Lincoln Electric IM542-D manual For use with machines having Code Numbers, Safety Depends on You

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IM542-D

INVERTEC POWER WAVE		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-

CAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

OPERATOR’S MANUAL

Copyright © 2001 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Contents For use with machines having Code Numbers Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéPlease Examine Carton and Equipment For Damage Immediately Thank YouTable of Contents Section C ViiSection D ViiiSection F Section ESection G SeriesTechnical Specifications Power Wave InstallationPower Wave AwgiecHigh Frequency Precautions Safety PrecautionsSelect Suitable Location Input ConnectionsInput Fuse and Supply Wire Considerations Input Power ConnectionsInput Voltage Reconnect Procedure Ground ConnectionsOutput Connections Wire Feeder ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operation Safety InstructionsOperating Instructions Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection OverlayOperation Then Select a Memory Location Robotic Interface Weld from MEMORY, Dual Procedure OverlayOperation Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Figure B.7 Setup Overlay Setup Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsFlux Cored ARC Welding Fcaw and Gmaw Procedures Overview of Welding ProceduresPulse Procedures Wave ControlGmaw Table B.3 Adjustble ParametersFcaw Overload Protection Pulse WeldingThermal Protection Current ProtectionRobotic Interface Robot Signal DescriptionsInterface Description GAS Fault Touch Sense SignalWire Fault Water FaultDual Procedure Switch COM- Mand Power Wave CircuitsWire Stick Detect Robot Controller Electrical CharacteristicsGAS Fault Touch Sense Command ARC DetectWater Fault Power Fault Dual Procedure Switch CommandWeld System Setup Robot Controller SetupWeld Equipment Setup Touch Sensing SetupConnections Power Wave Interface BoardArctool Welding Inputs and Outputs Miscellaneous ConnectionsWater Cooler Usage AccessoriesRecommended Coolants Priming the CoolerFor the Latest L9777 Wire Feed Unit Dimension PrintType Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Requires Installation of 2 51MM K162H Spindle KIT Feeding Electrode and Brake AdjustmentTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode Avoiding Wire Feeding Problems Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxConnector for 1/16 5/64 1.6 2.0 mm Wire Switch RequirementsRoutine and Periodic Maintenance MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchConnected Preventive Maintenance Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure D.4 General Component Locations HOW to USE Troubleshooting Guide TroubleshootingED Tests Authorized 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 New Lessons in Arc Welding How To Read Shop DrawingsNeed Welding Training? Basic CoursePrecaucion Aviso DE