 450 reads the current (amps) setting from
the remote control kit. It also controls the output of the
machine based on the position of the Output Terminals
switch, which is also located on the remote control kit.
When this switch is in the ON position, the output terminals of the Power Wave 450 are electrically hot.
When the switch is in the OFF position, the output terminals of the Power Wave 450 are electrically cold and
the machine cannot produce an output. In the Stick
Pro-cess, the LCD display shows Procedure
Description, and Pre-set Current (SET=). The Current
Trim is always equal to 1 (T=1.00). When the trigger is
pulled the Preset Current, Ac-tual Arc Voltage and
Actual Arc Current are displayed.
See Tables B.3 and B.4 for a summary of the information discussed above.

WAVE CONTROL
The wave control settings of all procedures can be
changed on the Power Wave 450 GMAW Pulse,
GMAW and FCAW, Stick Process Selection Overlay.
The wave control is a setup parameter that may be
adjusted when the welding procedures are set. This
feature pro-vides an easy way to change the arc
behavior without creating a new procedure. The wave
control setting of a procedure limits the speed at which
the current waveform of that procedure can change.
Typically, each procedure is programmed to have average wave con-trol (at the center of the scale).

POWER WAVE 450

B-20

OPERATION

In Pulse processes:

In Stick processes:

The wave control adjustment allows the frequency
setting to vary. Increasing the wave control allows the
frequency setting to increase, and decreasing the
wave control allows the frequency setting to
decrease. Varying the wave control setting affects the
droplet trans-fer and allows fine-tuning for different
welding positions.

The wave control adjusts the arc force. Increasing the
wave control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the wave control setting decreases the arc force,
making the arc softer and smoother.

In GMAW and FCAW processes:
The wave control adjusts the inductance. (Inductance
is inversely proportional to pinch.) Increasing the
wave control setting decreases the inductance, which
results in the arc getting colder and pinched tighter.
Decreasing the wave control setting increases the
induc-tance, which results in the arc getting wider.
TABLE B.3 – ADJUSTBLE PARAMETERS
Adjustable
Parameters

GMAW
Pulse

GMAW
FCAW

Wire Feeder
WFS Display

Wire Feed
Speed

—

Wire Feeder
Voltage Display

Arc Length
Trim

Preset
Voltage

—

Power Wave 450 Display
(with GMAW Pulse,
GMAW FCAW, Stick
Process Selection Overlay)

Wave
Control
(Frequency)

Wave
Control
(Inductance)

Wave
Control
(Arc Force)

Stick

TABLE B.4 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS
FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS
Wire Feeder

Power Wave 450
Trigger
Position1

Open

Closed

GMAW
Pulse

GMAW
FCAW

STICK1

WFS and
Arc Length Trim

WFS and
Preset Voltage

Preset
Current

WFS,
Actual Arc
Voltage,
Actual Arc
Current

Preset Current,
Actual Arc
Voltage, Actual
Arc Current

Pulse

GMAW
FCAW

WFS DISPLAY:
Wire Feed Speed
VOLTAGE
DISPLAY:
Arc Length Trim

WFS DISPLAY:
Wire Feed Speed
VOLTAGE
DISPLAY:
Preset Voltage

WFS DISPLAY:
Wire Feed Speed
VOLTAGE
DISPLAY:
Actual Arc Voltage

WFS DISPLAY:
Wire Feed Speed2
VOLTAGE
DISPLAY:
Actual Arc Voltage

In Stick, trigger is on Remote Control Kit K941-1.

Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder.
POWER WAVE 450

B-21

OPERATION

PULSE WELDING
Some people have trouble getting used to the behavior
of the pulsing arc. The parameters programmed into
the Power Wave have been thoroughly tested for their
ability to deliver a sound weld with good appearance.
There are, however, a few things to keep in mind when
pulse welding.
Spatter levels are often very low with the pulse
welding process. Pulsing is often used to eliminate
cleaning operations necessary when using other welding processes.
Fume levels are sometimes lower with the pulsing
process. Whether or not you will get lower fume levels
depends on the pulsing programs used. Certain waveform characteristics are necessary to get low fume levels. Unfortunately, low fume procedures are harder to
weld with than procedures designed to optimize the
welding process.
The pulsing process is not slower than other processes. The process is sometimes less forgiving when
the arc gets on or ahead of the puddle. More attention
must be paid to the weld to avoid losing the puddle.
Speed is a matter of deposition rate. All things being
equal regarding the joint being welded, the speed will
depend on the wire feed speed. The travel speed is
maximized by maintaining a very short arc. Often the
process is “trimmed” down until the arc “crackles.” The
spatter increases slightly, but many of the advantages
of pulsing are retained. When welding steel, the Power
Wave is designed to run well in this region between
pulse and short arc.
The pulsing process greatly affects the heat input
to the workpiece. This can be a valuable tool for either
increasing or decreasing the heat input with a given
process. For instance, it is possible to greatly increase
the heat input when welding steel at high deposition
rates. On the other hand, it is possible to reduce the
heat input using the pulsing process. For example, heat
input is reduced greatly with some of the low current
stainless steel procedures using the processes programmed into the Power Wave. In all cases, the Power
Wave procedures 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 produced are suitable and sound.

