Power-up Inspect the overlay bar code | Lincoln Electric IM542-D

F-6			F-6
		TROUBLESHOOTING
	TROUBLESHOOTING GUIDE		Observe Safety Guidelines
			detailed in the beginning of this manual.
	PROBLEMS	POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)	MISADJUSTMENT(S)	COURSE OF ACTION

		OUTPUT PROBLEMS
	Machine does not respond to keys	1. Each time an overlay is
	being pressed, or the machine has	changed make certain that the
	improper displays.	machine is powered-up with the
		new overlay in place.

2.Make certain that the correct overlay ID number is displayed on power-up. Refer to the Operation Section of this manual.

3.In some cases, some of the keys on the overlay may be locked out. Refer to the Operation Section of this manual for the overlay descriptions.

	Machine display reads “Error		If all recommended possible areas
	Machine display reads “Error	1. Make certain the overlay is	of misadjustments have been
	Invalid Overlay,” or it displays an	1. Make certain the overlay is	of misadjustments have been
	Invalid Overlay,” or it displays an	installed properly.	checked and the problem per-
	incorrect overlay ID number on	installed properly.	checked and the problem per-
	incorrect overlay ID number on		sists, contact your local Lincoln
	power-up.	2. Inspect the overlay bar code	sists, contact your local Lincoln
	power-up.	2. Inspect the overlay bar code	Authorized Field Service Facility.
		sensors on the front panel (Fig 17	Authorized Field Service Facility.
		sensors on the front panel (Fig 17
		Item 8). If they are dirty, blow them
		out with low pressure air and clean
		with soft cloth.
		3. Inspect for damage to the Bar
		Code(s) on the back of the overlay.

	1. Contact your local Lincoln
Machine displays “ERROR: S.L.	authorized Field Service Facility
NOT INITIALIZED” on power-up.	for Technical assistance.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE 450

Image 62

Lincoln Electric IM542-D manual Power-up Inspect the overlay bar code

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 Operating Instructions Safety InstructionsOperation Select your process information Save process information if desired General Description Controls and Settings Case Front Controls Overview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay 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 SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers 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 Fcaw Table B.3 Adjustble ParametersGmaw Thermal Protection Pulse WeldingOverload Protection Current Protection Interface Description Robot Signal DescriptionsRobotic Interface 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 Type L9777 Wire Feed Unit Dimension PrintFor the Latest 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 Feeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil 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 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 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 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 Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic Course Precaucion Aviso DE