Lincoln Electric IM542-D Select your process information, Save process information if desired

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B-2

B-2

OPERATION

QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY

Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave.

NOTE: Selection of certain options may limit the selection of subsequent options.

Step 1: Select your process information:

a.Install the desired PROCESS OVERLAY.

b.Turn the machine ON.

c.Select the desired welding

PROCESS1.

Step 2: Adjust the wire feed to speed “WFS” and voltage “V” or arc length “T” (if necessary).

a. Press the DISPLAY RECALL key

 

 

to

view additional procedure information.

 

b.Adjust wire feed speed and voltage or arc length trim through the controls on your wire feeder. The new values appear on both the wire feeder and the Power Wave display.

Step 3: Save process information (if desired).

a. Press the SAVE TO MEMORY key SAVE .

b.Press one of the MEMORY LOCATION keys (1-8).

You can recall your procedure later by pressing the

RECALL FROM MEMORY key RECALL and the appro-

priate MEMORY LOCATION key.

1

The electrode class, electrode size, and electrode/

d. Select ELECTRODE CLASS.

gas type you can select for your process will be

 

 

 

 

limited to the machine’s programmed recommenda-

 

 

 

 

tions. Therefore, selecting certain options may limit

 

 

other option selections.

2 The wave control scale displayed shows the default setting. (The higher the setting, the softer the arc.) If you change the setting, your new setting will be dis- played.

e. Select ELECTRODE SIZE.

f. Select ELECTRODE/GAS TYPE.

g. Press the WAVE CONTROL UP or DOWN keys to see the present setting. Press the WAVE CONTROL UP or

WAVE CONTROL DOWN keys to adjust2.

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 Connections Power Wave 450 Robotic Dimensions Power Wave 450 Robotic Safety Instructions OperationOperating Instructions Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName 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 Limits Overlay Optional Recall from Memory KEY Memory Location NumbersSET Limit KEY Limit UP / Down Keys 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 ControlTable B.3 Adjustble Parameters GmawFcaw Thermal Protection Pulse WeldingOverload Protection Current ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description 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 CoolerL9777 Wire Feed Unit Dimension Print For the LatestType 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 KITWire Loading of 13-14lb 6kg Innershield Coils To Mount a 50-60lb 22.7-27.2kg CoilFeeding Electrode 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 WireMaintenance Routine and Periodic MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified byConnected 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 Troubleshooting HOW to USE Troubleshooting GuideED Tests Troubleshooting Guide Authorized Field Service FacilitySists, 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Aviso DE