Lincoln Electric IM542-D manual Output Connections, Work and Electrode Cable Connections

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A-4

A-4

INSTALLATION

FIGURE A.3 – FRONTPANEL/BACK PANEL

6

5

 

 

 

 

(IN)

 

 

 

(OUT)

 

 

 

 

4

 

1

3

2

 

1

WORK TERMINAL

 

4

WATER COOLING FITTINGS (ON ACCESS PANEL)

2

ELECTRODE TERMINAL

5

WIRE FEEDER CONNECTIONS (ON BACK PANEL)

3

REMOTE CONTROL AMPHENOL RECEPTACLE

6

ELECTRODE TERMINAL

To reconnect your machine for the proper input volt- age, see the reconnect instructions on your input access door and:

1.Move the large input voltage switch to the proper position according to your input volt- age, and the labels near the switch.

2.Move the auxiliary “A” lead to the appropriate terminal, according to your input voltage and the labels near the terminals.

OUTPUT CONNECTIONS

See Figure A.3 for the location of the work terminal, electrode terminal, remote control amphenol recepta- cle, water cooler fittings and wire feeder connections.

WORK AND ELECTRODE CABLE CONNECTIONS

Size

Use the largest welding (electrode and ground) cables possible — at least 70mm2 (#2/0) copper wire — even if the output current does not require it. When pulsing, the pulse current often exceeds 650 amps with the Power Wave 450. Voltage drops can become exces- sive if undersized welding cables are used.

Routing

To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly. Avoid excessive lengths, bundle the electrode and ground cables together where practical, and do not coil excess cable.

WATER COOLER CONNECTIONS

The water cooler fittings are a quick-connect type. Refer to the Accessories and Maintenance sections of this manual for water cooler operation and recom- mended coolants.

WIRE FEEDER CONNECTIONS

Refer to the Accessories section for Wire Feeder Con- nections.

Refer to Setup overlay in Operation section for Wire Feeder Configuration.

POWER WAVE 450

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Contents Safety Depends on You For use with machines having Code NumbersSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Vii Section CViii Section DSection G Section ESection F SeriesPower Wave InstallationTechnical Specifications Power Wave AwgiecSelect Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsInput Voltage Reconnect Procedure Input Power ConnectionsInput Fuse and Supply Wire Considerations Ground ConnectionsWork and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operating Instructions Safety InstructionsOperation Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Robotic Interface Weld from MEMORY, Dual Procedure Overlay Select a Memory LocationOperation SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Setup Overlay Figure B.7 Setup OverlayPositive Polarity Voltage Sensing Wire Feeder Setup Description+/- Polarity KEY Table B.1 Positive Voltage Sensing OptionsPulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Wave ControlFcaw Table B.3 Adjustble ParametersGmaw Thermal Protection Pulse WeldingOverload Protection Current ProtectionInterface Description Robot Signal DescriptionsRobotic Interface Wire Fault Touch Sense SignalGAS Fault Water FaultWire Stick Detect Power Wave CircuitsDual Procedure Switch COM- Mand Robot Controller Electrical CharacteristicsWater Fault Touch Sense Command ARC DetectGAS Fault Power Fault Dual Procedure Switch CommandWeld Equipment Setup Robot Controller SetupWeld System Setup Touch Sensing SetupArctool Welding Inputs and Outputs Power Wave Interface BoardConnections Miscellaneous ConnectionsRecommended Coolants AccessoriesWater Cooler Usage Priming the CoolerType L9777 Wire Feed Unit Dimension PrintFor the Latest Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceAluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITFeeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil Periodic Maintenance of Wire Drive Unit Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireInput Filter Capacitor DIS Charge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.1 Resistor Locations Connected Discharge labels, on each of the four SwitchLocate the #9 and #12 terminals, identified by Preventive Maintenance G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure D.4 General Component Locations ED Tests TroubleshootingHOW to USE Troubleshooting Guide Sists, 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Aviso DE