Lincoln Electric IM579 manual Water Cooler Usage

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C-2

C-2

ACCESSORIES

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.

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 pressure switch, which is closed when there is adequate pressure in the water cooler hose for normal operation. If this pressure drops, the pressure switch opens. A couple of sec- onds after the pressure switch opens the water cooler shuts down. If the water cooler is enabled and the pressure switch opens, the machine beeps loudly indi- cating that there is a problem with the water cooler operation.

When the water-cooled system is turned on for the first time, the coolant lines must be bled. To accom- plish this, open the return line at the quick-connect fit- ting on the back of the Power Wave power source. The return line is the upper of the two coolant fittings. Place the return hose FROM THE FEEDER into a bucket to catch any spilled coolant and turn the machine off and on several times. Pause each time to allow the cooler to run a complete 3-second cycle. After 8 to 15 cycles, coolant will spray from the return hose with some force, indicating that the system is purged of air. Replace the return line into the quick- connect fitting. The system is bled and ready for oper- ation.

To avoid damage from freezing, the water cooler is shipped without coolant. The fill spout for the water cooling unit is located on the back panel of the machine on the left-hand side. See Figure C.1. The water cooler reservoir must be filled with coolant before use.

Use When Ambient Temperature is Above Freezing: Use tap, distilled, deionized, or well water. Do not use salt water.

Use When Ambient Temperature is Below Freezing: Use a mixture of 50% water and 50% automotive antifreeze, a mixture of 50% water and 50% pure ethylene glycol, or any commercial water alcohol mixture.

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.

POWER WAVE 450

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Contents Safety Depends on You Invertec Power WavetmFumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnFor Electrically pow- ered equipment Welding Sparks can cause fire or explosionCylinder may explode if damaged May be dangerous For Engine powered equipmentElectric and Magnetic Fields Précautions DE Sûreté Please Examine Carton and Equipment For Damage Immediately Thank YouTable of Contents Pulse Pulse and Background Current Range Voltage Range InstallationTechnical Specifications Power Wave Select Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsGround Connections Input Voltage Reconnect ProcedureInput Power Connections Input Fuse and Supply Wire ConsiderationsWater Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable ConnectionsFumes and Gases can be Safety InstructionsOperation Operating InstructionsSave process information if desired Select your process informationRecommended Processes Design Features and AdvantagesOperational Features and Controls Synergic WeldingCase Front Controls Controls and SettingsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection OverlayOperation Then Memory Location # is Empty Weld from Memory OverlayFigure B.6 Weld from MEMORY, Dual Procedure Overlay Weld from MEMORY, Dual Procedure OverlayOperation Position Procedure Dual Wire FEEDERS, Dual Procedure Overlay OptionalRecall from Memory KEY Memory Location Numbers Limits Overlay OptionalOperation Figure B.9 Setup Overlay Setup OverlayNegative Polarity Voltage Sensing Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsPositive Voltage Sensing Polarity STICK/TIG Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse ProceduresExplanation of Table B.3 Pulse processes Pulse WeldingOver Current Protection Overload ProtectionThermal Protection Guns and Cables AccessoriesOPTIONS/ACCESSORIES Wire Feeder SetupWater Cooler Usage Input Filter Capacitor DIS Charge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchPreventive Maintenance Figure D.4 General Component Locations HOW to USE Troubleshooting Guide TroubleshootingSists, contact your local Lincoln Troubleshooting GuideAuthorized Field Service Facility 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 Wiring Diagram Wiring DiagramsNeed Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Precaucion Aviso DE Limited Warranty
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