Lincoln Electric IM542-D manual Mounting the Wire Feed Unit Electrode Routing

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D-3

D-3

 

ACCESSORIES

MOUNTING THE WIRE FEED UNIT

ELECTRODE ROUTING

Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gear- box. See L9777 Dimension Print following, to find the size and location of the mounting holes. The gearbox assembly is electrically “hot” when the gun or nozzle is energized. Therefore, make certain the gearbox does not come in contact with the structure on which the unit is mounted.

The wire feed unit should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area. Position the mechanism so it will point down at about a 45˚ angle so the wire feed gun cable will not be bent sharply as it comes from the unit.

CONNECTING WIRE FEED UNIT TO POWER SOURCE

The Feeder to Control cable assemblies are available in two types:

K680-”L” Includes a control cable with 14 pin MS- style connectors on each end, and a 4/0 weld cable to route between the Wire Drive and the Control Box. Available in lengths “L” og 16ft. (4.9m) and 25ft. (7.6m).

K681-”L” Same as K680, but does not include weld cable. Available in lengths “L” of12ft. (3.6m), 16ft. (4.9m) and 25ft. (7.6m).

1.Making certain the cables are protected from any sharp corners which may damage their jackets, mount the cable assembly along the boom so the end with the female MS-style connector pins is at the wire feed unit.

2.Connect the 14-socket cable connector to the receptacle on the back of the wire feed unit con- nection box.

3.At the same end, connect the electrode lead to the connection stud of the brass gun connection block on the front of the wire feed unit.

4.At the control box end, connect the 14-pin connec- tor of the cable to the mating receptacle on the bot- tom of the control box.

The electrode supply may be either from reels, Readi- Reels, spools or bulk packaged drums or reels. Observe the following precautions:

1.The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum, and also that the force required to pull the wire from the reel into the wire feed unit is kept at a minimum.

2.The electrode is “hot” when the gun is energized and must be insulated from the boom and struc- ture.

3.If more than one wire feed unit shares the same boom, their wire and reels must be insulated from each other and insulated from their mounting struc- ture.

See later in this section for mounting of the K299 wire reel assembly.

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 Operation Safety InstructionsOperating Instructions Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys 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 ProceduresGmaw Table B.3 Adjustble ParametersFcaw Current Protection Pulse WeldingOverload Protection Thermal ProtectionRobotic Interface Robot Signal DescriptionsInterface Description 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 CoolantsFor the Latest L9777 Wire Feed Unit Dimension PrintType 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 AdjustmentTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode 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 RequirementsRoutine and Periodic Maintenance MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchConnected 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 HOW to USE Troubleshooting Guide TroubleshootingED Tests Authorized Field Service Facility Troubleshooting GuideSists, 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 Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Aviso DE
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