B-21

The Power Wave is optimized for use with a 0.75”
(1.9 cm) stickout. The adaptive behavior is programmed to support a stickout range from 0.5” to 1.25”
(1.3 to 3.2 cm). In the low and high end of the wire feed
speed ranges of most processes, the adaptive behavior may be restricted. This is a physical restriction due
to reaching the edge of the operating range for the
process. It is possible to achieve adaptive behavior for
longer stickout lengths. However, shielding gas is often
lost when the stickout is too long.
A longer electrical stickout is often used with the
puls-ing process at higher deposition rates. A long
stickout will increase the melt-off rate of the wire. In
pulse welding, like other wire welding processes, the
arc length is determined by the voltage setting. This
voltage is programmed at the factory for each process
and wire feed speed. It may be changed using the
Voltage setting on the wire feeder.
When adaptive processes are used, the voltage will
vary with stickout. The machine must change the voltage to keep a stable arc. It is very important to recognize this. “Actual” arc voltage when welding will vary
because the stickout will seldom be held at the nominal
0.75” (1.9 cm) value.

OVERLOAD PROTECTION
Thermal Protection
The Power Wave has thermostatic protection from
excessive duty cycles, overloads, loss of cooling, and
high ambient temperatures. When the power source is
subjected to any of the conditions mentioned above, a
thermostat will open. The yellow high temperature light
on the case front comes on. See Figure B.1 for location. Machine output is disabled, and welding is not
possible until the machine is allowed to cool and the
High Temperature Light goes out.

Current Protection
The Power Wave is limited to producing 750 amps peak
current. If the average current exceeds 540 amps, the
peak current will automatically be cut back to 100 amps
until the average current decreases to 50 amps.

POWER WAVE 450

C-1

ACCESSORIES

OPTIONS/ACCESSORIES

GUNS AND CABLES

•

Synergic 7 wire feeder (K632-1) standard speed,or (K632-2) high speed

•

MAGNUM 400 gun (K471-2) or 550 gun (K598)

Several MAGNUM guns are recommended for use
with the Power Wave as shown in Table C.1.

•

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

•

Dual Wire Feeders, Dual Procedures Overlay K946-9

•

Dual Feeder, Dual Procedure, Memory Selection Overlay K946-12

•

Test and Calibration Overlay

Place the proper liner in the gun and connect the gun
to the feeder. Consult the specific instructions supplied with the gun for detailed operating instructions.
FIGURE C.1 – WIRE FEEDER AND
WATER COOLER CONNECTIONS

WIRE FEEDER SETUP
The Power Wave must be used with wire feeders listed above. Mount the feeder in a location suitable to
your needs.
For most applications, connect the electrode cable
between the feeder and the positive (+) connection of
the power source. When negative electrode polarity is
required, such as in some Innershield™ applications,
connect the electrode cable between the feeder and
the negative (-) connection of the power source. See
Figure C.1.
Connect the control cable between the feeder and
power source. The cable has different connectors on
each end and will fit in only one way. If only one feeder is used, it must be connected to the Feeder 1
Amphenol located on the back panel in the upper lefthand corner (as you view the machine from the back).
If a second feeder is used, it must be plugged into the
Feeder 2 Amphenol receptacle located just to the right
of the Feeder 1 Amphenol receptacle.
Connect the work cable between the work and the
negative (-) connection of the power source. When
negative electrode polarity is required, such as in
some Innershield™ applications, connect the work
cable between the work and the positive (+) connection of the power source. See Figure C.1.
•

Connect the feeder to a welding gas supply.

•

Load the wire into the feeder and gun.

•

Configure wire feeders (Refer to Setup overlay in
operation section.

