Lincoln Electric Invertec Power Wave 450 Im524 D Users Manual

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IM524-D

October, 2001

For use with machines having Code Numbers: 10365 10511

10366 10512

10433 10520

10434 10607

10449 10610

INVERTEC POWER WAVE 450

OPERATOR’S MANUAL

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 thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS MAN-

UAL AND THE SAFETY PRE-

CAUTIONS CONTAINED

THROUGHOUT. And, most

importantly, think before you act

and be careful.

• 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

• World's Leader in Welding and Cutting Products •

Date of Purchase:

Serial Number:

Code Number:

Model:

Where Purchased:

RETURN TO MAIN MENU

FOR ENGINE

powered equipment.

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 weld-

ing arc or when the engine is running. Stop

the engine and allow it to cool before refuel-

ing 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 V-

belts, gears, fans and all other moving parts

when starting, operating or repairing equip-

ment.

____________________________________________________

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 con-

trol 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.

SAFETY

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 pur-

chase 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.

WARNING

Mar ‘95

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.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

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 Diesel Engines The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

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.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

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.

ELECTRIC SHOCK can kill.

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.

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.

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.

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

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

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

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

Electrical Code, all local codes and the manufacturer’s

recommendations.

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

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

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

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

electrically “hot” parts to touch a cylinder.

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

when opening the cylinder valve.

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

tight except when the cylinder is in use or connected for

use.

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

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

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

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

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

circuit is touching the work or ground. Accidental contact can

cause overheating and create a fire hazard.

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

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

welding. They may explode.

6.f.

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

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

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

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate circuits.

This can create fire hazards or overheat lifting chains or

cables until they fail.

6.h. Also see item 1.c.

SAFETY

PRÉCAUTIONS DE SÛRETÉ

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 suiv-

antes:

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 met-

allique 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 defonc-

tionnement.

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.

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 rayon-

nement 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, pan-

talons sans revers, et chaussures montantes.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

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.

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

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 debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

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!

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.

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

this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes 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.

TABLE OF CONTENTS

vi vi

POWER WAVE 450

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

vii vii

POWER WAVE 450

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

TECHNICAL SPECIFICATIONS - POWER WAVE 450

INPUT - THREE PHASE 50/60 HZ. ONLY

Input Voltages: 200 230 400 460 575

Input Currents

@ 500A/40 VDC 87 76 44 38 32

@ 450A/38 VDC 75 65 38 32 28

RATED OUTPUT

Duty Cycle Amps Volts at Rated Amperes

200 - 60% Duty Cycle 500 40 VDC

230/400/460 - 60% Duty Cycle 500 40 VDC

460/575 - 60% Duty Cycle 500 40 VDC

200 - 100% Duty Cycle 450 38 VDC

230/400/460 - 100% Duty Cycle 450 38 VDC

460/575 - 100% Duty Cycle 450 38 VDC

OUTPUT

Constant Open Continuous Process

Circuit Voltage Current RangeCurrent Ranges

75 Volts 5-540 Amps GMAW 50-540 Amps

FCAW 40-540 Amps

STICK 30-540 Amps

Pulse Pulse Pulse and Background Pulse

Current Range Voltage Range Time Range Frequency

5-750 Amps 5-55 Volts 100 Microsec - 3.3 Sec 0.15 - 1000 Hz

RECOMMENDED INPUT WIRE AND FUSE SIZES

Type 75°C Type 75°C Type 75°C

Input Duty Input Ampere Copper Wire in Ground Wire in (Super Lag)

Voltage/ Cycle Rating on Conduit Conduit or Breaker

FreqencyNameplate AWG[IEC] AWG[IEC] Size (Amps)

Sizes (MM2)Sizes (MM2)

200/50-60 60% 87 4 (25) 8 (10) 120

230/50-60 60% 76 4 (25) 8 (10) 100

400/50-60 60% 44 8 (10) 10 (6) 50

460/50-60 60% 38 8 (10) 10 (6) 50

575/50-60 60% 32 8 (10) 10 (6) 50

200/50-60 100% 75 4 (25) 8 (10) 100

230/50-60 100% 65 4 (25) 8 (10) 100

400/50-60 100% 38 8 (10) 10 (6) 50

460/50-60 100% 32 8 (10) 10 (6) 50

575/50-60 100% 28 8 (10) 10 (6) 40

PHYSICAL DIMENSIONS

Height Width Depth Weight

905 mm 515 mm 1010 mm 138 kg

35.6 in. 20.3 in. 39.8 in. 304 lbs.

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° to 40°C -50° to 85°C

INSTALLATION

A-1 A-1

Read this entire installation section before you

start installation.

SAFETY PRECAUTIONS

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.

• 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 fil-

ters. Failure to observe these precautions can result in

excessive operating temperatures and nuisance shut-

downs.

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 other-

wise submerge parts of the machine in water. This

may cause improper operation and is a possible safe-

ty hazard.

STACKING

Power Wave machines cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-

face. 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.

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.

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 loca-

tion of the rating plate.

