Lincoln Electric IM542-D manual Power-up Inspect the overlay bar code

Page 62

F-6

 

F-6

 

 

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 does not respond to keys

1. Each time an overlay is

 

 

 

being pressed, or the machine has

changed make certain that the

 

 

 

improper displays.

machine is powered-up with the

 

 

 

 

new overlay in place.

 

 

2.Make certain that the correct overlay ID number is displayed on power-up. Refer to the Operation Section of this manual.

3.In some cases, some of the keys on the overlay may be locked out. Refer to the Operation Section of this manual for the overlay descriptions.

Machine display reads “Error

 

If all recommended possible areas

1. Make certain the overlay is

of misadjustments have been

Invalid Overlay,” or it displays an

installed properly.

checked and the problem per-

incorrect overlay ID number on

 

sists, contact your local Lincoln

power-up.

2. Inspect the overlay bar code

Authorized Field Service Facility.

 

sensors on the front panel (Fig 17

 

 

 

Item 8). If they are dirty, blow them

 

 

out with low pressure air and clean

 

 

with soft cloth.

 

 

3. Inspect for damage to the Bar

 

 

Code(s) on the back of the overlay.

 

 

1. Contact your local Lincoln

Machine displays “ERROR: S.L.

authorized Field Service Facility

NOT INITIALIZED” on power-up.

for Technical assistance.

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 Operating Instructions Safety InstructionsOperation Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay 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 SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers 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 ControlFcaw Table B.3 Adjustble ParametersGmaw Thermal Protection Pulse WeldingOverload Protection Current ProtectionInterface Description Robot Signal DescriptionsRobotic Interface 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 CoolerType L9777 Wire Feed Unit Dimension PrintFor the Latest 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 KITFeeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil 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 WireInput 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 G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Aviso DE
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