Lincoln Electric IM542-D manual Viii, Section D

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viii

viii

3.1.5 WIRE STICK DETECT	C-3
4. POWER WAVE CIRCUITS	C-3
4.1 VOLTAGE COMMAND	C-3
4.2 WIRE SPEED COMAND	C-3
4.3 TOUCH SENSE SIGNAL	C-3
4.4 ARC DETECT	C-4
4.5 GAS FAULT	C-4
4.6 WATER FAULT	C-4
4.7 POWER FAULT	C-4
4.8 VOLTAGE FEEDBACK	C-4
4.9 CURRENT FEEDBACK	C-4
4.10 WELD START	C-4
4.11 GAS START	C-4
4.12 TOUCH SENSE COMMAND	C-4
4.13 WIRE+ & WIRE-	C-4
4.14 DUAL PROCEDURE SWITCH COMMAND	C-4
4.15 WIRE STICK DETECT	C-4
5. ROBOT CONTROLLER SETUP	C-5
5.1 WELD SYSTEM SETUP	C-5
5.2 WELD EQUIPMENT SETUP	C-5
5.3 SYSTEM VARIABLES	C-5
5.4 TOUCH SENSING SETUP	C-5
6. CONNECTIONS	C-6
6.1 POWER WAVE INTERFACE BOARD	C-6
6.2 ARCTOOL WELDING INPUTS AND OUTPUTS	C-6
6.3 MISCELLANEOUS CONNECTIONS	C-6

Accessories	Section D
Water Cooler Usage	D-1
Recommended Coolants	D-1
Priming the Cooler	D-1
Wire Feed Unit Dimension Print	D-2
Mounting the Wire Feed Unit	D-3
Connecting Wire Feed Unit to Power Source	D-3
Electrode Routing	D-3
Drive Roll and Guide Tube Kits	D-4
Procedure to Install Drive Roll & Guide Tubes	D-4
Idle Roll Pressure Setting	D-5
K659-1 Gas Guard Regulator	D-5
Wire Reel Loading	D-5
Routine Maintenance of Wire Feed Unit	D-8
Gun Cable Connector Requirements	D-9

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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 ViiiSection F Section ESection G SeriesTechnical Specifications Power Wave InstallationPower Wave AwgiecHigh Frequency Precautions Safety PrecautionsSelect Suitable Location Input ConnectionsInput Fuse and Supply Wire Considerations Input Power ConnectionsInput Voltage Reconnect Procedure Ground ConnectionsOutput Connections Wire Feeder ConnectionsWork and Electrode Cable Connections Water Cooler 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 Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsFlux Cored ARC Welding Fcaw and Gmaw Procedures Overview of Welding ProceduresPulse Procedures Wave ControlTable B.3 Adjustble Parameters GmawFcaw Overload Protection Pulse WeldingThermal Protection Current ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description GAS Fault Touch Sense SignalWire Fault Water FaultDual Procedure Switch COM- Mand Power Wave CircuitsWire Stick Detect Robot Controller Electrical CharacteristicsGAS Fault Touch Sense Command ARC DetectWater Fault Power Fault Dual Procedure Switch CommandWeld System Setup Robot Controller SetupWeld Equipment Setup Touch Sensing SetupConnections Power Wave Interface BoardArctool Welding Inputs and Outputs Miscellaneous ConnectionsWater Cooler Usage AccessoriesRecommended Coolants Priming the CoolerL9777 Wire Feed Unit Dimension Print For the LatestType Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle 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 Avoiding Wire Feeding Problems Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxConnector 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 New Lessons in Arc Welding How To Read Shop DrawingsNeed Welding Training? Basic CoursePrecaucion Aviso DE