INSTALLATION

A-2 A-2

POWER WAVE 450

WARNING

1. RATING PLATE

2. RECONNECT/INPUT ACCESS DOOR

3. INPUT CORD ACCESS HOLE

Only a qualified electrician should connect the input

leads to the Power Wave. Connections should be

made in accordance with all local and national electri-

cal 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.

Use a three-phase supply line. The Power Wave has

a 1.375” (35 mm) access hole for the input cord, but

the input cord is not supplied.

WARNING

FIGURE A.1 - RATING PLATE LOCATION

Failure to follow these instructions can cause immedi-

ate failure of components within the welder.

GROUND CONNECTIONS

The frame of the welder must be grounded.

A ground terminal marked with the symbol

is located inside the reconnect/input

access door for this purpose. See your

local and national electrical codes for proper ground-

ing 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 recon-

nect/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 recom-

mended 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 cir-

cuit 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

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 con-

nection for a different input voltage, refer to reconnect

instructions which follow and to the reconnect dia-

gram supplied with your machine, located inside your

reconnect access door. See example Figure A.2.

INSTALLATION

A-3 A-3

POWER WAVE 450

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

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

nitude of the current increases.

NOTE: Turn main input power to

mthe machine OFF before perform-

ing reconnect procedure. Failure to

do so will result in damage to the

machine. DO NOT switch the re-

connect bar with machine power

ON.

CAUTION

WARNING

SAMPLE ONLY

REFER TO YOUR

SPECIFIC DIAGRAM

INSTALLATION

A-4 A-4

POWER WAVE 450

FIGURE A.3 – FRONTPANEL/BACK PANEL

(OUT)

(IN)

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 volt-

age, 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 volt-

age, 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.

OUTPUT CONNECTIONS

See Figure A.3 for the location of the work terminal,

electrode terminal, remote control amphenol recepta-

cle, water cooler fittings and wire feeder connections.

WORK AND ELECTRODE CABLE

CONNECTIONS

Size

Use the largest welding (electrode and ground) cables

possible — at least 70mm2(#2/0) copper wire — even

if the output current does not require it. When pulsing,

the pulse current often exceeds 650 amps with the

Power Wave 450. Voltage drops can become exces-

sive 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.

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 recom-

mended coolants.

WIRE FEEDER CONNECTIONS

Refer to the Accessories section for Wire Feeder Con-

nections.

Refer to Setup overlay in Operation section for Wire

Feeder Configuration.

OPERATION

B-1 B-1

POWER WAVE 450

OPERATING INSTRUCTIONS

Read and understand this entire section of operating

instructions before operating the machine.

SAFETY INSTRUCTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet cloth-

ing.

• Insulate yourself from the work and 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 com-

bustibles.

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.

WARNING

QUICK START REFERENCE FOR

USING THE PROCESS SELECTION

OVERLAY

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.

Step 1: Select your process information:

a. Install the desired PROCESS OVERLAY.

b. Turn the machine ON.

c. Select the desired welding

PROCESS1.

d. Select ELECTRODE CLASS.

e. Select ELECTRODE SIZE.

f. 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.

Step 2: Adjust the wire feed to speed “WFS” and

voltage “V” or arc length “T” (if necessary).

a. Press the DISPLAY RECALL key to

view additional procedure information.

b. Adjust wire feed speed and voltage or arc

length trim through the controls on your wire

feeder. The new values appear on both the

wire feeder and the Power Wave display.

Step 3: Save process information (if desired).

a. Press the SAVE TO MEMORY key .

b. Press one of the MEMORY LOCATION keys

(1-8).

You can recall your procedure later by pressing the

RECALL FROM MEMORY key and the appro-

priate MEMORY LOCATION key.

1The electrode class, electrode size, and electrode/

gas type you can select for your process will be

limited to the machine’s programmed recommenda-

tions. Therefore, selecting certain options may limit

other option selections.

2The 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 dis-

played.

OPERATION

B-2 B-2

POWER WAVE 450

SAVE

RECALL

GENERAL DESCRIPTION

The INVERTEC Power Wave power source is a high

performance, digitally controlled inverter welding

power source capable of complex, high-speed wave-

form 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.

SYNERGIC WELDING

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 nei-

ther can achieve individually.”

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 syner-

gic system, the wire feeder and power source must

“talk” together. This means that only certain wire feed-

ers 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 sound-

ness, appearance, and repeatability of welds.

Refer to the Accessories section of this manual for

available wire feeders.

RECOMMENDED PROCESSES

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 proce-

dures.

OPERATIONAL FEATURES AND

CONTROLS

The Power Wave, through use of a keypad overlay

system, provides various options and controls such as

Multiple Process/Procedure Selection; Memory

Storage of Procedures; Weld from Memory Only oper-

ation; Dual Process/Dual Feeder capability.

DESIGN FEATURES AND ADVANTAGES

• Designed to NEMA Standards.

• 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).

• Modular construction for easy servicing.

• Thermostatically protected.

• Electronic overcurrent protection.

