Power Wave 450 Robotic | Lincoln Electric IM542-D instruction

A-6

A-6

INSTALLATION

POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT

COMPONENTS DIAGRAM

POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT

COMPONENTS DIAGRAM

POWER WAVE 450 ROBOTIC

K1447-1 (W/O

WATER COOLER)

K1447-2 (W/

WATER COOLER)

TO ROBOT

CONTROLLER

TO WORK

SYNERGIC 7F WIRE DRIVE

K679-1 (LOW SPEED)

K679-2 (HIGH SPEED)

CONSULT IM559 FOR

LATEST INFORMATION

DRIVE ROLLS

CONSULT IM559 FOR

LATEST INFORMATION

CUSTOMER MUST PROVIDE

WIRE DEREELING METHOD

K680

K681

CONTROL TO WIRE DRIVE CABLES

REQUIRED:

•APPROPRIATE WORK CABLE SIZE AND LENGTH

•APPROPRIATE MAGNUM GUN AND CABLE ASSEMBLY AND ADAPTER IF REQUIRED.

•WIRE FEEDER CONTROLS ARE LOCATED WITHIN THE POWER WAVE 450 ROBOTIC POWER SOURCE.

POWER WAVE 450

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Lincoln Electric IM542-D manual Power Wave 450 Robotic

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 E Section FSection G Series Installation Technical Specifications Power WavePower Wave Awgiec Safety Precautions High Frequency PrecautionsSelect Suitable Location Input Connections Input Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Ground Connections Wire Feeder Connections Output ConnectionsWork and Electrode Cable 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 Wire Feeder Setup Description +/- Polarity KEYPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing Options Overview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures Wave Control Gmaw Table B.3 Adjustble ParametersFcaw Pulse Welding Overload ProtectionThermal Protection Current Protection Robotic Interface Robot Signal DescriptionsInterface Description Touch Sense Signal GAS FaultWire Fault Water Fault Power Wave Circuits Dual Procedure Switch COM- MandWire Stick Detect Robot Controller Electrical Characteristics Touch Sense Command ARC Detect GAS FaultWater Fault Power Fault Dual Procedure Switch Command Robot Controller Setup Weld System SetupWeld Equipment Setup Touch Sensing Setup Power Wave Interface Board ConnectionsArctool Welding Inputs and Outputs Miscellaneous Connections Accessories Water Cooler UsageRecommended Coolants 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 Procedure to Install Drive Roll and Guide Tubes Steel Wire Sizes RollAluminum Wire Sizes 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 Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils Avoiding Wire Feeding ProblemsPeriodic Maintenance of Wire Drive Unit 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic Course Precaucion Aviso DE