Lincoln Electric IM542-D manual Ground Connections, Input Power Connections

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A-3

A-3

INSTALLATION

CAUTION

Failure to follow these instructions can cause immedi- ate failure of components within the welder.

GROUND CONNECTIONS

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 ground- ing methods. See example Figure A.2 for the location of the reconnect/input access door and your specific connection diagram.

INPUT POWER CONNECTIONS

Connect L1, L2, L3 according to the Input Supply Connection Diagram decal located on your recon- nect/input access door. See example Figure A.2.

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 recom- mended super lag fuses or delay type circuit breakers. Choose an input and grounding wire size according to local or national electrical codes. Using fuses or cir- cuit 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 RECONNECT

PROCEDURE

WARNING

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.

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Welders are shipped connected for the highest input voltage listed on the rating plate. To change this con- nection for a different input voltage, refer to reconnect instructions which follow and to the reconnect dia- gram supplied with your machine, located inside your reconnect access door. See example Figure A.2.

FIGURE A.2 - CONNECTION DIAGRAM ON RECONNECT/INPUT ACCESS DOOR

NOTE: Turn main input power to mthe machine OFF before perform- ing reconnect procedure. Failure to do so will result in damage to the machine. DO NOT switch the re- connect bar with machine power ON.

RESAFERMPLE

SPECIFIC

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GRAM

Note:The above connection diagram is a sample of what may be found on the reconnect/input door. If it is not the correct diagram for your machine use the one on the reconnect/input access door. See the written connec- tion instructions in this section.

Also called “inverse time” or “thermal/magnetic” circuit breakers. These breakers have a delay in tripping action that decreases as the mag- nitude of the current increases.

POWER WAVE 450

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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
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