• Overvoltage protection.

• Digital signal processor and microprocessor control.

• RS232 interface for future welding application

updates.

• Simple, reliable reconnection for various input volt-

ages.

• 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).

• Simple control through use of overlays that limit

access to only those keys required for a given appli-

cation.

WELDING CAPABILITY

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 cur-

rents. If the duty cycles are exceeded, a thermostat

will shut off the output until the machine cools to a rea-

sonable operating temperature.

LIMITATIONS

• The Power Wave is not recommended for process-

es other than those specified by available overlays.

• The Power Wave is not recommended for pipe

thawing.

OPERATION

B-3 B-3

POWER WAVE 450

CONTROLS AND SETTINGS

All operator controls and adjustments are located on

the case front of the Power Wave. Refer to Figure B.1

and corresponding explanations.

FIGURE B.1 – CASE FRONT CONTROLS

CASE FRONT CONTROLS

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

controls:

1. LCD DISPLAY: Provides welding procedure infor-

mation 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.

3. HIGH TEMPERATURE LIGHT (thermal overload): A

yellow light that comes on when an over tempera-

ture 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.

OPERATION

B-4 B-4

POWER WAVE 450

1 LCD DISPLAY

2 POWER SWITCH

3 HIGH TEMPERATURE LIGHT

4 REMOTE CONTROL AMPHENOL RECEPTACLE

5 5 AMP CIRCUIT BREAKER

6 LCD DISPLAY ADJUSTMENT

OPERATING OVERLAYS

OVERVIEW

The Power Wave is controlled by a panel of keys (key-

pad) located on the front of the machine. The opera-

tor can access controls by placing an overlay over the

keys.

An 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 print-

ed 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.

FIGURE B.2 – TYPICAL POWER WAVE OVERLAY

Before the Power Wave is turned ON, the operator

selects the desired overlay and mounts it in the over-

lay 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.

INSTALLING AN OVERLAY

1. Open the ACCESS DOOR by grasping the provid-

ed indent on the door and pulling the door for-

ward. See Figure B.3 for door location.

FIGURE B.3 – OVERLAY ACCESS DOOR

2. Select the desired overlay from the storage com-

partment 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.

OPERATION

B-5 B-5

POWER WAVE 450

HIGH TEMP.

DISPLAY

M1M2

M3M4

M5M6

M7M8

PROGRAM LIST

WARNING

RECALL

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9361-2 WELD FROM MEMORY

MEMORY RECALL

INVERTEC POWER WAVE 350

1 OVERLAY ACCESS DOOR

2 OVERLAY FRAME

3 ACCESS DOOR INDENT

4 TRACKS

5 LOCATING PINS

™

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 proce-

dures by selecting and adjusting the various weld-

ing 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 lim-

its 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 Overlay Figure

Type Name No.

1 PULSE, GMAW,

FCAW, STICK PROCESS

SELECTION OVERLAY B.4

2 WELD FROM MEMORY

OVERLAY B.5

2 WELD FROM MEMORY, DUAL

PROCEDURE OVERLAY B.6

2 *DUAL WIRE FEEDERS, DUAL

PROCEDURES OVERLAY B.7

2 *DUAL FEEDER, DUAL

PROCEDURE, MEMORY

SELECTION OVERLAY --

3 *LIMITS OVERLAY B.8

3 SETUP OVERLAY B.9

4 *TEST & CALIB. OVERLAY --

*These overlays are optional. See Accessories

Section for Order Numbers.

OPERATION

B-6 B-6

POWER WAVE 450

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 compo-

nents: 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.

NOTE: The following four selections should

always be performed in this order: process, elec-

trode class, electrode size, electrode/gas type.

Selecting a setting for one component narrows

your choice of available settings in remaining com-

ponents. This is why the order of performing the

steps is important. However, if you make compo-

nent selections out of order, the machine will

prompt you to make a new selection for any set-

tings that do not apply.

2. PROCESS SELECT KEY: Use the PROCESS

SELECT key to select from the processes avail-

able in the machine. Press the PROCESS

SELECT key until the light by the desired process

is lit.

OPERATION

B-7 B-7

POWER WAVE 450

345 7

FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY

1 LCD DISPLAY WINDOW

2 PROCESS SELECT KEY

3 ELECTRODE CLASS UP/DOWN KEYS

4 ELECTRODE SIZE UP/DOWN KEYS

5 ELECTRODE/GAS TYPE UP/DOWN KEYS

6 WAVE CONTROL UP/DOWN KEYS

7 DISPLAY RECALL KEY

8 SAVE TO MEMORY KEY

9 MEMORY LOCATION NUMBER KEYS

10 RECALL FROM MEMORY KEY

11 HIGH TEMPERATURE LIGHT

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.

3. ELECTRODE CLASS UP/DOWN: Use the ELEC-

TRODE CLASS UP or DOWN keys to select from

the material types available for the selected

process. Press the ELECTRODE CLASS UP or

DOWN key until the desired material type is dis-

played.

