Lincoln electric welding system user manual (39 pages)
Summary of Contents for Lincoln Electric INVERTEC POWER WAVE IM542-D
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INVERTEC POWER WAVE 450 ROBOTIC For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
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WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
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PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
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This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
TABLE OF CONTENTS 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...
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Limits Overlay...B-12 Setup Overlay...B-14 Wire Feeder Setup Description ...B-15 Overview of Welding Procedures ...B-16 FCAW and GMAW...B-16 Pulse Procedures ...B-16 Wave Control...B-16 Pulse Welding...B-18 Overload Protection...B-18 Thermal Protection ...B-18 Current Protection ...B-18 Robotic Interface ...Section C 1. INTERFACE DESCRIPTION...C-1 1.1 WELDING VOLTAGE ...C-1 1.2 WIRE BURNBACK FUNCTION ...C-1 1.3 WIRE STICK RESET FUNCTION ...C-1 1.4 COLD WIRE INCHING FUNCTION ...C-1...
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viii 3.1.5 WIRE STICK DETECT ...C-3 4. POWER WAVE CIRCUITS...C-3 4.1 VOLTAGE COMMAND...C-3 4.2 WIRE SPEED COMAND...C-3 4.3 TOUCH SENSE SIGNAL ...C-3 4.4 ARC DETECT ...C-4 4.5 GAS FAULT ...C-4 4.6 WATER FAULT...C-4 4.7 POWER FAULT...C-4 4.8 VOLTAGE FEEDBACK...C-4 4.9 CURRENT FEEDBACK ...C-4 4.10 WELD START ...C-4 4.11 GAS START ...C-4 4.12 TOUCH SENSE COMMAND...C-4...
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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...
Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Using filters on the air intake to prevent dirt from building up restricts air flow.
Failure to follow these instructions can cause immedi- ate failure of components within the welder. GROUND CONNECTIONS The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper ground- ing methods.
FIGURE A.3 – FRONTPANEL/BACK PANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPTACLE To reconnect your machine for the proper input volt- age, see the reconnect instructions on your input access door and: 1. Move the large input voltage switch to the proper position according to your input volt- age, and the labels near the switch.
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INSTALLATION POWER WAVE 450 ROBOTIC DIMENSIONS POWER WAVE 450...
POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT 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 INSTALLATION COMPONENTS DIAGRAM REQUIRED: • APPROPRIATE WORK CABLE SIZE AND LENGTH TO WORK •...
OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. •...
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QUICK START REFERENCE FOR USING THE PROCESS SELECTION OVERLAY Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference procedure to operate the Power Wave. NOTE: Selection of certain options may limit the selection of subsequent options.
GENERAL DESCRIPTION The INVERTEC Power Wave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses three-phase input power only. The Power Wave is designed to be used as a synergic welding system in conjunction with a wire feeder.
LCD display on the Power Wave shows the following: LINCOLN ELECTRIC This display is shown for a few seconds followed by another display that depends on the overlay placed on the machine. At this point, the machine is ready for operation.
The bar code allows the machine to identify the overlay. FIGURE B.2 – TYPICAL POWER WAVE OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9361-2 WELD FROM MEMORY INVERTEC POWER WAVE 350 WARNING...
OVERLAY TYPES Four types of overlays can be used with the Power Wave. 1. Process Overlays. These overlays are used to create, save and recall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power Wave at the factory.
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1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLAY ID...
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3. ELECTRODE CLASS UP/DOWN: Use the ELEC- TRODE CLASS UP or DOWN keys to select from the material types available for the selected process. Press the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4.
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10. RECALL FROM MEMORY KEY: This key is used to recall an existing procedure from memory. You can recall and use any of the previously created welding procedures that are stored in one of the eight memory locations. RECALL FROM MEMORY key appropriate MEMORY LOCATION NUMBER key.
1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
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3. PROGRAM LIST: The PROGRAM LIST block in the center of this overlay provides a convenient place to record a brief description of each welding procedure stored in memory. A “Dry Erase” mark- er should be used for this purpose. 4.
1. LCD DISPLAY WINDOW: Power up the machine with this overlay in place. When the Power Wave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC Version X.X This display is followed by: OVERLAY ID...
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Use the LIMIT UP and LIMIT DOWN keys to change the maximum wire feed speed to the desired value. Press the SET LIMIT key again. The new maximum and old minimum wire feed speeds will be dis- played. Use the LIMIT UP and LIMIT DOWN keys to change the minimum wire feed speed to the desired value.
OPERATION FIGURE B.7 – SETUP OVERLAY C COPYRIGHT 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA L9660 SETUP OVERLAY 5 WIRE FEEDER 1+/- POLARITY KEY 6 WIRE FEEDER 1 ELECTRODE SENSE LEAD KEY 7 WIRE FEEDER 1 WORK SENSE LEAD KEY 3.
When the “WATER COOLER PRESSURE” light turns on, release the key. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press this key to change the present voltage sensing polari- ty of wire feeder 1. The present polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY”...
OVERVIEW OF WELDING PROCEDURES FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES For each wire feed speed, a corresponding voltage is preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average volt- age for the procedure at the given wire feed speed. If the wire feed speed is changed on the wire feeder, the voltage automatically changes with it.
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OPERATION TABLE B.3 – ADJUSTBLE PARAMETERS Adjustable Parameters WFS Display Voltage Display Power Wave 450 Display (with GMAW Pulse, GMAW and FCAW Selection Overlay) TABLE B.4 – DISPLAYS OF THE POWER WAVE AND WIRE FEEDERS FOR DIFFERENT PROCESSES IN BOTH TRIGGER POSITIONS Power Wave 450 Trigger Position...