2
4
3
1
2
3
4
5

WIRE FEEDER CONNECTIONS (LOCATION)
WATER COOLER LINE (IN)
WATER COOLER LINE (OUT)
CIRCUIT BREAKER (WATER COOLER)
FILL SPOUT (WATER COOLER)

Using a water-cooled gun is recommended to reduce
the size of the gun and improve parts life. The Power
Wave comes with a standard internal water cooler.
However, an external cooler may also be used.

TABLE C.1 – RECOMMENDED GUNS FOR USE
WITH POWER WAVE 450
Gun

Application

Cooling

Product No.

MAGNUM 400

GMAW

Gas

K471-2

MAGNUM 550

GMAW

Gas

K598

WATER COOLER USAGE
The Power Wave is equipped with an optional internal
water cooler. We recommend using the water cooler
when welding above 300 amps with argon blends on a
regular basis. The gun heating from pulsing above 300
amps average current is often excessive and leads to
reduced consumable life, reduced gun life, and operator discomfort. Water cooling greatly increases the
durability of the gun and parts at high current.

Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operator’s
Manual for available options.

POWER WAVE 450

C-2

ACCESSORIES

There are two water connections on the rear of the
Power Wave. See Figure C.1. Connect the water lines
between these connectors and those on the wire feeder. The water is fed through the feeder into the gun.
When a water cooler is used, the water cooler must be
enabled by using the Setup Overlay.
The water cooler contains a flow switch, which is
closed when there is adequate coolant circulating in
the system. If this flow rate drops below the switch
manufacturer’s set point, the flow switch opens. A couple of seconds after the flow switch opens the water
cooler shuts down. If the water cooler is enabled and
the flow switch opens, the machine beeps loudly indicating that there is a problem with the water cooler
operation.

RECOMMENDED COOLANTS

3. Prime the cooler:
a. Install the Set-up overlay.
b. Keep accessories’ hose lengths horizontal, either
coiled or straight, and no higher than 4 feet of the
specified coolant level.
c. Switch on the Power Wave machine.
d. Press the "WATER COOLER ENABLE" button so
that the "WATER COOLER ENABLED" light is
illuminated.
e. Press the "PRIME WATER COOLER" button until
the "WATER COOLER PRESSURE" light is
steadily illuminated.
4. Check coolant level. Add more if required.

1. The following coolants have been determined to be
compatible with the wetted materials used in the
G3503-[ ] cooler assembly:
• Distilled or deionized water
• Potable tap water
• Sediment-free mixtures containing a maximum of 50% ethylene glycol or automotivegrade antifreeze and the balance of distilled
or deionized water.

Rear Panel of
Power Wave
Reservoir Screen

Visible Coolant Level

2. Ethylene glycol mixtures should be selected if the
cooler may be exposed to a temperature below the
freezing point of water.

0.25 to 0.50
inches

Figure C.2
3. Consult gun, torch, and wire feeder manuals for
coolant recommendations and select one from the
above list.
4. Pure solutions and mixtures of, or materials (i.e.
towels) wetted with ethylene glycol are toxic to
humans and animals. They must not be haphazardly discarded, especially by pouring 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.

Do Not Use: Any prepacked welding industry coolant
mixture, such as those offered by Miller, OKI,
Bernhard, or Dynaflux. These coolants contain substances which attack plastic components and may
shorten the life of the system. Once added, these
substances are virtually impossible to purge from the
system. DO NOT USE OIL-BASED COOLANTS OF
ANY TYPE.

K961-1 Single Cylinder Undercarriage Designed for quick installation in the field. Consists of
a front caster assembly, a rear platform assembly, a
handle, and an upper cylinder support.

PRIMING THE COOLER
1. Select a recommended coolant and fill cooler to
specified level (see Fig. C.2).
2. Attach desired water-cooled accessory (gun and
wire feeder or TIG torch) to cooler’s QDs.

K962-1 Dual Cylinder Undercarriage Designed for quick installation in the field. Consists of
a front caster assembly, a dual bottle rear platform
assembly, a handle, and a dual bottle upper cylinder
support.

POWER WAVE 450

D-1

MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn 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 months.

WARNING
Prior to performing preventive maintenance it is important to perform the following capacitor discharge procedure to avoid electric shock.

INPUT FILTER CAPACITOR DISCHARGE 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-around machine cover.
3. Remove the two case sides. There are hex head
screws on each side.

CAUTION
TO PREVENT DAMAGE TO MACHINE, AVOID
UNNECESSARY MOVEMENT OF FRONT PANEL.