4. ELECTRODE SIZE UP/DOWN: Use the ELEC-

TRODE SIZE UP or DOWN keys to select from the

wire diameters available for the 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 select-

ed 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 pre-

sent 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.

7. DISPLAY RECALL KEY: Since not all the informa-

tion 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 de-

scription 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 sec-

onds, the window changes back to the default dis-

play.

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 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 memo-

ry with the RECALL FROM MEMORY key.

OPERATION

B-8 B-8

POWER WAVE 450

SAVE

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 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 loca-

tion. 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.

Press the SAVE TO MEMORY key and then

the RECALL FROM MEMORY key . (Do not

press both keys at the same time.) A message in

the display window will ask you to press the MEM-

ORY 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 tempera-

ture 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.

OPERATION

B-9 B-9

POWER WAVE 450

RECALL

SAVE

RECALL

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

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 mem-

ory location of the desired welding procedure by

pressing the appropriate MEMORY RECALL

NUMBER key.

If no procedure was saved in the selected memo-

ry location, the following message appears:

MEMORY LOCATION

# IS EMPTY

Select another memory location.

When a welding procedure is recalled from mem-

ory, the display window will show the procedure

description, wire feed speed, and arc length trim

or preset voltage.

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 perma-

nent part of the procedure.

If limits have been set on the wire feed speed, volt-

age 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 over-

lay.

3. PROGRAM LIST: The PROGRAM LIST block in

the center of this overlay provides a convenient

place to record a brief description of each welding

procedure stored in memory. A “Dry Erase” mark-

er 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 se-

lected 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 tempera-

ture 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.

OPERATION

B-10 B-10

POWER WAVE 450

WELD FROM MEMORY OVERLAY

The Weld From Memory Overlay lets an operator recall and use any welding procedure stored in one of eight mem-

ory locations. See Figure B.5.

FIGURE B.5 – WELD FROM MEMORY OVERLAY

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

This display is followed by:

OVERLAY ID

NUMBER = 3

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

Select a memory location PAIR for the two desired

welding procedures by pressing either of the two cor-

responding MEMORY RECALL NUMBER keys.

If no procedure was saved to one of the memory pair

locations, the following message appears:

MEMORY LOCATION

# IS EMPTY

In this case select another memory pair.

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 proce-

dure from memory location 4.

OPERATION

B-11 B-11

POWER WAVE 450

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

1 LCD DISPLAY WINDOW

2 MEMORY RECALL KEYS

3 PROGRAM LIST

4 DISPLAY RECALL KEY

5 HIGH TEMPERATURE LIGHT

6 MEMORY LIGHTS

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

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 pro-

cedure 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 perma-

nent part of the procedure.

If limits have been set on the wire feed speed, volt-

age 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 over-

lay.

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” mark-

er 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 dis-

play for a few seconds.

5. HIGH TEMPERATURE LIGHT: The high tempera-

ture 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.

OPERATION

B-12 B-12

POWER WAVE 450

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

This display is followed by:

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 weld-

ing procedure recall from memory is as follows:

Active Gun Trigger Memory Location

Wire Feeder Position of Procedure

#1 A 1

#1 B 2

#2 A 3

#2 B 4

Pull the trigger on either wire feeder.

Depending on the gun switch position, the corre-

sponding memory location is automatically

recalled. The wire feeders memory chart has no

keys; it is simply a chart.

The display window will show the procedure

description, wire feed speed, and the preset volt-

age or arc length trim of the last active welding

procedure.

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 perma-

nent part of the procedure.

If limits have been set on the wire feed speed, volt-

age 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 over-

lay.

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 tempera-

ture 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.

OPERATION

B-13 B-13

POWER WAVE 450

1 LCD DISPLAY WINDOW

2 WIRE FEEDERS MEMORY CHART

3 DISPLAY RECALL KEY

4 HIGH TEMPERATURE LIGHT

5 MEMORY LIGHTS

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 feed-

ers 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. 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

This display is followed by:

OVERLAY ID

NUMBER = 4

This message is then replaced by the following

message:

SELECT A MEMORY

LOCATION

2. RECALL FROM MEMORY KEY:

AND

3. MEMORY LOCATION NUMBERS:

The RECALL FROM MEMORY key is used

to recall a welding procedure from memory.

Determine the memory location number of the

welding procedure for which you want to set lim-

its.Then press the RECALL FROM MEMORY key

followed by the MEMORY LOCATION NUM-

BER key for the selected procedure.

If no procedure was saved in the selected memo-

ry location, the following message appears:

MEMORY LOCATION

# IS EMPTY

Select another memory location.

4. SET LIMIT KEY:

AND

5. LIMIT UP / DOWN KEYS:

The 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.

OPERATION

B-14 B-14

POWER WAVE 450

457

1 LCD DISPLAY WINDOW

2 RECALL FROM MEMORY KEY

3 MEMORY LOCATION NUMBER KEYS

4 SET LIMIT KEY

5 LIMIT UP/DOWN KEYS

6 SAVE TO MEMORY KEY

7 DISPLAY RECALL KEY

8 MEMORY LIGHTS

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

RECALL

Use the LIMIT UP and LIMIT DOWN keys to

change the maximum wire feed speed to the

desired value.

