Lincoln Electric IM542-D manual

Contents

Main INVERTEC POWER WAVE 450 ROBOTIC IM542-D OPERATORS MANUAL FOR ENGINE powered equipment. i ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Thank You vv Please Examine Carton and Equipment For Damage Immediately TABLE OF CONTENTS Page Page Page TECHNICAL SPECIFICATIONS - POWER WAVE 450 INPUT - THREE PHASE 50/60 HZ. ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS SAFETY PRECAUTIONS SELECT SUITABLE LOCATION STACKING TILTING LIFTING GROUND CONNECTIONS INPUT POWER CONNECTIONS INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS INPUT VOLTAGE RECONNECT PROCEDURE SAMPLE ONLY REFERTO YOUR SPECIFIC DIAGRAM OUTPUT CONNECTIONS WORK AND ELECTRODE CABLE CONNECTIONS Size Routing WATER COOLER CONNECTIONS WIRE FEEDER CONNECTIONS POWER WAVE 450 ROBOTIC DIMENSIONS A-6 A-6 POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY GENERAL DESCRIPTION SYNERGIC WELDING RECOMMENDED PROCESSES OPERATIONAL FEATURES AND CONTROLS DESIGN FEATURES AND ADVANTAGES CONTROLS AND SETTINGS CASE FRONT CONTROLS OPERATING OVERLAYS OVERVIEW INVERTEC POWER WAVE 350 INSTALLING AN OVERLAY OVERLAY TYPES 1 10 8 9 345 7 11 2 6 PULSE, GMAW,FCAW, AND STICK/TIG PROCESS SELECTION OVERLAY Page Page ROBOTIC INTERFACE WELD FROM MEMORY,DUAL PROCEDURE OVERLAY Page LIMITS OVERLAY (OPTIONAL) Page SETUP OVERLAY WIRE FEEDER SETUP DESCRIPTION OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES PULSE PROCEDURES WAVE CONTROL In Pulse processes: Page PULSE WELDING OVERLOAD PROTECTION Thermal Protection Current Protection 1. INTERFACE DESCRIPTION 1.1 WELDING VOLTAGE 1.2 WIRE BURNBACK FUNCTION 1.3 WIRE STICK RESET FUNCTION 1.4 COLD WIRE INCHING FUNCTION 2.3 TOUCH SENSE SIGNAL 2.4 ARC DETECT 2.9 VOLTAGE FEEDBACK 2.5 GAS FAULT 2.6 WIRE FAULT 3. INTERFACE CIRCUIT DESCRIP- TIONS 3.1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS 4. POWER WAVE CIRCUITS Page 5. ROBOT CONTROLLER SETUP 5.1 WELD SYSTEM SETUP 5.2 WELD EQUIPMENT SETUP 5.3 SYSTEM VARIABLES 5.4 TOUCH SENSING SETUP 6. CONNECTIONS Nov97 6.2 ARCTOOL WELDING INPUTS AND OUTPUTS 6.1 POWER WAVE INTERFACE BOARD 6.3 MISCELLANEOUS CONNECTIONS WATER COOLER USAGE RECOMMENDED COOLANTS PRIMING THE COOLER D-2 D-2 L9777 WIRE FEED UNIT DIMENSION PRINT L9777 4.Check coolant level. Add more if required. Visible Coolant Level Figure D.2 MOUNTING THE WIRE FEED UNIT CONNECTING WIRE FEED UNIT TO POWER SOURCE ELECTRODE ROUTING Standard 4-Roll Kits (KP655 and KP656) DRIVE ROLL AND GUIDE TUBE KITS: PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES Idle Roll Pressure Setting K659-1 - Gas Guard Regulator Gas Guard Regulator Setting (Optional K659-1) Wire Reel Loading - Readi-Reels and Spools (using K162H Spindle Kit with 2 (51mm) spindle) To Mount 10 to 44 lb (4.5-20kg) Spool (12 /300mm Diameter): Feeding Electrode and Brake Adjustment Feeding Electrode Wire Loading of 13-14lb (6kg) Innershield Coils To Mount a 50-60lb (22.7-27.2kg) Coil: Routine Maintenance of Wire Feed Unit Wire Reel Mounting - 50 (22.7kg) and 60lb (27.2kg) Coils Wire Reel Mounting - Readi-Reels and 10 through 30lb (4.5-14kg) Spools Avoiding Wire Feeding Problems Periodic Maintenance of Wire Drive Unit Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Units Page ELECTRIC SHOCK can kill. D I S C H A R G E PREVENTIVE MAINTENANCE RECOMMENDED TOOLS FOR INSTAL- LATION OR SERVICE OF COOLER: G3503-[ ] INSTALLATION OR SER- VICE TOOL USAGE REMOVING AND INSTALLING THE G3503-[ ] COOLER E-6 E-6 G3503-[ ] COOLER PERIODIC MAINTENANCE G3503-[ ] COOLER SERVICE Page HOW TO USE TROUBLESHOOTING GUIDE Page Page Page Page Page Page Page Now Available...12th Edition The Procedure Handbook of Arc Welding How To Read Shop Drawings New Lessons in Arc Welding Need Welding Training? Lincoln Welding School AVISO DE PRECAUCION ATTENTION WARNUNG ATENO AVISO DE PRECAUCION ATTENTION WARNUNG ATENO