Lincoln Electric IM542-D manual Feeding Electrode and Brake Adjustment

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D-6

D-6

ACCESSORIES

7)To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from the spindle.

To Mount 10 to 44 lb (4.5-20kg) Spool (12”/300mm Diameter): (For 8” (200mm) spools, a K468 spindle adapter must be used.)

REQUIRES INSTALLATION OF 2” (51MM) K162H

SPINDLE KIT.

1)Remove the locking collar on the 2” (51mm) diame- ter spindle.

2)Place the spool on the spindle making certain the brake holding pin enters one of the holes in the back side of the spool. Be certain the wire comes off the reel in a clockwise direction when de-reeled from the bottom of the coil.

Wire Reel Loading - 50-60lb (22.7-27.2kg) Coils (K299 Wire Reel Mounting Kit)

Adjustable Wire Reel Brake

The mount for standard 50-60 lb (22.7-27.2 kg) elec- trode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 in/min. (10m/m). It should be at the outer position for the faster wire speeds often used when feeding small diameter electrode.

To adjust the brake position, remove the wire reel. Pull the cotter pin that holds the brake shoe to the arm, move the shoe and replace the cotter pin. Do not bend the cotter pin - it is held in place by a friction fit.

3) Replace and tighten the locking collar.

Feeding Electrode and Brake Adjustment

1)Turn the Readi-Reel or spool until the free end of the electrode is accessible.

WARNING

When feeding with the gun energized, the electrode and drive mechanism are always “HOT” to work and ground and could remain “HOT” several seconds after the gun trigger is released.

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2)While tightly holding the electrode, cut off the bent end and straighten the first 6” (150mm). Cut off the first 1” (25mm). (If the electrode is not properly straightened, it may not feed or may not go into the outgoing guide tube causing a “birdnest”.)

3)Insert the free end through the incoming guide tube.

4)Press the Cold Inch key or the gun trigger and push the electrode into the drive roll.

5)Feed the electrode through the gun.

6)Adjust the brake tension with the thumbscrew on the spindle hub, until the reel turns freely but with lit- tle or no overrun when wire feeding is stopped. Do not overtighten.

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 G Section ESection F SeriesPower Wave InstallationTechnical Specifications Power Wave AwgiecSelect Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsInput Voltage Reconnect Procedure Input Power ConnectionsInput Fuse and Supply Wire Considerations Ground ConnectionsWork and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operation Safety InstructionsOperating Instructions Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.7 Setup OverlayPositive Polarity Voltage Sensing Wire Feeder Setup Description+/- Polarity KEY Table B.1 Positive Voltage Sensing OptionsPulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Wave ControlGmaw Table B.3 Adjustble ParametersFcaw Thermal Protection Pulse WeldingOverload Protection Current ProtectionRobotic Interface Robot Signal DescriptionsInterface Description Wire Fault Touch Sense SignalGAS Fault Water FaultWire Stick Detect Power Wave CircuitsDual Procedure Switch COM- Mand Robot Controller Electrical CharacteristicsWater Fault Touch Sense Command ARC DetectGAS Fault Power Fault Dual Procedure Switch CommandWeld Equipment Setup Robot Controller SetupWeld System Setup Touch Sensing SetupArctool Welding Inputs and Outputs Power Wave Interface BoardConnections Miscellaneous ConnectionsRecommended Coolants AccessoriesWater Cooler Usage Priming the CoolerFor the Latest L9777 Wire Feed Unit Dimension PrintType Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceAluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode Periodic Maintenance of Wire Drive Unit Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireRoutine 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 G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Aviso DE
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