Section E, Section F, Section G, Series | Lincoln Electric IM542-D

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Maintenance	Section E
Safety Precautions	E-1
Routine and Periodic Maintenance	E-1
Input Filter Capacitor Discharge Procedure	E-1
Resistor Locations	E-2
Discharge Label	E-3
Resistors with Leads	E-3
Preventive Maintenance	E-4
Recommended Tools for Installation or Service of Cooler	E-5
G3503-[ ] Installation or Service Tool Usage	E-5
Removing and Installing the G3503-[ ] Cooler	E-5
G3503-[ ] Cooler Periodic Maintenance	E-6
G3503-[ ] Cooler Service	E-6
General Component Locations	E-7

Troubleshooting and Repair	Section F
How To Use Troubleshooting Guide	F-1
Troubleshooting Guide	F-2

Electrical Diagrams	Section G

Parts Manual	P-261 Series

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Lincoln Electric IM542-D manual Section E, Section F, Section G, Series

Contents

Safety Depends on You For use with machines having Code Numbers Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Thank You Please Examine Carton and Equipment For Damage Immediately Table of Contents Vii Section C Viii Section D Section G Section ESection F Series Power Wave InstallationTechnical Specifications Power Wave Awgiec Select Suitable Location Safety PrecautionsHigh Frequency Precautions Input Connections Input Voltage Reconnect Procedure Input Power ConnectionsInput Fuse and Supply Wire Considerations Ground Connections Work and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler Connections Power Wave 450 Robotic Dimensions Power Wave 450 Robotic Operation Safety InstructionsOperating Instructions Select your process information Save process information if desired General Description Controls and Settings Case Front Controls Operating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Location Operation Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.7 Setup Overlay Positive Polarity Voltage Sensing Wire Feeder Setup Description+/- Polarity KEY Table B.1 Positive Voltage Sensing Options Pulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Wave Control Gmaw Table B.3 Adjustble ParametersFcaw Thermal Protection Pulse WeldingOverload Protection Current Protection Robotic Interface Robot Signal DescriptionsInterface Description Wire Fault Touch Sense SignalGAS Fault Water Fault Wire Stick Detect Power Wave CircuitsDual Procedure Switch COM- Mand Robot Controller Electrical Characteristics Water Fault Touch Sense Command ARC DetectGAS Fault Power Fault Dual Procedure Switch Command Weld Equipment Setup Robot Controller SetupWeld System Setup Touch Sensing Setup Arctool Welding Inputs and Outputs Power Wave Interface BoardConnections Miscellaneous Connections Recommended Coolants AccessoriesWater Cooler Usage Priming the Cooler For the Latest L9777 Wire Feed Unit Dimension PrintType Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power Source Aluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Drive Roll and Guide Tube Kits Idle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KIT To Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode Periodic Maintenance of Wire Drive Unit Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Wire Drive Motor and Gearbox Switch Requirements Connector for 1/16 5/64 1.6 2.0 mm Wire Routine 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 G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 Cooler G3503- Cooler Periodic Maintenance G3503- Cooler Service Figure 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic Course Precaucion Aviso DE