Lincoln Electric IM542-D manual Troubleshooting Guide, Sists, contact your local Lincoln

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F-2

F-2

TROUBLESHOOTING

TROUBLESHOOTING GUIDE

Observe Safety Guidelines detailed in the beginning of this manual.

	PROBLEMS	POSSIBLE AREAS OF			RECOMMENDED
	(SYMPTOMS)	MISADJUSTMENT(S)			COURSE OF ACTION

			OUTPUT PROBLEMS
	Major physical or electrical dam-	1.	Contact your local authorized
	age is evident when the sheet	Lincoln Electric Field Service
	metal cover(s) are removed.	Facility for technical assistance.

	Machine is dead – no output – no	1.	Make certain that the input
	fans – no displays.	power switch (S1) is in the “ON”
		position.
		2.	Check for proper input voltage
		– must match the rating on the
		machine nameplate.
		3.	Make certain the reconnect		If all recommended possible areas
		panel is configured properly for			of misadjustments have been
		the applied voltage.			checked and the problem per-
		4.	Check fuse (F1) in the recon-		sists, contact your local Lincoln
		4.	Check fuse (F1) in the recon-		Authorized Field Service Facility.
		nect panel. If faulty, replace with			Authorized Field Service Facility.
		nect panel. If faulty, replace with
		5-amp slow-blow fuse.

	Machine has no output – fans are	1.	Turn power OFF immediately.
	Machine has no output – fans are
	running – display is on – a “click-	2.	Check for proper input voltage
	ing” sound is heard coming from	(per machine nameplate).
	the machine.	3.	Make certain the reconnect
		3.	Make certain the reconnect
		panel is configured properly for
		the applied voltage.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

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