4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not supplied with the machine. Secure
this resistor to a piece of insulating material such
as a glastic board. See Figure D.3. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
POWER WAVE 450

D-1

D-2

MAINTENANCE
FIGURE D.1 – RESISTOR LOCATIONS

5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN EACH
TERMINAL AND FROM EACH RESISTOR
TO CASE GROUND

5. Locate two sets of two resistors on the left side of
the machine and three sets of two resistors 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 across the terminals 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.

WARNING
ELECTRIC SHOCK can kill.
• Proceed with caution being careful not to touch any internal
machine components during the
discharge procedure.

POWER WAVE 450

D-2

D-3

MAINTENANCE

6. Locate the #9 and #12 terminals, identified by the
“Discharge” labels, on each of the four Switch
Boards. See Figure D.2.

D-3

FIGURE D.3 – RESISTORS WITH LEADS
CONNECTED

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. Carefully connect the needle nose end of one of
the jumper leads to terminal #9. See Figure D.3.
Connect the needle nose end of the other jumper
lead to terminal #12. Terminals #9 and #12 are
indicated by the “Discharge” label. Leave resistor
connected for 10 seconds. DO NOT TOUCH TERMINALS, RESISTORS, OR ANY INTERNAL
MACHINE COMPONENT DURING THIS PROCEDURE!
FIGURE D.2 – DISCHARGE LABEL

D
I
S
C
H
A
R
G
E

9. Check voltage across terminals (9 and 12) with a
DC voltmeter. Terminal 9 has positive polarity and
terminal 12 has negative polarity. Voltage should
be zero. If any voltage remains, repeat this capacitor discharge procedure.
10. Repeat discharge procedure (steps 7, 8 and 9) for
each of the other three Switch Boards.

POWER WAVE 450

D-4

MAINTENANCE

PREVENTIVE MAINTENANCE
Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record
tag attached to the machine works best.

D-4

8. Reconnect the shunt and wire #467 to the negative (-) output terminal. Make sure the connection
is tight.
9. Replace and secure the machine covers and handle bar.

1. Remove the hex head screws from the sides and
top of the machine. Remove the handle bar and
the machine wrap-around cover. Remove the two
case sides. There are hex head screws on each
side.

10. Remove the overlay from the front panel of the
machine. Clean the plastic case with a low pressure airstream. Wipe the sensors (Fig D.4 Item 8)
with a clean, soft cloth. Make sure the sensors are
not scratched in the process.

2. Perform the input filter capacitor discharge procedure described at the beginning of the
Maintenance Section.

11. Check the back of the overlays. If the bar code
(black square(s)) on the back of the overlay is
scratched, apply a dull black spray finish to the
scratched-off areas only. If a large area of the bar
code is scratched off, the machine either will not
recognize the overlay or will mistake the overlay
for another one.

3. Disconnect the shunt from the negative (-) output
terminal. Failure to do this could cause damage to
the shunt circuitry.
4. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following
components thoroughly (Refer to Figure D.4):
•

Display, Snubber, and Shunt printed circuit
boards

•

Power Switch

•

Main Transformer

•

Auxiliary Transformers

•

Input Rectifier

•

Heat Sink Fins

•

Input Filter Capacitors

•

Output Terminals

•

Terminal Strip

12. Inspect gun and cables for good condition.

5. Examine the capacitors for leakage or oozing.
Replace if needed.
6. Examine the wrap-around and side covers for
dents and breakage. Repair them as needed. The
covers must be kept in good condition to assure
that high voltage parts are protected and that correct spacings are maintained.
7. Remove welding cables and check the electrical
ground continuity. Use an ohmmeter to measure
the resistance between each output terminal and
an unpainted surface of the machine case. The
meter reading should be 500,000 ohms or more. If
the meter reading is less than 500,000 ohms,
check for electrical components that are not properly insulated from the case. Correct component
insulation, if needed.

POWER WAVE 450

D-5

MAINTENANCE

D-5

RECOMMENDED TOOLS FOR INSTAL- REMOVING AND INSTALLING THE G3503-[ ]
COOLER
LATION OR SERVICE OF COOLER:
• absorbent towels
• alcohol wipe
• 3 mm allen wrench (G3503 only)
• socket wrench
• 4 inch long minimum socket extension
• 1/4, 5/16, and 3/8 hex standard depth sockets
• 5/32 allen socket
• medium blade slotted screwdriver
• large blade slotted screwdriver, 8 inches long
minimum
• two 7/16 open or box end wrenches
• one 7/8 open or box end wrench
• needlenose pliers
• two 10 inch long adjustable wrenches
• wire cutter
• molex pin removal tools
• tape measure
• small mechanic’s mirror
• flashlight
• dental pick
• digital multimeter (DMM)

G3503-[ ] INSTALLATION OR SERVICE TOOL USAGE
Fastener Usage

Qty.

