Table of Contents | Lincoln Electric IM542-D specification

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	TABLE OF CONTENTS
		Page
	Safety	i-iv

	Installation	Section A
	Technical Specifications	A-1
	Safety Precautions	A-2
	Select Suitable Location	A-2
	Stacking	A-2
	Tilting	A-2
	Lifting	A-2
	High Frequency Precautions	A-2
	Input Connections	A-2
	Ground Connections	A-3
	Input Power Connections	A-3
	Input Fuse and Supply Wire Connections	A-3
	Input Voltage Reconnect Procedure	A-3
	Output Connections	A-4
	Work and Electrode Cable Connections	A-4
	Water Cooler Connections	A-4
	Wire Feeder Connections	A-4
	Dimension Print	A-5
	Component Diagram	A-6

	Operation	Section B
	Safety Instructions	B-1
	Quick Start Reference for Process Selection Overlay	B-2
	General Description	B-3
	Synergic Welding	B-3
	Recommended Processes	B-3
	Operational Features and Controls	B-3
	Design Features and Advantages	B-3
	Welding Capability	B-3
	Limitations	B-3
	Controls and Settings	B-4
	Case Front Controls	B-4
	Operating Overlays	B-5
	Overview	B-5
	Installing an Overlay	B-5
	Overlay Types	B-6
	Pulse, GMAW, FCAW, Stick Overlay	B-7
	Robotic Interface, Weld from Memory, Dual Procedure Overlay	B-10

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Lincoln Electric IM542-D manual Table of Contents

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 Operation Safety InstructionsOperating Instructions Save process information if desired Select your process information General Description Case Front Controls Controls and Settings Operating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys 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 Gmaw Table B.3 Adjustble ParametersFcaw Current Protection Pulse WeldingOverload Protection Thermal Protection Robotic Interface Robot Signal DescriptionsInterface Description 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 For the Latest L9777 Wire Feed Unit Dimension PrintType 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 To Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode 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 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 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 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 Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training? Precaucion Aviso DE