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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 D.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
below the switch manufacturer’s set point, the pressure
switch opens. A couple of seconds 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 indicating 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. D.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 illu-
minated.
e. Press the "PRIME WATER COOLER" button until
the "WATER COOLER PRESSURE" light is
steadily illuminated.
ACCESSORIES
D-1 D-1
POWER WAVE 450
1
5
2
4
3
FIGURE D.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)