Lincoln Electric IM542-D manual PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay

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B-7

B-7

OPERATION

PULSE, GMAW, FCAW, AND STICK/TIG

PROCESS SELECTION OVERLAY

An operator can use this overlay to create a new welding procedure, save a newly created welding procedure, view an existing welding procedure, recall an existing welding procedure, and clear a memory location. See Figure B.4. The steps for performing each of these functions are given below.

FIGURE B.4 – PULSE, GMAW, FCAW, STICK/TIG PROCESS SELECTION OVERLAY

1			11
			11
10			2
8			6
			6
9
3	4	5	7

1	LCD DISPLAY WINDOW	7	DISPLAY RECALL KEY
2	PROCESS SELECT KEY	8	SAVE TO MEMORY KEY
3	ELECTRODE CLASS UP/DOWN KEYS	9	MEMORY LOCATION NUMBER KEYS
4	ELECTRODE SIZE UP/DOWN KEYS	10	RECALL FROM MEMORY KEY
5	ELECTRODE/GAS TYPE UP/DOWN KEYS	11	HIGH TEMPERATURE LIGHT
6	WAVE CONTROL UP/DOWN KEYS

1.LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears on the display for a few seconds:

LINCOLN ELECTRIC

VERSION X.X

This display is followed by:

OVERLAY ID

NUMBER = 1

A welding procedure is made up of seven compo- nents: process, material type, wire diameter, program, wire feed speed, voltage or arc length trim, and wave control. A new welding procedure is created by selecting a combination of these components from the ones that have been programmed into the Power Wave. See Figure B.4 for key locations.

NOTE: The following four selections should

always be performed in this order: process, elec- trode class, electrode size, electrode/gas type. Selecting a setting for one component narrows your choice of available settings in remaining com- ponents. This is why the order of performing the steps is important. However, if you make compo- nent selections out of order, the machine will prompt you to make a new selection for any set- tings that do not apply.

2.PROCESS SELECT KEY: Use the PROCESS SELECT key to select from the processes avail- able in the machine. Press the PROCESS SELECT key until the light by the desired process is lit.

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 ViiiSeries Section ESection F Section GAwgiec InstallationTechnical Specifications Power Wave Power WaveInput Connections Safety PrecautionsHigh Frequency Precautions Select Suitable LocationGround Connections Input Power ConnectionsInput Fuse and Supply Wire Considerations Input Voltage Reconnect ProcedureWater Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operating Instructions Safety InstructionsOperation Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay 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 SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Figure B.7 Setup Overlay Setup OverlayTable B.1 Positive Voltage Sensing Options Wire Feeder Setup Description+/- Polarity KEY Positive Polarity Voltage SensingWave Control Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse ProceduresFcaw Table B.3 Adjustble ParametersGmaw Current Protection Pulse WeldingOverload Protection Thermal ProtectionInterface Description Robot Signal DescriptionsRobotic Interface Water Fault Touch Sense SignalGAS Fault Wire FaultRobot Controller Electrical Characteristics Power Wave CircuitsDual Procedure Switch COM- Mand Wire Stick DetectPower Fault Dual Procedure Switch Command Touch Sense Command ARC DetectGAS Fault Water FaultTouch Sensing Setup Robot Controller SetupWeld System Setup Weld Equipment SetupMiscellaneous Connections Power Wave Interface BoardConnections Arctool Welding Inputs and OutputsPriming the Cooler AccessoriesWater Cooler Usage Recommended CoolantsType L9777 Wire Feed Unit Dimension PrintFor the Latest Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingDrive Roll and Guide Tube Kits Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Aluminum Wire SizesIdle Roll Pressure Setting Requires Installation of 2 51MM K162H Spindle KIT Feeding Electrode and Brake AdjustmentFeeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil Wire Drive Motor and Gearbox Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Periodic Maintenance of Wire Drive UnitConnector for 1/16 5/64 1.6 2.0 mm Wire Switch RequirementsInput 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 Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure 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 Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Aviso DE