Tool

1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
2. Remove cooler assembly G3503-[ ]:
a. remove gas cylinder(s) from tray.
b. remove cooler access panel.
c. Remove both fasteners from base that hold cooler in place. Remove ground lead, if present.
Carefully pull cooler assembly rearward, until
cooler’s Molex connectors are visible.
d. disconnect cooler’s connectors from the P3 and
P4 harnesses. Continue pulling the cooler out of
the Power Wave.
3. If necessary, perform periodic maintenance or service on the cooler.

4. Reinstall cooler by reversing tasks in step 2. Be sure
to reattach ground lead, if previously removed.
5. If necessary, fill cooler with selected coolant to specified level (see Fig. 1).
6. Attach desired water-cooled accessory (gun and
wire feeder or TIG torch) to cooler’s QDs.
7. Reconnect service input power to the Power Wave:
• verify that the reconnect panel setting and lead
placement match the service voltage.

Shroud to cooler base
Quick Disconnect (QD) bracket
Heat exchanger to cooler base
Relay to cooler base

4
2
2
2

all use 5/16 hex screw and 3/8 hex
nut. Relay may require large blade
slotted screwdriver 8 in. long min.

Screw to
fasten reservoir to cooler base

3 mm allen wrench (G3503 only)
5/16 Hex Socket (G3503-1 only)

Hose Clamp

1/4 hex or medium slotted screwdriver

Fan set screw

5/32 allen socket with wrench and 4
in. min. extension

Pump carbonator clamp screw

5/16 hex socket with ratchet wrench

Motor mounting bolts

two 7/16 open or box end wrenches

Motor access door

1/4 hex socket with wrench

Motor harness ground at motor
terminals

1
2

1/4 hex socket with wrench
needlenose pliers

8. Prime the cooler:
a. Install the Set-up overlay.
b. Keep accessories’ hose lengths horizontal,
either coiled or straight, and no higher than 4
feet of the specified coolant level (Fig. 1).
c. Switch on the Power Wave machine.
d. Press the "WATER COOLER ENABLE" button
so that the "WATER COOLER ENABLED" light
is illuminated .
e. Press the "PRIME WATER COOLER" button
until the "WATER COOLER PRESSURE" light is
steadily illuminated.

relay terminals 1 and 2

large blade slotted screwdriver 8 in.
minimum long.

9. Check coolant level. Add more if required.

relay terminals 3 and 4

medium slotted screwdriver

All plumbing components

N/R

two 10 inch adjustable wrenches

POWER WAVE 450

D-6

MAINTENANCE

D-6

G3503-[ ] COOLER PERIODIC MAINTENANCE

G3503-[ ] COOLER SERVICE

1. Preparation:
• Always switch off the Power Wave machine power.
• Always disconnect the Power Wave machine from
service input power.
• Do not remove the pump relief valve’s 3/4 in. acorn
hex nut or attempt to adjust the relief valve setting.

2. Remove the G3503-[ ] cooler from the Power Wave
machine.

2. Remove the G3503-[ ] cooler from the Power Wave
machine whenever:
• replacing major cooler components (i.e. pump,
motor, heat exchanger, etc.).
• replacing hoses and electrical harnesses that are
kinked or damaged (cut, abraded, deteriorated or
swollen, etc.).
• investigating suspect coolant leakage.