PULSE WELDING Some people have trouble getting used to the behavior of the pulsing arc. The parameters programmed into the Power Wave have been thoroughly tested for their ability to deliver a sound weld with good appearance. There are, however, a few things to keep in mind when pulse welding.
1. INTERFACE DESCRIPTION This interface is designed for a Power Wave 450 and a Fanuc robot using ArcTool software (V1.30P) with touch sensing and through arc tracking. The interface responds to all of the ArcTool welding inputs and out- puts except wire fault and wire stick alarm. All of the circuitry for touch sensing is internal to the Power Wave, no external power supply is required.
2.3 TOUCH SENSE SIGNAL This is an active low input to the robot controller which indicates that the welding electrode has touched the work piece. To start touch sensing the touch sensing command must be held low by the robot controller. Then the Power Wave mon- itors the current through the electrode to deter- mine if it is touching the work piece.
2.17 DUAL PROCEDURE SWITCH COM- MAND This is an active low output from the robot con- troller used to activate the dual procedure switch. When the Power Wave is running a dual proce- dure overlay this output is used to switch between procedures.
ting and clearing the miscellaneous output #4. ARC DETECT The arc detect signal is generated from the voltage and current signals on the control board. The arc detect cir- cuit is calibrated to detect a minimum arc of 15V and 30A.
FIGURE D.1 – WIRE FEEDER AND WATER COOLER CONNECTIONS 1 WIRE FEEDER CONNECTIONS (LOCATION) 2 WATER COOLER LINE (IN) 3 WATER COOLER LINE (OUT) 4 CIRCUIT BREAKER (WATER COOLER) 5 FILL SPOUT (WATER COOLER) WATER COOLER USAGE The Power Wave is equipped with an optional internal water cooler.
4. Check coolant level. Add more if required. Rear Panel of Power Wave Reservoir Screen Figure D.2 L9777 WIRE FEED UNIT DIMENSION PRINT 6.75 6.25 8.06 1.00 1.31 INLET GAS FITTING 1.44 TYP. INPUT CONNECTOR ACCESSORIES Do Not Use: Any prepacked welding industry coolant mixture, such as those offered by Miller, OKI, Bernhard, or Dynaflux.
MOUNTING THE WIRE FEED UNIT Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gear- box. See L9777 Dimension Print following, to find the size and location of the mounting holes. The gearbox assembly is electrically “hot”...
1) Release the incoming idle roll pressure arm, then press end of gun against a solid object that is elec- trically isolated from the welder output and press the gun trigger for several seconds. 2) If the wire “birdnests”, jams, or breaks at the drive roll, the idle roll pressure is too great.
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7) To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from the spindle. To Mount 10 to 44 lb (4.5-20kg) Spool (12”/300mm Diameter): spools, a K468 spindle adapter must be used.) REQUIRES INSTALLATION OF 2”...
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To Mount a 50-60lb (22.7-27.2kg) Coil: 1) To remove the wire reel from its shaft, grasp the spring loaded knob and pull it out. This straightens the knob so it seats into the shaft when released. Remove the reel. 2) Lay the reel flat on the floor, loosen the spinner nut and remove the cover plate.
Routine Maintenance of Wire Feed Unit WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground. •...
Gun Cable Connector Requirements to Permit Proper Connection to Wire Feed Units Style "A" Connector must be insulated in this area 1.00 (25.4) 2.00 1.25 (51.0) (31.7) Connector for 1/16 - 5/64” (1.6 - 2.0 mm) Wire Style "B" Connector for .023 - .052” (19.0 / 18.9 mm) Wire (For all other dimensions, See Diagram above).
MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following preventive maintenance at least...
MAINTENANCE FIGURE D.1 – RESISTOR LOCATIONS 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE GROUND 5. Locate two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine.
6. Locate the #9 and #12 terminals, identified by the “Discharge” labels, on each of the four Switch Boards. See Figure D.2. 7. Using insulated, needle nose-type jumper leads and insulated gloves, connect one jumper lead to one end of the resistor obtained in step 4. Connect the other jumper lead to the other end of the resistor.
PREVENTIVE MAINTENANCE Perform the following preventive maintenance proce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance record; a record tag attached to the machine works best. 1. Remove the hex head screws from the sides and top of the machine.
RECOMMENDED TOOLS FOR INSTAL- LATION OR SERVICE OF COOLER: • absorbent towels • alcohol wipe • 3 mm allen wrench (G3503 only) • socket wrench • 4 inch long minimum socket extension • 1/4, 5/16, and 3/8 hex standard depth sockets •...
• Do not discard old pump. Remove both fittings, Keep v-clamp, Seal old pump in a waterproof bag, Package into protective container, and Return to nearest Lincoln Electric FSS center. g. Install new pump and v-band clamp: • Do not apply any lubricant to pump’s drive coupling.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance. WARNING Step 3. CONSULT LOCAL AUTHORIZED FIELD...
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. TROUBLESHOOTING POSSIBLE AREAS OF...
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– fans run – circuit breaker (5-amp) repeatedly trips. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
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The fans run and the display is on. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
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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. TROUBLESHOOTING...
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NOT INITIALIZED” on power-up. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
The machine beeps without the keys being pressed. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
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Machine often “noodle welds” with a particular procedure. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. AMERICAN EXPRESS MasterCard AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45)
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● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
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● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
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• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...
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