Press the SET LIMIT key again. The new maximum

and old minimum wire feed speeds will be dis-

played.

Use the LIMIT UP and LIMIT DOWN keys to

change the minimum wire feed speed to the

desired value.

Press the SET LIMIT key. The present maximum

and 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.)

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 MEMO-

RY KEY is used to save the procedure with the

newly set limits to memory. Press the SAVE TO

MEMORY key followed by the MEMORY

LOCATION NUMBER key of the desired memory

location. This does not have to be the original

location from which the procedure was recalled.

Step 6 can be performed any time during the limit-

setting 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 proce-

dure from memory and change the limits to the

maximum range available. Then save the proce-

dure to memory.

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.

OPERATION

B-15 B-15

POWER WAVE 450

SAVE

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

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.

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.

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 informa-

tion in ACCESSORIES section. To prime the water

cooler, hold the PRIME WATER COOLER key

down. While this key is pressed, the display will

show:

PRIME WATER

COOLER

OPERATION

B-16 B-16

POWER WAVE 450

1 LCD DISPLAY WINDOW

2 WATER COOLER ON/OFF KEY

3 WATER COOLER PRESSURE LIGHT

4 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

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

WARNING

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

L9660 SETUP OVERLAY

WATER

COOLER

ENABLE

WATER

COOLER

PRIME

WATER COOLER PRESSURE

POLARITY

ELECTRODE

WORK

+POLARITY

ELECTRODE

WATER COOLER CAN ONLY BE

PRIME THE WATER COOLER

UNTIL WATER COOLER PRESSURE

SENSE LEAD

WORK SENSE

LEAD ENABLED

LEAD

SENSE

LEAD

SENSE

WATER COOLER SETUP

WIRE WIRE

FEEDER 2FEEDER 1

+POLARITY

ELECTRODE

SENSE LEAD

WORK SENSE

LEAD ENABLED

+/ -

WORK

SENSE

LEAD

ELECTRODE

SENSE

LEAD

POLARITY

+/ -

WATER COOLER ENABLED

PRIMED WHEN IT IS ENABLED.

LIGHT TURNS ON.

ENABLED ENABLED

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 polari-

ty 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 elec-

trode 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:

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 volt-

age is automatically measured between the Power

Wave’s output studs.

I. Select arc voltage sensing polarity first.

+/- POLARITY KEY

A. Positive Polarity Voltage Sensing:

In most welding applications the electrode cable is

connected to the + output 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 cir-

cumstances. 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.

B. Negative Polarity Voltage Sensing:

In some welding applications (such as Inner-

shield®) 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

OPERATION

B-17 B-17

POWER WAVE 450

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 circum-

stances. 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.

OPERATION

B-18 B-18

POWER WAVE 450

Power

Wave

Control Cable (includes 67 lead)

Electrode Sense Lead

Electrode Cable

Work Cable

Wire Feeder

Block

POSITIVE VOLTAGE SENSING POLARITY

FIGURE 11B

Power

Wave

Electrode

Cable

Work Cable

Wire Feeder

Block

NEGATIVE VOLTAGE SENSING POLARITY

Control Cable (includes 67 lead)

Electrode Sense Lead

FIGURE B.10

FIGURE B.11

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 volt-

age 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.

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 pre-

set 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.

Increasing the arc length by 10 percent at a given wire

feed speed also increases all the other arc length set-

tings 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 pro-

grammed to a default at the factory and may be adjust-

ed 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 previ-

ously 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 ter-

minals of the Power Wave 450 are electrically hot.

When the switch is in the OFF position, the output ter-

minals 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 informa-

tion 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 aver-

age wave con-trol (at the center of the scale).

OPERATION

B-19 B-19

POWER WAVE 450

OPERATION

B-20 B-20

POWER WAVE 450

Trigger

Position1GMAW GMAW STICK1Pulse GMAW

Pulse FCAW FCAW

WFS DISPLAY: WFS DISPLAY:

Wire Feed Speed Wire Feed Speed

WFS and WFS and Preset VOLTAGE VOLTAGE

Open Arc Length Trim Preset Voltage Current DISPLAY: DISPLAY:

Arc Length Trim Preset Voltage

WFS, WFS, WFS DISPLAY: WFS DISPLAY:

Actual Arc Actual Arc Preset Current, Wire Feed Speed Wire Feed Speed2

Closed Voltage, Voltage, Actual Arc VOLTAGE VOLTAGE

Actual Arc Actual Arc Voltage, Actual DISPLAY: DISPLAY:

Current Current Arc Current Actual Arc Voltage Actual Arc Voltage

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

2Arc Current, not wire feed speed, is displayed if a Remote Control Kit is attached to the wire feeder.

Power Wave 450 Wire Feeder

In Pulse 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.

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.

In Stick processes:

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.

