Lincoln Electric IM542-D manual Accessories, Water Cooler Usage, Recommended Coolants

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D-1

D-1

ACCESSORIES

FIGURE D.1 – WIRE FEEDER AND

WATER COOLER CONNECTIONS

1

5

2

4

3

1WIRE FEEDER CONNECTIONS (LOCATION)

2WATER COOLER LINE (IN)

3WATER COOLER LINE (OUT)

4CIRCUIT BREAKER (WATER COOLER)

5FILL SPOUT (WATER COOLER)

WATER COOLER USAGE

The Power Wave is equipped with an optional internal water cooler. We recommend using the water cooler when welding above 300 amps with argon blends on a regular basis. The gun heating from pulsing above 300 amps average current is often excessive and leads to reduced consumable life, reduced gun life, and opera- tor discomfort. Water cooling greatly increases the durability of the gun and parts at high current.

There are two water connections on the rear of the Power Wave. See Figure D.1. Connect the water lines between these connectors and those on the wire feed- er. The water is fed through the feeder into the gun.

When a water cooler is used, the water cooler must be enabled by using the Setup Overlay.

The water cooler contains a pressure switch, which is closed when there is adequate pressure in the water cooler hose for normal operation. If this pressure drops below the switch manufacturer’s set point, the pressure switch opens. A couple of seconds after the pressure switch opens the water cooler shuts down. If the water cooler is enabled and the pressure switch opens, the machine beeps loudly indicating that there is a problem with the water cooler operation.

RECOMMENDED COOLANTS

1.The following coolants have been determined to be compatible with the wetted materials used in the

G3503-[ ] cooler assembly:

•Distilled or deionized water

•Potable tap water

•Sediment-free mixtures containing a maxi- mum of 50% ethylene glycol or automotive- grade antifreeze and the balance of distilled or deionized water.

2.Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water.

3.Consult gun, torch, and wire feeder manuals for coolant recommendations and select one from the above list.

4.Pure solutions and mixtures of, or materials (i.e. towels) wetted with ethylene glycol are toxic to humans and animals. They must not be haphazard- ly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information.

5.The cooler’s reservoir has a nominal liquid capacity of 1.6 gallons.

PRIMING THE COOLER

1.Select a recommended coolant and fill cooler to specified level (see Fig. D.2).

2.Attach desired water-cooled accessory (gun and wire feeder or TIG torch) to cooler’s QDs.

3.Prime the cooler:

a.Install the Set-up overlay.

b.Keep accessories’ hose lengths horizontal, either coiled or straight, and no higher than 4 feet of the specified coolant level.

c.Switch on the Power Wave machine.

d.Press the "WATER COOLER ENABLE" button so that the "WATER COOLER ENABLED" light is illu- minated.

e.Press the "PRIME WATER COOLER" button until the "WATER COOLER PRESSURE" light is steadily illuminated.

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 ViiiSection F Section ESection G SeriesTechnical Specifications Power Wave InstallationPower Wave AwgiecHigh Frequency Precautions Safety PrecautionsSelect Suitable Location Input ConnectionsInput Fuse and Supply Wire Considerations Input Power ConnectionsInput Voltage Reconnect Procedure Ground ConnectionsOutput Connections Wire Feeder ConnectionsWork and Electrode Cable Connections Water Cooler 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 Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsFlux Cored ARC Welding Fcaw and Gmaw Procedures Overview of Welding ProceduresPulse Procedures Wave ControlFcaw Table B.3 Adjustble ParametersGmaw Overload Protection Pulse WeldingThermal Protection Current ProtectionInterface Description Robot Signal DescriptionsRobotic Interface GAS Fault Touch Sense SignalWire Fault Water FaultDual Procedure Switch COM- Mand Power Wave CircuitsWire Stick Detect Robot Controller Electrical CharacteristicsGAS Fault Touch Sense Command ARC DetectWater Fault Power Fault Dual Procedure Switch CommandWeld System Setup Robot Controller SetupWeld Equipment Setup Touch Sensing SetupConnections Power Wave Interface BoardArctool Welding Inputs and Outputs Miscellaneous ConnectionsWater Cooler Usage AccessoriesRecommended Coolants Priming the CoolerType L9777 Wire Feed Unit Dimension PrintFor the Latest Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle 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 Avoiding Wire Feeding Problems Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxConnector 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 New Lessons in Arc Welding How To Read Shop DrawingsNeed Welding Training? Basic CoursePrecaucion Aviso DE
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