Lincoln Electric IM542-D manual Controls and Settings, Case Front Controls

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B-4

B-4

OPERATION

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the Power Wave. Refer to Figure B.1 and corresponding explanations.

FIGURE B.1 – CASE FRONT CONTROLS

6

3 1

2

45

1LCD DISPLAY

2POWER SWITCH

3HIGH TEMPERATURE LIGHT

4REMOTE CONTROL AMPHENOL RECEPTACLE

55 AMP CIRCUIT BREAKER

6LCD DISPLAY ADJUSTMENT

CASE FRONT CONTROLS

Refer to Figure B.1 for the location of the following controls:

1.LCD DISPLAY: Provides welding procedure infor- mation and parameters such as wire type, gas type, WFS, trim, etc.

2.POWER SWITCH: Controls input power to the Power Wave. When the switch is turned to the ON position, the connected wire feeder meters light up and the LCD display on the Power Wave shows the following:

LINCOLN ELECTRIC

Version X.X

This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine. At this point, the machine is ready for operation.

3.HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over tempera- ture situation occurs. Output is disabled until the machine cools down. At that point the light goes out and output is enabled again.

4.REMOTE CONTROL AMPHENOL RECEPTACLE: Allows remote current control during stick welding via a hand or foot Amptrol accessory.

5.5 AMP CIRCUIT BREAKER: Protects two auxiliary

power circuits: the 24V supply used by the trigger circuits and the 42V supply used by the internal machine circuits and the wire feeders.

6.LCD DISPLAY ADJUSTMENT: Use a small flat blade screw driver to adjust the viewing angle of the LCD display.

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 E Section FSection G SeriesInstallation Technical Specifications Power WavePower Wave AwgiecSafety Precautions High Frequency PrecautionsSelect Suitable Location Input ConnectionsInput Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Ground ConnectionsWire Feeder Connections Output ConnectionsWork and Electrode Cable 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 OverlayWire Feeder Setup Description +/- Polarity KEYPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsOverview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures Wave ControlFcaw Table B.3 Adjustble ParametersGmaw Pulse Welding Overload ProtectionThermal Protection Current ProtectionInterface Description Robot Signal DescriptionsRobotic Interface Touch Sense Signal GAS FaultWire Fault Water FaultPower Wave Circuits Dual Procedure Switch COM- MandWire Stick Detect Robot Controller Electrical CharacteristicsTouch Sense Command ARC Detect GAS FaultWater Fault Power Fault Dual Procedure Switch CommandRobot Controller Setup Weld System SetupWeld Equipment Setup Touch Sensing SetupPower Wave Interface Board ConnectionsArctool Welding Inputs and Outputs Miscellaneous ConnectionsAccessories Water Cooler UsageRecommended Coolants Priming the CoolerType L9777 Wire Feed Unit Dimension PrintFor the Latest Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceProcedure to Install Drive Roll and Guide Tubes Steel Wire Sizes RollAluminum Wire Sizes 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 Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils Avoiding Wire Feeding ProblemsPeriodic Maintenance of Wire Drive Unit 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic CoursePrecaucion Aviso DE