Lincoln Electric IM542-D manual To Mount a 50-60lb 22.7-27.2kg Coil, Feeding Electrode

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D-7

D-7

ACCESSORIES

To Mount a 50-60lb (22.7-27.2kg) Coil:

1)To remove the wire reel from its shaft, grasp the spring loaded knob and pull it out. This straightens the knob so it seats into the shaft when released. Remove the reel.

2)Lay the reel flat on the floor, loosen the spinner nut and remove the cover plate.

3)Before cutting the tie wires, place the coil of elec- trode on the reel so it unwinds as the reel rotates clockwise.

a)Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires (see illustration below).

b)When loading .030-.045” (0.8-1.2mm) elec- trode, be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner. This provides the positive compression of the coil sides need- ed for trouble-free wire feeding (see illustration).

c)Put the cover plate on the reel so that the four arms of the cover straddle and are in line with the spring loaded arm of the reel proper.

4)Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms.

5)Cut and remove only the tie wire holding the free end of the coil. Insert the free end into one of the holes in the cover and secure it by bending it back. Cut and remove the remaining tie wires.

CAUTION

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in “backlashing” of the coil, which may tangle the wire. A tangled coil will not feed so it must either be untangled or discarded.

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6)Replace the reel on the wire feeder. Grasp the shaft knob, pull it out and swing it across the reel hub, locking the reel in place.

Feeding Electrode

1)

Turn the reel until the free end of the electrode is

 

accessible. While tightly holding the electrode, cut

 

off the bent end.

2)

Straighten the first 6” (150mm) and cut off the first

SPINNER

NUT

COVER

PLATE

COIL

REEL

SLOTS

CARDBOARD COIL LINER

TIE WIRE

SPRING

LOADED

ARM

1” (25mm). Insert the free end through the incoming

guide tube. Press the Cold Inch key or the gun trigger

and push the electrode into the drive roll. Feed the

electrode through the gun. (If the electrode is not prop-

erly straightened, it may not feed or may not go into the

outgoing guide tube causing a “birdnest”.)

WARNING

When feeding with the gun trigger, 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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Wire Loading of 13-14lb (6kg) Innershield Coils

Requires use of K162H Spindle Kit and K435 14 lb. Coil Adapter.

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
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