Installation, Awgiec, Power Wave | Lincoln Electric IM542-D instruction

A-1					INSTALLATION													A-1
					INSTALLATION
	TECHNICAL SPECIFICATIONS - POWER WAVE 450

			INPUT - THREE PHASE 50/60						HZ. ONLY
			Input Voltages:			200		230				400			460			575
			Input Currents
			@ 500A/40 VDC			87		76				44			38			32
			@ 450A/38 VDC			75		65				38			32			28

					RATED OUTPUT
	Duty Cycle						Amps					Volts at Rated Amperes
	200 - 60% Duty Cycle					500								40 VDC
	230/400/460 - 60% Duty Cycle					500								40 VDC
	460/575 - 60% Duty Cycle					500								40 VDC
	200 - 100% Duty Cycle					450								38 VDC
	230/400/460 - 100% Duty Cycle					450								38 VDC
	460/575 - 100% Duty Cycle					450								38 VDC
						OUTPUT
	Constant Open					Continuous								Process
	Circuit Voltage					Current Range							Current Ranges
	75 Volts					5-540 Amps							GMAW 50-540 Amps
													FCAW 40-540 Amps
													STICK 30-540 Amps

	Pulse				Pulse		Pulse and Background									Pulse
	Current Range			Voltage Range				Time Range							Frequency

	5-750 Amps			5-55 Volts			100 Microsec - 3.3 Sec								0.15 - 1000 Hz

			RECOMMENDED INPUT WIRE AND FUSE SIZES
							Type 75°C					Type 75°C				Type 75°C
	Input		Duty	Input Ampere Copper Wire in						Ground Wire in						(Super Lag)
	Voltage/		Cycle		Rating on		Conduit					Conduit				or Breaker
	Freqency			Nameplate			AWG[IEC]					AWG[IEC]				Size (Amps)
							Sizes (MM2)					Sizes (MM2)

200/50-60			60%	87		4		(25)				8	(10)					120
230/50-60			60%	76		4		(25)				8	(10)					100
400/50-60			60%	44		8		(10)				10	(6)					50
460/50-60			60%	38		8		(10)				10	(6)					50
575/50-60			60%	32		8		(10)				10	(6)					50
200/50-60			100%	75		4 (25)						8	(10)					100
230/50-60			100%	65		4		(25)				8	(10)					100
400/50-60			100%	38		8		(10)				10	(6)					50
460/50-60			100%	32		8		(10)				10	(6)					50
575/50-60			100%	28		8		(10)				10	(6)					40

					PHYSICAL DIMENSIONS
	Height				Width			Depth							Weight
	905 mm				515 mm			1010 mm							138 kg
	35.6 in.				20.3 in.			39.8 in.							304 lbs.

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° to 40°C

-50° to 85°C

POWER WAVE 450

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Lincoln Electric IM542-D manual Installation, Technical Specifications Power Wave, Awgiec

Contents

For use with machines having Code Numbers Safety Depends on You California Proposition 65 Warnings Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Please Examine Carton and Equipment For Damage Immediately Thank You Table of Contents Section C Vii Section D Viii Series Section ESection F Section G Awgiec InstallationTechnical Specifications Power Wave Power Wave Input Connections Safety PrecautionsHigh Frequency Precautions Select Suitable Location Ground Connections Input Power ConnectionsInput Fuse and Supply Wire Considerations Input Voltage Reconnect Procedure Water Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable Connections Power Wave 450 Robotic Dimensions Power Wave 450 Robotic Operating Instructions Safety InstructionsOperation Save process information if desired Select your process information General Description Case Front Controls Controls and Settings Overview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Operation Then Select a Memory Location Robotic Interface Weld from MEMORY, Dual Procedure Overlay Operation SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Figure B.7 Setup Overlay Setup Overlay Table B.1 Positive Voltage Sensing Options Wire Feeder Setup Description+/- Polarity KEY Positive Polarity Voltage Sensing Wave Control Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse Procedures Fcaw Table B.3 Adjustble ParametersGmaw Current Protection Pulse WeldingOverload Protection Thermal Protection Interface Description Robot Signal DescriptionsRobotic Interface Water Fault Touch Sense SignalGAS Fault Wire Fault Robot Controller Electrical Characteristics Power Wave CircuitsDual Procedure Switch COM- Mand Wire Stick Detect Power Fault Dual Procedure Switch Command Touch Sense Command ARC DetectGAS Fault Water Fault Touch Sensing Setup Robot Controller SetupWeld System Setup Weld Equipment Setup Miscellaneous Connections Power Wave Interface BoardConnections Arctool Welding Inputs and Outputs Priming the Cooler AccessoriesWater Cooler Usage Recommended Coolants Type L9777 Wire Feed Unit Dimension PrintFor the Latest Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode Routing Drive Roll and Guide Tube Kits Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Aluminum Wire Sizes Idle Roll Pressure Setting Requires Installation of 2 51MM K162H Spindle KIT Feeding Electrode and Brake Adjustment Feeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil Wire Drive Motor and Gearbox Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Periodic Maintenance of Wire Drive Unit Connector for 1/16 5/64 1.6 2.0 mm Wire Switch Requirements Input Filter Capacitor DIS Charge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.1 Resistor Locations Connected Discharge labels, on each of the four SwitchLocate the #9 and #12 terminals, identified by Preventive Maintenance Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool Usage G3503- Cooler Service G3503- Cooler Periodic Maintenance Figure D.4 General Component Locations ED Tests TroubleshootingHOW to USE Troubleshooting Guide Sists, contact your local Lincoln Troubleshooting GuideAuthorized Field Service Facility 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