Lincoln Electric IM542-D manual Observe Safety Guidelines

Page 60

F-4

TROUBLESHOOTING

F-4

 

 

 

 

 

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 – fans run

1. Make sure that the machine

 

 

 

– display is on.

was powered up with a properly

 

 

 

 

installed overlay. (With no overlay

 

 

 

 

on the machine or an invalid over-

 

 

 

 

lay, the machine will have no out-

 

 

 

 

put.)

 

 

 

 

2. Check to see if the Limits or

 

 

 

 

Setup overlay is installed on the

 

 

 

 

front panel. These two overlays

 

 

 

 

can not be used for welding.

 

 

 

 

3. Check for proper input voltage

 

 

 

 

(per machine nameplate).

 

 

 

 

4. Make certain the reconnect

 

 

 

 

panel is configured properly.

 

 

 

 

5. Check that when the trigger is

 

 

 

 

pulled on the wire feeder, the wire

 

 

 

 

feeder’s voltage display changes

If all recommended possible areas

 

 

to indicate arc voltage. If this does

of misadjustments have been

 

 

not happen, feeder may be faulty.

checked and the problem per-

 

 

6. Check feeder control cable for

sists, contact your local Lincoln

 

 

Authorized Field Service Facility.

 

 

loose or faulty connections.

 

 

 

 

 

 

7. If the machine is connected for

 

 

 

 

380 VAC or higher and has not

 

 

 

 

been used for a long period of

 

 

 

 

time, the capacitors may require

 

 

 

 

“conditioning.” Let the machine

 

 

 

 

run at an idle state (no load) for 30

 

 

 

 

minutes.

 

 

 

Machine regularly overheats – yel-

1. Welding application may

 

 

 

low light (LED) on the front panel

 

 

 

exceed recommended duty cycle.

 

 

 

glows, indicating a thermal over-

 

 

 

 

 

 

 

load. The fans run and the display

2. Dirt and dust may have clogged

 

 

 

is on.

the cooling channels inside the

 

 

 

 

machine. Refer to the

 

 

 

 

Maintenance Section of this man-

 

 

 

 

ual.

 

 

 

 

3. Air intake and exhaust louvers

 

 

 

 

may be blocked due to inade-

 

 

 

 

quate clearance around machine.

 

 

 

 

 

 

 

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

Page 59 Page 61
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Page 59 Page 61
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 E Section FSection G SeriesInstallation Technical Specifications Power WavePower Wave AwgiecSafety Precautions High Frequency PrecautionsSelect Suitable Location Input ConnectionsInput Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Ground ConnectionsWire Feeder Connections Output ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Safety Instructions OperationOperating Instructions Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName 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 Limits Overlay Optional Recall from Memory KEY Memory Location NumbersSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.7 Setup OverlayWire Feeder Setup Description +/- Polarity KEYPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsOverview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures Wave ControlTable B.3 Adjustble Parameters GmawFcaw Pulse Welding Overload ProtectionThermal Protection Current ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description Touch Sense Signal GAS FaultWire Fault Water FaultPower Wave Circuits Dual Procedure Switch COM- MandWire Stick Detect Robot Controller Electrical CharacteristicsTouch Sense Command ARC Detect GAS FaultWater Fault Power Fault Dual Procedure Switch CommandRobot Controller Setup Weld System SetupWeld Equipment Setup Touch Sensing SetupPower Wave Interface Board ConnectionsArctool Welding Inputs and Outputs Miscellaneous ConnectionsAccessories Water Cooler UsageRecommended Coolants Priming the CoolerL9777 Wire Feed Unit Dimension Print For the LatestType Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceProcedure to Install Drive Roll and Guide Tubes Steel Wire Sizes RollAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITWire Loading of 13-14lb 6kg Innershield Coils To Mount a 50-60lb 22.7-27.2kg CoilFeeding Electrode Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils Avoiding Wire Feeding ProblemsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireMaintenance Routine and Periodic MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified byConnected 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 Troubleshooting HOW to USE Troubleshooting GuideED Tests Troubleshooting Guide Authorized Field Service FacilitySists, 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic CoursePrecaucion Aviso DE
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