Lincoln Electric IM542-D manual Touch Sense Signal, ARC Detect, GAS Fault, Wire Fault, Water Fault

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C-2

C-2

ROBOTIC INTERFACE

2.3 TOUCH SENSE SIGNAL

This is an active low input to the robot controller which indicates that the welding electrode has touched the work piece. To start touch sensing the touch sensing command must be held low by the robot controller. Then the Power Wave mon- itors the current through the electrode to deter- mine if it is touching the work piece. If the touch sense command is held low and the electrode is touching the work piece then the touch sense signal will be held low to report a “touch” to the robot controller.

2.4 ARC DETECT

This is an active low input to the robot controller which indicates that a welding arc has been detected. The Power Wave monitors the arc volt- age and current to determine if an arc is estab- lished. If an arc is not established then the arc detect signal is held high to report an error to the robot controller.

2.5 GAS FAULT

This is an active low input to the robot controller which indicates that the shielding gas is missing. The Power Wave has external connections avail- able for a normally open gas pressure or flow switch. If a switch is installed and the gas fault function is enabled then gas loss errors will be reported to the robot controller.

2.6WIRE FAULT

This is an active low input to the robot controller which indicates a wire feeding problem or the lack of welding wire. This signal is not connect- ed in the Power Wave.

2.7 WATER FAULT

This is an active low input to the robot controller which indicates a water cooling problem. The Power Wave monitors the water cooling pressure to decide if a water fault has occurred. If the water cooling pressure drops below 5-8psi then the water fault signal is held low to report an error to the robot controller.

2.8 POWER FAULT

This is an active low input to the robot controller which indicates a power fault in the Power Wave. If for some reason the 15V power supply in the Power Wave is below 15V then the power fault signal is held low to report an error to the robot controller.

This is an analog input to the robot controller with a range of 0 to 10V. The internal arc voltage sig- nal in the Power Wave is multiplied by 2 and iso- lated to produce the voltage feedback signal. A voltage feedback signal of 7.620V is equal to an arc voltage of 80.0V.

2.10 CURRENT FEEDBACK

This is an analog input to the robot controller with a range of 0 to 10V. The internal arc current sig- nal in the Power Wave is multiplied by 4 and iso- lated to produce the current feedback signal. A current feedback signal of 8.317V is equal to an arc current of 750A.

2.11 WELD START

This is an active low output from the robot con- troller which commands the Power Wave to start an arc.

2.12 GAS START

This is an active low output from the robot con- troller which commands the Power Wave to open the shielding gas solenoid.

2.13 TOUCH SENSE COMMAND

This is an active low output from the robot con- troller which commands the Power Wave to turn on touch sensing. When touch sensing is enabled the Power Wave regulates a pulse volt- age wave form while monitoring the current through the electrode. If current flows through the electrode then the touch sense signal is held low to report a “touch” to the robot controller.

2.14 WIRE+

This is an active low output from the robot con- troller which commands the Power Wave to cold inch wire at 80 IPM.

2.15 WIRE-

This is an active low output from the robot con- troller which commands the Power Wave to cold inch wire at -80 IPM.

2.16 WIRE STICK ALARM

This is an active low output from the robot con- troller used to indicate a wire stick. This signal is not connected in the Power Wave.

2.9 VOLTAGE FEEDBACK

POWER WAVE 450

APR97

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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 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 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 ControlTable B.3 Adjustble Parameters GmawFcaw Pulse Welding Overload ProtectionThermal Protection Current ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description 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 CoolerL9777 Wire Feed Unit Dimension Print For the LatestType 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 KITWire Loading of 13-14lb 6kg Innershield Coils To Mount a 50-60lb 22.7-27.2kg CoilFeeding Electrode 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 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic CoursePrecaucion Aviso DE
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