Adjustable GMAW GMAW

Parameters Pulse FCAW Stick

Wire Feeder Wire Feed Wire Feed —

WFS Display Speed Speed

Wire Feeder Arc Length Preset —

Voltage Display Trim Voltage

Power Wave 450 Display

(with GMAW Pulse, Wave Wave Wave

GMAW FCAW, Stick Control Control Control

Process Selection Overlay) (Frequency) (Inductance) (Arc Force)

TABLE B.3 – ADJUSTBLE PARAMETERS

TABLE B.4 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS

FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS

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 weld-

ing 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 wave-

form characteristics are necessary to get low fume lev-

els. 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 pro-

cesses. 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 pro-

grammed 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 pro-

duced are suitable and sound.

The Power Wave is optimized for use with a 0.75”

(1.9 cm) stickout. The adaptive behavior is pro-

grammed 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 behav-

ior 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 volt-

age to keep a stable arc. It is very important to recog-

nize 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 loca-

tion. 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.

OPERATION

B-21 B-21

POWER WAVE 450

OPTIONS/ACCESSORIES

•

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

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

• Internal water 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

WIRE FEEDER SETUP

The Power Wave must be used with wire feeders list-

ed 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 feed-

er is used, it must be connected to the Feeder 1

Amphenol located on the back panel in the upper left-

hand 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 (+) connec-

tion of the power source. See Figure C.1.

• Connect the feeder to a welding gas supply.

• Load the wire into the feeder and gun.

• Configure wire feeders (Refer to Setup overlay in

operation section.

GUNS AND CABLES

Several MAGNUM guns are recommended for use

with the Power Wave as shown in Table C.1.

Place the proper liner in the gun and connect the gun

to the feeder. Consult the specific instructions sup-

plied with the gun for detailed operating instructions.

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 opera-

tor discomfort. Water cooling greatly increases the

durability of the gun and parts at high current.

ACCESSORIES

C-1 C-1

POWER WAVE 450

FIGURE C.1 – WIRE FEEDER AND

WATER COOLER CONNECTIONS

1 WIRE FEEDER CONNECTIONS (LOCATION)

2 WATER COOLER LINE (IN)

3 WATER COOLER LINE (OUT)

4 CIRCUIT BREAKER (WATER COOLER)

5 FILL SPOUT (WATER COOLER)

1Use 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.

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 feed-

er. 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 cou-

ple 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 indi-

cating that there is a problem with the water cooler

operation.

RECOMMENDED COOLANTS

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 maxi-

mum of 50% ethylene glycol or automotive-

grade antifreeze and the balance of distilled

or deionized water.

2. Ethylene glycol mixtures should be selected if the

cooler may be exposed to a temperature below the

freezing point of water.

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 haphazard-

ly 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.

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.

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.

Figure C.2

Do Not Use: Any prepacked welding industry coolant

mixture, such as those offered by Miller, OKI,

Bernhard, or Dynaflux. These coolants contain sub-

stances 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.

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.

ACCESSORIES

C-2 C-2

POWER WAVE 450

0.25 to 0.50

inches

Visible Coolant Level

Rear Panel of

Power Wave

Reservoir Screen

SAFETY PRECAUTIONS

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.

Prior to performing preventive maintenance it is impor-

tant to perform the following capacitor discharge pro-

cedure to avoid electric shock.

INPUT FILTER CAPACITOR DIS-

CHARGE PROCEDURE

1. Turn off input power and disconnect input power

lines.

2. Remove the hex head screws from the top and the

sides of the machine. Remove the handle bar and

the wrap-around machine cover.

3. Remove the two case sides. There are hex head

screws on each side.

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.

MAINTENANCE

D-1 D-1

POWER WAVE 450

WARNING

CAUTION

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 termi-

nals of each resistor and from each resistor to

case ground (20 measurements in all). If a voltage

is present, be careful not to touch these resistors.

ELECTRIC SHOCK can kill.

• Proceed with caution being care-

ful not to touch any internal

machine components during the

discharge procedure.

MAINTENANCE

D-2 D-2

POWER WAVE 450

5 PAIRS OF RESISTORS

CHECK VOLTAGES BETWEEN EACH

TERMINAL AND FROM EACH RESISTOR

TO CASE GROUND

FIGURE D.1 – RESISTOR LOCATIONS

WARNING

6. Locate the #9 and #12 terminals, identified by the

“Discharge” labels, on each of the four Switch

Boards. See Figure D.2.

7. Using insulated, needle nose-type jumper leads

and insulated gloves, connect one jumper lead to

one end of the resistor obtained in step 4.

Connect the other jumper lead to the other end of

the resistor.

8. 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 TER-

MINALS, RESISTORS, OR ANY INTERNAL

MACHINE COMPONENT DURING THIS PROCE-

DURE!

FIGURE D.3 – RESISTORS WITH LEADS

CONNECTED

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 capac-

itor discharge procedure.

10. Repeat discharge procedure (steps 7, 8 and 9) for

each of the other three Switch Boards.

