Lincoln Electric IM542-D manual Saved in memory are different

Page 63

F-7

TROUBLESHOOTING

F-7

 

 

 

 

 

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

 

 

 

The Beeper (Piezoelectric Buzzer) cannot be

1. Background noise may be too loud for user

 

 

 

heard – machine operating normally.

to hear beeper.

 

 

 

 

 

 

 

 

The welding parameters that were

1. Make certain that a remote control unit is

 

 

 

saved in memory are different

not connected. When a remote control unit is

 

 

 

when recalled.

used, the weld parameters are set by the

 

 

 

 

remote control potentiometers.

 

 

 

 

 

 

 

 

The water cooler does not turn on.

1. Make sure that the water cooler has been

 

 

 

enabled. Refer to the Setup Overlay descrip-

 

 

 

 

 

 

 

 

tion in the Operation Section of this manual.

 

 

 

 

2. The cooler’s circuit breaker may have tripped.

 

 

 

 

3. If the water cooler is enabled but generates

 

 

 

 

insufficient coolant pressure, the machine will

 

 

 

 

beep loudly and the water cooler will shut

 

 

 

 

down. In this case, prime the water cooler.

 

 

 

 

Refer to the Setup Overlay description in the

 

 

 

 

Operation Section of this manual.

If all recommended possible areas

 

The machine beeps without the

If the water cooler is enabled and the pres-

 

keys being pressed.

of misadjustments have been

 

sure switch inside the water cooler opens (due

 

 

checked and the problem per-

 

 

to inadequate coolant pressure), the machine

 

 

sists, contact your local Lincoln

 

 

indicates this by beeping. This happens

 

 

Authorized Field Service Facility.

 

 

regardless of the overlay placed on the

 

 

 

 

 

 

machine. In this case do the following:

 

 

 

 

1. Turn the machine off and on a couple of

 

 

 

 

times and see if the beeping continues. If the

 

 

 

 

pressure dropped momentarily then turning

 

 

 

 

the machine off and on eliminates the beep-

 

 

 

 

ing. A momentary pressure drop could be due

 

 

 

 

to someone stepping on the water cooler

 

 

 

 

hose, for example.

 

 

 

 

2 Check the water cooler and accessory

 

 

 

 

hoses for kinks, internal obstructions or block-

 

 

 

 

age, or ruptures. If such problems were found

 

 

 

 

then correct them and turn the machine off

 

 

 

 

and on to check if the beeping has been elimi-

 

 

 

 

nated.

 

 

 

 

3. Check the water cooler fluid level. Low coolant

 

 

 

 

level could cause the pressure to drop.

 

 

 

 

4. Prime the water cooler. Refer to the Setup

 

 

 

 

Overlay section of this manual for instructions.

 

 

 

 

 

 

 

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 Safety Instructions OperationOperating Instructions Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName 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 Limits Overlay Optional Recall from Memory KEY Memory Location NumbersSET Limit KEY Limit UP / Down Keys 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 ProceduresTable B.3 Adjustble Parameters GmawFcaw Current Protection Pulse WeldingOverload Protection Thermal ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description 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 CoolantsL9777 Wire Feed Unit Dimension Print For the LatestType 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 AdjustmentWire Loading of 13-14lb 6kg Innershield Coils To Mount a 50-60lb 22.7-27.2kg CoilFeeding Electrode 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 RequirementsMaintenance 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 Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure 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 Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Aviso DE
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