3. Clean the pump’s inlet strainer:
• Drain the reservoir of coolant and dispose of it in an
environmentally
responsible
manner
(see
Recommended Coolants).
• Place absorbent towels underneath pump head.
• Hold pump head to apply countertorque when loosening strainer’s 7/8 acorn nut. Do not confuse with
3/4 acorn nut. Remove nut and slide inlet strainer
down and out from pump head.
• Gently rinse strainer under running water to thoroughly clean it.
• Use the mirror to inspect inside of pump for contamination. Carefully remove hardened debris with dental pick if necessary, without scratching inside of the
pump.
• Reinstall strainer and acorn nut, tightening with
75±15 in.-lbs. of torque. Wipe dry all areas wetted by
coolant. Dispose of towels in an environmentally
responsible manner (see Recommended Coolants).
4. Gently rinse the reservoir’s strainer under running water to
thoroughly clean it.
5. Remove fan shroud and inspect hoses and electrical harnesses for kinking or damage (cut, abrasion, swelling,
etc.). Replace if necessary.
6. Remove accumulated dust from cooler, especially from the
motor and heat exchanger, by blowing it off with shop air
or vacuuming it out.
• The heat exchanger fins are sharp but can be easily
bent. Treat them with care to avoid personal injury
and damaging them.
• Remove the cooler from the machine for a more thorough cleaning job.
7. Motor lubrication is recommended once a year:
• Remove plug over lube port at top of motor near fan
end.
• Add 20 drops of electric motor or SAE 10 oil then
reinstall plug.
8. Flush coolant from the system and replace with fresh, recommended coolant at least once a year. More frequent
flushing may be necessary, depending upon a user’s particular system or its usage.
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.

3. Pump replacement:
a. Drain the reservoir of coolant and dispose of it in an
environmentally responsible manner (see
Recommended Coolants).
b. Remove fan shroud.
c. Place absorbent towels underneath pump head and
wherever coolant system is opened.
d. Carefully pull pump inlet hose and its elbow from
reservoir (bottom).
e. Loosen pump outlet hose clamp at QD then carefully
remove from fitting.
f. Disconnect v-band clamp from motor and remove
pump:
• Do not drop or lose drive coupling between pump
and motor.
• Do not discard old pump. Remove both fittings,
Keep v-clamp, Seal old pump in a waterproof bag,
Package into protective container, and Return to
nearest Lincoln Electric FSS center.
g. Install new pump and v-band clamp:
• Do not apply any lubricant to pump’s drive coupling.
• Pump body is properly oriented with its strainer at
the 6:00 position.
• Tighten v-clamp with 15 to 30 in-lbs. of torque.
h. Attach coolant lines to QD and reservoir.
i. Wipe dry all areas wetted by coolant. Dispose of towels in an environmentally responsible manner (see
Recommended Coolants).
j. Reinstall cooler into machine.
4. Motor removal or replacement:
• Do not reuse the 4 internal-tooth star washers.
Replace with new parts..
5. Installing the fan:
• Slide onto motor shaft until the fan is located
between 0.25 to 0.50 inches from the heat
exchanger.
• Tighten set screw with 65 to 75 in-lbs of torque
against motor shaft’s flat.
• Fan rotation is counterclockwise, as viewed from
fan-end of motor’s shaft.
• Fan pulls air through the heat exchanger, blows it
over the motor, then exhausts it through the reservoir.

D-7

MAINTENANCE
FIGURE D.4 – GENERAL COMPONENT LOCATIONS

1
2
3
4
5
6
7
8
9

DISPLAY BOARD (BACK OF PANEL)
POWER SWITCH
MAIN TRANSFORMER
AUXILIARY TRANSFORMER
INPUT RECTIFIER
HEAT SINK FINS
OUTPUT TERMINALS
OVERLAY BAR CODE SENSORS
TERMINAL STRIP (LOCATION)

9
4

1
8

6
2

POWER WAVE 450

E-1

TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized
repairs per-formed on this equipment may result in danger to the technician and machine operator and
will invalidate your factory warranty. For your safety, please observe all safety notes and precautions
detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting
this equipment.

This Troubleshooting Guide is provided to help
you lo-cate and correct possible machine misadjustments. Simply follow the three-step procedure
listed below.
Step 1. LOCATE PROBLEM (SYMPTOM)

Step 3. CONSULT LOCAL AUTHORIZED FIELD
SERVICE FACILITY
If you have exhausted all of the recommended
tests in step 2, consult your local Authorized Field
Service Facility.

Look under the column labeled “PROBLEM
(SYMP-TOMS).” This column describes possible
symptoms that your machine may exhibit. Find the
listing that best describes the symptom that your
machine is exhibiting.
Step 2. PERFORM EXTERNAL RECOMMENDED TESTS
The second column labeled “POSSIBLE AREAS
OF MISADJUSTMENT(S)” lists the obvious external pos-sibilities that may contribute to the
machine symptom. Perform these tests/checks in
the order listed. In gen-eral, these tests can be
conducted without removing the case wraparound
cover.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs
safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE 450

E-1

E-2

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

E-2

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Major physical or electrical damage is evident when the sheet
metal cover(s) are removed.

