Lincoln Electric IM542-D manual Preventive Maintenance

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MAINTENANCE

PREVENTIVE MAINTENANCE

Perform the following preventive maintenance proce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance record; a record tag attached to the machine works best.

1.Remove the hex head screws from the sides and top of the machine. Remove the handle bar and the machine wrap-around cover. Remove the two case sides. There are hex head screws on each side.

2.Perform the input filter capacitor discharge proce- dure described at the beginning of the Maintenance Section.

3.Disconnect the shunt from the negative (-) output terminal. Failure to do this could cause damage to the shunt circuitry.

4.Clean the inside of the machine with a low pres- sure airstream. Be sure to clean the following components thoroughly (Refer to Figure D.4):

•Display, Snubber, and Shunt printed circuit boards

•Power Switch

•Main Transformer

•Auxiliary Transformers

•Input Rectifier

•Heat Sink Fins

•Input Filter Capacitors

•Output Terminals

•Terminal Strip

8.Reconnect the shunt and wire #467 to the nega- tive (-) output terminal. Make sure the connection is tight.

9.Replace and secure the machine covers and han- dle bar.

10.Remove the overlay from the front panel of the machine. Clean the plastic case with a low pres- sure airstream. Wipe the sensors (Fig D.4 Item 8) with a clean, soft cloth. Make sure the sensors are not scratched in the process.

11.Check the back of the overlays. If the bar code (black square(s)) on the back of the overlay is scratched, apply a dull black spray finish to the scratched-off areas only. If a large area of the bar code is scratched off, the machine either will not recognize the overlay or will mistake the overlay for another one.

12.Inspect gun and cables for good condition.

5.Examine the capacitors for leakage or oozing. Replace if needed.

6.Examine the wrap-around and side covers for dents and breakage. Repair them as needed. The covers must be kept in good condition to assure that high voltage parts are protected and that cor- rect spacings are maintained.

7.Remove welding cables and check the electrical ground continuity. Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case. The meter reading should be 500,000 ohms or more. If the meter reading is less than 500,000 ohms, check for electrical components that are not prop- erly insulated from the case. Correct component insulation, if needed.

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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