Lincoln Electric IM542-D manual Play fans run Check circuit breaker 5-amp

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F-3

F-3

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
Machine has no output – no fans –	1. Check for proper input voltage
no display. Main input fuses are	connections.
open, indicating excessive input	2. Make certain the reconnect
current draw.	2. Make certain the reconnect
current draw.	panel is configured properly for the
	panel is configured properly for the
	applied voltage.
	3. Replace the input fuses with
	proper size and ratings. If the
	fuses fail again, contact your local
	Lincoln Authorized Field Service
	Facility.	If all recommended possible areas
		If all recommended possible areas
		of misadjustments have been
		checked and the problem per-
Machine has no output – no dis-		sists, contact your local Lincoln
play – fans run.	1. Check circuit breaker (5-amp)	Authorized Field Service Facility.
	located on the front panel. Reset if
	necessary.

	Machine has no output – no dis-	1. Remove the feeder control cable
	play – fans run – circuit breaker
		from the machine. If symptoms
	(5-amp) repeatedly trips.
		disappear, feeder or control cable

		is faulty.

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 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