MAINTENANCE

D-3 D-3

POWER WAVE 450

FIGURE D.2 – DISCHARGE LABEL

PREVENTIVE MAINTENANCE

Perform the following preventive maintenance proce-

dures at least once every six months. It is good prac-

tice to keep a preventive maintenance record; a record

tag attached to the machine works best.

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.

2. Perform the input filter capacitor discharge proce-

dure described at the beginning of the

Maintenance Section.

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 pres-

sure 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

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 cor-

rect 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 prop-

erly insulated from the case. Correct component

insulation, if needed.

8. Reconnect the shunt and wire #467 to the nega-

tive (-) output terminal. Make sure the connection

is tight.

9. Replace and secure the machine covers and han-

dle bar.

10. Remove the overlay from the front panel of the

machine. Clean the plastic case with a low pres-

sure airstream. Wipe the sensors (Fig D.4 Item 8)

with a clean, soft cloth. Make sure the sensors are

not scratched in the process.

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.

12. Inspect gun and cables for good condition.

MAINTENANCE

D-4 D-4

POWER WAVE 450

MAINTENANCE

D-5 D-5

POWER WAVE 450

RECOMMENDED TOOLS FOR INSTAL-

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 SER-

VICE TOOL USAGE

Fastener Usage Qty. Tool

Shroud to cooler base 4 all use 5/16 hex screw and 3/8 hex

Quick Disconnect (QD) bracket 2 nut. Relay may require large blade

Heat exchanger to cooler base 2 slotted screwdriver 8 in. long min.

Relay to cooler base 2

Screw to 4 3 mm allen wrench (G3503 only)

fasten reservoir to cooler base 5/16 Hex Socket (G3503-1 only)

Hose Clamp 10 1/4 hex or medium slotted screwdriver

Fan set screw 1 5/32 allen socket with wrench and 4

in. min. extension

Pump carbonator clamp screw 1 5/16 hex socket with ratchet wrench

Motor mounting bolts 4 two 7/16 open or box end wrenches

Motor access door 2 1/4 hex socket with wrench

Motor harness ground at motor 1 1/4 hex socket with wrench

terminals 2 needlenose pliers

relay terminals 1 and 2 2 large blade slotted screwdriver 8 in.

minimum long.

relay terminals 3 and 4 2 medium slotted screwdriver

All plumbing components N/R two 10 inch adjustable wrenches

REMOVING AND INSTALLING THE G3503-[ ]

COOLER

1. Preparation:

• Always switch 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 cool-

er 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 ser-

vice 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 spec-

ified 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.

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.

9. Check coolant level. Add more if required.

MAINTENANCE

D-6 D-6

G3503-[ ] COOLER PERIODIC MAINTENANCE

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.

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 loos-

ening 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 thor-

oughly clean it.

• Use the mirror to inspect inside of pump for contam-

ination. Carefully remove hardened debris with den-

tal 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 har-

nesses 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 thor-

ough 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, rec-

ommended coolant at least once a year. More frequent

flushing may be necessary, depending upon a user’s par-

ticular 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.

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 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. 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 tow-

els 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 reser-

voir.

MAINTENANCE

D-7 D-7

POWER WAVE 450

FIGURE D.4 – GENERAL COMPONENT LOCATIONS

1 DISPLAY BOARD (BACK OF PANEL)

2 POWER SWITCH

3 MAIN TRANSFORMER

4 AUXILIARY TRANSFORMER

5 INPUT RECTIFIER

6 HEAT SINK FINS

7 OUTPUT TERMINALS

8 OVERLAY BAR CODE SENSORS

9 TERMINAL STRIP (LOCATION)

TROUBLESHOOTING

E-1 E-1

POWER WAVE 450

HOW TO USE TROUBLESHOOTING GUIDE

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.

CAUTION

WARNING

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.

This Troubleshooting Guide is provided to help

you lo-cate and correct possible machine misad-

justments. Simply follow the three-step procedure

listed below.

Step 1. LOCATE PROBLEM (SYMPTOM)

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 RECOMMEND-

ED TESTS

The second column labeled “POSSIBLE AREAS

OF MISADJUSTMENT(S)”lists the obvious exter-

nal 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.

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.

Major physical or electrical dam-

age is evident when the sheet

metal cover(s) are removed.

Machine is dead – no output – no

fans – no displays.

Machine has no output – fans are

running – display is on – a “click-

ing” sound is heard coming from

the machine.

1. Contact your local authorized

Lincoln Electric Field Service

Facility for technical assistance.

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 recon-

nect panel. If faulty, replace with

5-amp slow-blow fuse.

1. Turn power OFF immediately.

2. Check for proper input voltage

(per machine nameplate).

3. Make certain the reconnect

panel is configured properly for

the applied voltage.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-2 E-2

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

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.

Machine has no output – no dis-

play – fans run.

Machine has no output – no dis-

play – fans run – circuit breaker

(5-amp) repeatedly trips.

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.

1. Check circuit breaker (5-amp)

located on the front panel. Reset if

necessary.

