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IM542-D
TM
October, 2001
INVERTEC POWER WAVE
450 ROBOTIC
For use with machines having Code Numbers:
10344 10513 10611
10345 10514
10346 10515
10347 10516
10431 10608
10432 10609
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
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque d’inc
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ��� Thank You as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications .............................................................................................................A-1 Safety Precautions............
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vii vii Limits Overlay.....................................................................................................................B-12 Setup Overlay.....................................................................................................................B-14 Wire Feeder Setup Description..........................................................................................B-15 Overview of Welding Procedures ..................................................................
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viii viii 3.1.5 WIRE STICK DETECT ...........................................................................................C-3 4. POWER WAVE CIRCUITS.....................................................................................................C-3 4.1 VOLTAGE COMMAND....................................................................................................C-3 4.2 WIRE SPEED COMAND.................................................................................................C-3
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ix ix Maintenance..........................................................................................................................Section E Safety Precautions......................................................................................................................E-1 Routine and Periodic Maintenance.............................................................................................E-1 Input Filter Capacitor Discharge Procedure .......................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE 50/60 HZ. ONLY Input Voltages: 200 230 400 460 575 Input Currents @ 500A/40 VDC 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 C
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A-2 A-2 INSTALLATION Read this entire installation section before you HIGH FREQUENCY PRECAUTIONS start installation. 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 SAFETY PRECAUTIONS controlled equipment, which may result in bodily injury or damage to the equipment. WARNING INPUT CONNECTIONS ELECTRIC SHOCK can kill. Be sure the voltage, phase, and frequency of the input � Only qualified pe
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SAMPLE ONLY REFER TO YOUR SPECIFIC DIAGRAM A-3 A-3 INSTALLATION wire sizes. Fuse the input circuit with the recom- CAUTION mended super lag fuses or delay type circuit breakers. Choose an input and grounding wire size according to Failure to follow these instructions can cause immedi- local or national electrical codes. Using fuses or cir- ate failure of components within the welder. cuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if
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A-4 A-4 INSTALLATION FIGURE A.3 – FRONTPANEL/BACK PANEL 6 5 (IN) (OUT) 4 2 1 3 1 WORK TERMINAL 4 WATER COOLING FITTINGS (ON ACCESS PANEL) 2 ELECTRODE TERMINAL 5 WIRE FEEDER CONNECTIONS (ON BACK PANEL) 3 REMOTE CONTROL AMPHENOL RECEPTACLE 6 ELECTRODE TERMINAL To reconnect your machine for the proper input volt- WORK AND ELECTRODE CABLE age, see the reconnect instructions on your input CONNECTIONS access door and: Size 1. Move the large input voltage switch to the Use the largest welding (
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A-5 A-5 INSTALLATION POWER WAVE 450 ROBOTIC DIMENSIONS POWER WAVE 450 15.50 32.26 35.82 38.82 16.08 18.76 29.49 19.50 35.00 A M17793
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A-6 A-6 INSTALLATION POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM SYNERGIC 7F WIRE DRIVE K679-1 (LOW SPEED) K679-2 (HIGH SPEED) CONSULT IM559 FOR LATEST INFORMATION DRIVE ROLLS CONSULT IM559 FOR LATEST INFORMATION POWER WAVE 450 ROBOTIC CUSTOMER MUST PROVIDE K1447-1 (W/O WIRE DEREELING METHOD WATER COOLER) K1447-2 (W/ WATER COOLER) K680 K681 CONTROL TO WIRE DRIVE CABLES TO ROBOT CONTROLLER REQUIRED: � A
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. � Do not touch electrically live parts or electrodes with your skin or wet 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 S
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B-2 B-2 OPERATION Step 2: Adjust the wire feed to speed “WFS” and QUICK START REFERENCE FOR voltage “V” or arc length “T” (if necessary). USING THE PROCESS SELECTION a. Press the DISPLAY RECALL key to OVERLAY view additional procedure information. Read and understand the “Controls and Settings” and b. Adjust wire feed speed and voltage or arc “Operating Overlays” sections of this manual before length trim through the controls on your wire using the following Quick Start Reference p
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B-3 B-3 OPERATION DESIGN FEATURES AND ADVANTAGES GENERAL DESCRIPTION � Designed to NEMA Standards. The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding � Multiple process output ranges 5 - 540 amps. power source capable of complex, high-speed wave- � 2-line LCD display. form control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic � Easy access for input connections. Connections welding system in conjun
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B-4 B-4 OPERATION CASE FRONT CONTROLS CONTROLS AND SETTINGS Refer to Figure B.1 for the location of the following All operator controls and adjustments are located on controls: the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations. 1. LCD DISPLAY: Provides welding procedure infor- mation and parameters such as wire type, gas FIGURE B.1 – CASE FRONT CONTROLS type, WFS, trim, etc. 6 2. POWER SWITCH: Controls input power to the Power Wave. When the switch is turned
