Lincoln Electric IM542-D manual Table of Contents

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vivi

	TABLE OF CONTENTS
		Page
	Safety	i-iv

	Installation	Section A
	Technical Specifications	A-1
	Safety Precautions	A-2
	Select Suitable Location	A-2
	Stacking	A-2
	Tilting	A-2
	Lifting	A-2
	High Frequency Precautions	A-2
	Input Connections	A-2
	Ground Connections	A-3
	Input Power Connections	A-3
	Input Fuse and Supply Wire Connections	A-3
	Input Voltage Reconnect Procedure	A-3
	Output Connections	A-4
	Work and Electrode Cable Connections	A-4
	Water Cooler Connections	A-4
	Wire Feeder Connections	A-4
	Dimension Print	A-5
	Component Diagram	A-6

	Operation	Section B
	Safety Instructions	B-1
	Quick Start Reference for Process Selection Overlay	B-2
	General Description	B-3
	Synergic Welding	B-3
	Recommended Processes	B-3
	Operational Features and Controls	B-3
	Design Features and Advantages	B-3
	Welding Capability	B-3
	Limitations	B-3
	Controls and Settings	B-4
	Case Front Controls	B-4
	Operating Overlays	B-5
	Overview	B-5
	Installing an Overlay	B-5
	Overlay Types	B-6
	Pulse, GMAW, FCAW, Stick Overlay	B-7
	Robotic Interface, Weld from Memory, Dual Procedure Overlay	B-10

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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 Operation Safety InstructionsOperating Instructions Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET 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 ProceduresGmaw Table B.3 Adjustble ParametersFcaw Current Protection Pulse WeldingOverload Protection Thermal ProtectionRobotic Interface Robot Signal DescriptionsInterface 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 CoolantsFor the Latest L9777 Wire Feed Unit Dimension PrintType 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 AdjustmentTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding 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 RequirementsRoutine 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 Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure 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 Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Aviso DE