1. Remove the feeder control cable

from the machine. If symptoms

disappear, feeder or control cable

is faulty.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-3 E-3

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Machine has no output – fans run

– display is on.

Machine regularly overheats – yel-

low light (LED) on the front panel

glows, indicating a thermal over-

load. The fans run and the display

is on.

1. Make sure that the machine

was powered up with a properly

installed overlay. (With no overlay

on the machine or an invalid over-

lay, the machine will have no out-

put.)

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.

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.

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 man-

ual.

3. Air intake and exhaust louvers

may be blocked due to inade-

quate clearance around machine.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-4 E-4

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

The voltage and/or wire feed

speed will not adjust to user satis-

faction.

The voltage and/or wire feed

speed can be adjusted on the wire

feeder but the changes are not

shown 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 clear-

ly or can not be seen at all.

1. Certain limits may have been

imposed on the welding parame-

ters. Refer to the Limits Overlay

section in the Operations section

of this manual to change the set

limits.

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 connect-

ed to the Power Wave, only one of

the feeder’s settings can be dis-

played on the Power Wave at one

time. Pull the trig-ger of the wire

feeder whose settings you want

displayed on the Power Wave.

1. Check for proper installation of

the Dual Procedure overlay.

2. Check the Dual Procedure Gun

Trigger or separate Dual

Procedure switch.

1. Adjust the viewing angle of the

display. Follow the instructions pro-

vided in the Operation Section of

this manual. (Look under the “LCD

DISPLAY ADJUSTMENT”in the

“CONTROLS AND SETTINGS”

sub-section of the Operation sec-

tion.)

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-5 E-5

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

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.

Machine display reads “Error

Invalid Overlay,”or it displays an

incorrect overlay ID number on

power-up.

Machine displays “ERROR: S.L.

NOT INITIALIZED”on power-up.

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.

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.

3. Inspect for damage to the Bar

Code(s) on the back of the overlay.

1. Contact your local Lincoln

authorized Field Service Facility

for Technical assistance.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-6 E-6

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

The Beeper (Piezoelectric Buzzer) cannot be

heard – machine operating normally.

The welding parameters that were

saved in memory are different

when recalled.

The water cooler does not turn on.

The machine beeps without the

keys being pressed.

1. Background noise may be too loud for user

to hear beeper.

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.

1. Make sure that the water cooler has been

enabled. Refer to the Setup Overlay descrip-

tion 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.

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:

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 beep-

ing. 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 block-

age, or ruptures. If such problems were found

then correct them and turn the machine off

and on to check if the beeping has been elimi-

nated.

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.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-7 E-7

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Machine loses output while weld-

ing. Fans and display are function-

ing properly.

For no apparent reason the weld

characteristics have changed.

Machine often “noodle welds”with

a particular procedure.

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 connec-

tions.

1. Check for proper wire feed

speed setting. In the MIG/ MAG

and FCAW Modes, check for prop-

er voltage settings. In the

MIG/MAG Pulse Modes, check the

arc length trim setting. These con-

trols are on the wire feeder.

2. Check for proper shielding gas

and gas flow.

3. Check for loose or faulty weld-

ing cables.

1. The machine may be trying to

deliver too much power. When the

average output current exceeds a

maximum limit, the peak current is

drastically cut back. Lower the

welding parameter settings and/or

increase the stickout length to

eliminate this problem.

If all recommended possible areas

of misadjustments have been

checked and the problem per-

sists, contact your local Lincoln

Authorized Field Service Facility.

TROUBLESHOOTING

E-8 E-8

POWER WAVE 450

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-

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

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

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WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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 HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

●Do not touch electrically live parts or

electrode with skin or wet clothing.

●Insulate yourself from work and

ground.

●No toque las partes o los electrodos

bajo carga con la piel o ropa moja-

da.

●Aislese del trabajo y 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 molha-

da.

●Isole-se da peça e terra.

●Keep flammable materials away.

●Mantenga el material combustible

fuera del área de trabajo.

●Gardez à l’écart de tout matériel

inflammable.

●Entfernen Sie brennbarres Material!

●Mantenha inflamáveis bem guarda-

dos.

●Wear eye, ear and body protection.

●Protéjase los ojos, los oídos y el

cuerpo.

●Protégez vos yeux, vos oreilles et

votre corps.

●Tragen Sie Augen-, Ohren- und Kör-

perschutz!

●Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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.

●Keep your head out of fumes.

●Use ventilation or exhaust to

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-

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.

●Turn power off before servicing.

●Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

●Débranchez le courant avant l’entre-

tien.

●Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

●Não opere com as tampas removidas.

●Desligue a corrente antes de fazer

serviço.

●Não toque as partes elétricas nuas.

●Do not operate with panel open or

guards off.

●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

oder Innenschutzverkleidung in

Betrieb setzen!

●Mantenha-se afastado das partes

moventes.

●Não opere com os paineis abertos

ou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

Lincoln Electric Invertec Power Wave 450 Im524 D Users Manual

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