Lincoln Electric IM524-D manual Options/Accessories, Wire Feeder Setup, Guns and Cables

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POWER WAVE 450

C-1

C-1

ACCESSORIES

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.

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.

FIGURE C.1 – WIRE FEEDER AND

WATER COOLER CONNECTIONS

1

5

2

4 3

1WIRE FEEDER CONNECTIONS (LOCATION)

2WATER COOLER LINE (IN)

3WATER COOLER LINE (OUT)

4CIRCUIT BREAKER (WATER COOLER)

5FILL SPOUT (WATER COOLER)

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

TABLE C.1 – RECOMMENDED GUNS FOR USE

WITH POWER WAVE 450

Gun

Application

Cooling

Product No.

MAGNUM 400

GMAW

Gas

K471-2

MAGNUM 550

GMAW

Gas

K598

 

 

 

 

•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.

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.

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.

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Contents Safety Depends on You For use with machines having Code NumbersSafety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Thank You Table of Contents Section E Section CSection D Section FPulse Pulse and Background Current Range Technical Specifications Power WaveFrequency Select Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsInput Voltage Reconnect Procedure Input Power ConnectionsInput Fuse and Supply Wire Considerations Power WaveWork and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler ConnectionsSafety Instructions Operating InstructionsSelect your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Weld from Memory Overlay Figure B.5 Weld from Memory OverlayWeld from MEMORY, Dual Procedure Overlay Figure B.6 Weld from MEMORY, Dual Procedure OverlayOperation Dual Wire FEEDERS, Dual Procedure Overlay Optional Position ProcedureRecall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.9 Setup OverlayWire Feeder Setup Description +/- Polarity KEYPositive Voltage Sensing Polarity Pulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures ProceduresFcaw Table B.3 Adjustble ParametersGmaw Gmaw StickPulse Welding Overload ProtectionTable C.1 Recommended Guns for USE With Power Wave OPTIONS/ACCESSORIESWire Feeder Setup Guns and CablesRecommended Coolants Priming the CoolerRoutine and Periodic Maintenance Input Filter Capacitor DIS Charge ProcedureFigure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchConnected Preventive Maintenance G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure D.4 General Component Locations Consult Local Authorized Field Service Facility HOW to USE Troubleshooting GuideLocate Problem Symptom Perform External RecommendAuthorized Field Service Facility Troubleshooting GuideSists, contact your local Lincoln Play fans run Check circuit breaker 5-amp Observe Safety Guidelines Controls and Settings Power-up Inspect the overlay bar code Saved in memory are different Check for proper shielding gas Basic Course $700.00Precaucion Aviso DE
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