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manual abstract
3 PHASE OUTPUT CONDITIONS INPUT CURRENT AMPS IDLE POWER POWER FACTOR @ RATED OUPUT EFFICIENCY @ RATED OUPUT 460/500/575V 500A@40V.100% 31/29/25 800 Watts Max. .95 MIN. 84% OUTPUT OPEN CIRCUIT VOLTAGE CURRENT RANGE DC PULSE FREQUENCY PULSE VOLTAGE RANGE PULSE AND BACKGROUND TIME RANGE AUXILIARY POWER (CIRCUIT BREAKER PROTECTED) 90VDC 20-500 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. 3.3 SEC. 40 VDC AT 10 AMPS 115 VAC AT 10 AMPS PROCESS CURRENT RANGES (AC or DC) CURRENT SAW / MIG / MAG FCAW Pulse 50-500 Average Amps 40-500 Average Amps 15-725 Peak Amps RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE / FREQUENCY 50/60HZ TYPE 75°C COPPER WIRE IN CONDUIT AWG[IEC] SIZES (MM2) TYPE 75°C GROUND WIRE IN CONDUIT AWG[IEC] SIZES (MM2) TYPE 75°C (SUPER LAG) OR BREAKER SIZE (AMPS) 460V 500V 575V 8 (10) 8 (10) 10 (6) 10 (6) 10 (6) 10 (6) 45 40 35 PHYSICAL DIMENSIONS HEIGHT 38 in 965 mm WIDTH 19 in 483 mm DEPTH 33 in 838 mm WEIGHT 490 lbs. 222 kg. TEMPERATURE RANGES OPERATING TEMPERATURE RANGE -20°C to +40°C STORAGE TEMPERATURE RANGE -40°C to +40°C POWER WAVE AC/DC A-2 A-2 INSTALLATION SAFETY PRECAUTIONS LIFTING Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment. • Do not touch electrically hot parts. • Always connect the Power Wave grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground. SELECT SUITABLE LOCATION Do not use Power Waves in outdoor environments. The Power Wave power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area. Do not mount the PowerWave over combustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate atleast .060" (1.6mm) thick, which shall extend not less than 5.90" (150mm) beyond the equipment on all sides. Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bottom. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns. Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it. STACKING Power Wave AC/DC machine cannot be stacked. MACHINE GROUNDING The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods. HIGH FREQUENCY PROTECTION Locate the Power Wave away from radio controlled machinery. CAUTION 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. POWER WAVE AC/DC INSTALLATION A-3 POWER WAVE AC/DC A-3 INPUT CONNECTION 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. ------------------------------------------------------------- Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the upper left case back next to the input access door. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A.1 . INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose an input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents. INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY) Welders are shipped connected for the highest input voltage listed on the rating plate. To move t...