1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.

Machine is dead – no output – no
fans – no displays.

1. Make certain that the input
power switch (S1) is in the “ON”
position.
2. Check for proper input voltage
– must match the rating on the
machine nameplate.
3. Make certain the reconnect
panel is configured properly for
the applied voltage.
4. Check fuse (F1) in the reconnect panel. If faulty, replace with
5-amp slow-blow fuse.

Machine has no output – fans are
running – display is on – a “clicking” sound is heard coming from
the machine.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

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 applied voltage.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-3

TROUBLESHOOTING GUIDE

PROBLEMS
(SYMPTOMS)

E-3

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine has no output – no fans –
no display. Main input fuses are
open, indicating excessive input
current draw.

1. Check for proper input voltage
connections.
2. Make certain the reconnect
panel is configured properly for the
applied voltage.
3. Replace the input fuses with
proper size and ratings. If the
fuses fail again, contact your local
Lincoln Authorized Field Service
Facility.

Machine has no output – no display – fans run.

Machine has no output – no display – fans run – circuit breaker
(5-amp) repeatedly trips.

1. Check circuit breaker (5-amp)
located on the front panel. Reset if
necessary.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

1. Remove the feeder control cable
from the machine. If symptoms
disappear, feeder or control cable
is faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-4

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

E-4

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine has no output – fans run
– display is on.

1. Make sure that the machine
was powered up with a properly
installed overlay. (With no overlay
on the machine or an invalid overlay, the machine will have no output.)
2. Check to see if the Limits or
Setup overlay is installed on the
front panel. These two overlays
can not be used for welding.
3. Check for proper input voltage
(per machine nameplate).
4. Make certain the reconnect
panel is configured properly.
5. Check that when the trigger is
pulled on the wire feeder, the wire
feeder’s voltage display changes
to indicate arc voltage. If this does
not happen, feeder may be faulty.
6. Check feeder control cable for
loose or faulty connections.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

7. If the machine is connected 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.
Machine regularly overheats – yellow light (LED) on the front panel
glows, indicating a thermal overload. The fans run and the display
is on.

1. Welding application may
exceed recommended duty cycle.
2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the
Maintenance Section of this manual.
3. Air intake and exhaust louvers
may be blocked due to inadequate clearance around machine.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-5

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

E-5

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
The voltage and/or wire feed
speed will not adjust to user satisfaction.

1. Certain limits may have been
imposed on the welding parameters. Refer to the Limits Overlay
section in the Operations section
of this manual to change the set
limits.

The voltage and/or wire feed
speed can be adjusted on the wire
feeder but the changes are not
shown on the Power Wave.

1. When the Limits Overlay or the
Setup Overlay is placed on the
machine, the Power Wave’s and
feeder’s displays do not match.
These overlays can not be used
for welding.
2. If two wire feeders are connected to the Power Wave, only one of
the feeder’s settings can be displayed on the Power Wave at one
time. Pull the trig-ger of the wire
feeder whose settings you want
displayed on the Power Wave.

The Dual Procedure overlay is
installed. The user cannot change
from procedure “A” to procedure
“B,” or vice versa.

The display can not be seen clearly or can not be seen at all.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

1. Check for proper installation of
the Dual Procedure overlay.
2. Check the Dual Procedure Gun
Trigger or separate Dual
Procedure switch.

1. Adjust the viewing angle of the
display. Follow the instructions provided in the Operation Section of
this manual. (Look under the “LCD
DISPLAY ADJUSTMENT” in the
“CONTROLS AND SETTINGS”
sub-section of the Operation section.)

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-6

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

E-6

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine does not respond to keys
being pressed, or the machine has
improper displays.

1. Each time an overlay is
changed make certain that the
machine is powered-up with the
new overlay in place.
2. Make certain that the correct
overlay ID number is displayed on
power-up. Refer to the Operation
Section of this manual.
3. In some cases, some of the
keys on the overlay may be locked
out. Refer to the Operation Section
of this manual for the overlay
descriptions.

Machine display reads “Error
Invalid Overlay,” or it displays an
incorrect overlay ID number on
power-up.

1. Make certain the overlay is
installed properly.
2. Inspect the overlay 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.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

3. Inspect for damage to the Bar
Code(s) on the back of the overlay.

Machine displays “ERROR: S.L.
NOT INITIALIZED” on power-up.

1. Contact your local Lincoln
authorized Field Service Facility
for Technical assistance.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-7

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

E-7

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
The Beeper (Piezoelectric Buzzer) cannot be
heard – machine operating normally.

1. Background noise may be too loud for user
to hear beeper.

The welding parameters that were
saved in memory are different
when recalled.

1. Make certain that a remote control unit is
not connected. When a remote control unit is
used, the weld parameters are set by the
remote control potentiometers.

The water cooler does not turn on.

1. Make sure that the water cooler has been
enabled. Refer to the Setup Overlay description in the Operation Section of this manual.
2. The cooler’s circuit breaker may have tripped.
3. If the water cooler is enabled but generates
insufficient coolant flow rate, the machine will
beep loudly and the water cooler will shut
down. In this case, prime the water cooler.
Refer to the Setup Overlay description in the
Operation Section of this manual.

The machine beeps without the
keys being pressed.

If the water cooler is enabled and the flow
switch inside the water cooler opens (due to
inadequate coolant flow rate), the machine
indicates this by beeping. This happens
regardless of the overlay placed on the
machine. In this case do the following:

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

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 beeping. A momentary drop in flow rate could be
due to someone stepping on the water cooler
hose, for example.
2 Check the water cooler and accessory
hoses for kinks, internal obstructions or blockage, or ruptures. If such problems were found
then correct them and turn the machine off
and on to check if the beeping has been eliminated.
3. Check the water cooler fluid level. Low coolant
level could cause the flow rate to drop.
4. Prime the water cooler. Refer to the Setup
Overlay section of this manual for instructions.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

E-8

TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)

E-8

TROUBLESHOOTING

Observe Safety Guidelines
detailed in the beginning of this manual.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine loses output while welding. Fans and display are functioning properly.

1. Check for proper input voltages
(per machine nameplate).
2. Check for balanced three-phase
input supply voltage.
3. Check electrode and work
cables for loose or poor connections.

For no apparent reason the weld
characteristics have changed.

1. Check for proper wire feed
speed setting. In the MIG/ MAG
and FCAW Modes, check for proper voltage settings. In the
MIG/MAG Pulse Modes, check the
arc length trim setting. These controls are on the wire feeder.
2. Check for proper shielding gas
and gas flow.

If all recommended possible areas
of misadjustments have been
checked and the problem persists, contact your local Lincoln
Authorized Field Service Facility.

3. Check for loose or faulty welding cables.

Machine often “noodle welds” with
a particular procedure.

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 and/or
increase the stickout length to
eliminate this problem.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 450

Now Available...12th Edition
The Procedure Handbook of Arc Welding

New Lessons in Arc Welding

This printing will go fast so don’t delay. Place your
order now using the coupon below.

Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects, such
as distortion; and supplemental information on arc welding
applications, speeds and costs. Practice materials, exercises,
questions and answers are suggested for each
lesson.

The hardbound book contains over 750 pages of welding information, techniques and procedures. Much of this material
has never been included in any other book.

528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
$5.00 postage paid U.S.A. Mainland

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.

A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
a reference for all students by taking advantage of the low quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland

Need Welding Training?
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and draftsmen use the “short-cut” language of symbols to pass on
assembly and welding information to shop personnel.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear in
their assembled form.

The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
“hands on”
For details write:

Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.

and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.

187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
$4.50 postage paid U.S.A. Mainland

Lincoln Welding School
BASIC COURSE
5 weeks of fundamentals

$700.00

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(ED-80)
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(ED-93)
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(JFLF-515)

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Titles:
New Lessons in Arc Welding
Procedure Handbook “Twelfth Edition”
How to Read Shop Drawings
Incentive Management
A New Approach to Industrial Economics
The American Century of John C. Lincoln
Welding Preheat Calculator
Pipe Welding Charts

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$5.00
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● Do not touch electrically live parts or

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

● Keep flammable materials away.

● Wear eye, ear and body protection.

● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

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 mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Mantenha inflamáveis bem guarda-

dos.

● Use proteção para a vista, ouvido e

corpo.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.
● Use ventilation or exhaust to

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

remove fumes from breathing zone.
● Los humos fuera de la zona de res-

piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von

Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Strom vor Wartungsarbeiten

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

oder Innenschutzverkleidung in
Betrieb setzen!

● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer

● Mantenha-se afastado das partes

serviço.
● Não toque as partes elétricas nuas.

● Não opere com os paineis abertos

moventes.

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

ou guardas removidas.
Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •
• 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

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Lincoln Electric Invertec Power Wave 450 Im524 D Users Manual

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