Lincoln Electric IM542-D Manual do Utilizador

INVERTEC POWER WAVE 450 ROBOTICIM542-DOctober, 2001For use with machines having Code Numbers:TMOPERATOR’S MANUALSafety Depends on YouLincoln arc we

ix ixMaintenance...Section ESaf

POWER WAVE 450TECHNICAL SPECIFICATIONS - POWER WAVE 450INPUT - THREE PHASE 50/60 HZ. ONLYInput Voltages: 200 230 400 460 575Input Currents@ 500A/40 VD

Read this entire installation section before youstart installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qualified personnel shouldperform

Failure to follow these instructions can cause immedi-ate failure of components within the welder.GROUND CONNECTIONSThe frame of the welder must be gr

INSTALLATIONA-4 A-4POWER WAVE 450231FIGURE A.3 – FRONTPANEL/BACK PANEL1 WORK TERMINAL2 ELECTRODE TERMINAL3 REMOTE CONTROL AMPHENOL RECEPTACLE4 WAT

INSTALLATIONA-5 A-5POWER WAVE 450POWER WAVE 450 ROBOTIC DIMENSIONS18.7619.5015.5035.82A16.0829.4932.2635.0038.82M17793

INSTALLATIONA-6 A-6POWER WAVE 450POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNITCOMPONENTS DIAGRAMPOWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNITCOMPO

OPERATIONB-1 B-1POWER WAVE 450OPERATING INSTRUCTIONSRead and understand this entire section of operatinginstructions before operating the machine.SAFE

QUICK START REFERENCE FORUSING THE PROCESS SELECTIONOVERLAYRead and understand the “Controls and Settings” and“Operating Overlays” sections of this ma

GENERAL DESCRIPTIONThe INVERTEC Power Wave power source is a highperformance, digitally controlled inverter weldingpower source capable of complex, hi

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

CONTROLS AND SETTINGSAll operator controls and adjustments are located onthe case front of the Power Wave. Refer to Figure B.1and corresponding expla

OPERATING OVERLAYSOVERVIEWThe Power Wave is controlled by a panel of keys (key-pad) located on the front of the machine. The opera-tor can access con

OVERLAY TYPES Four types of overlays can be used with the PowerWave.1. Process Overlays. These overlays are used tocreate, save and recall specific we

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears onthe display f

3. ELECTRODE CLASS UP/DOWN: Use the ELEC-TRODE CLASS UP or DOWN keys to select fromthe material types available for the selectedprocess. Press the EL

10. RECALL FROM MEMORY KEY: This key is usedto recall an existing procedure from memory. Youcan recall and use any of the previously createdwelding p

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

3. PROGRAM LIST: The PROGRAM LIST block inthe center of this overlay provides a convenientplace to record a brief description of each weldingprocedure

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Wave isturned on, the following message appears in thedisplay w

Use the LIMIT UP and LIMIT DOWN keys tochange the maximum wire feed speed to thedesired value.Press the SET LIMIT key again. The new maximumand old mi

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

1. LCD DISPLAY WINDOW: Power up the machinewith this overlay in place. When the Power Waveis turned on, the following message appears in thedisplay w

When the “WATER COOLER PRESSURE” lightturns on, release the key. 5. WIRE FEEDER 1 +/- POLARITY KEY: Press thiskey to change the present voltage sensin

OVERVIEW OF WELDING PROCEDURESFLUX CORED ARC WELDING (FCAW) ANDGMAW PROCEDURESFor each wire feed speed, a corresponding voltage ispreprogrammed into t

OPERATIONB-17 B-17POWER WAVE 450TriggerPosition Pulse GMAWFCAWWFS and WFS andOpen Arc Length Trim Preset VoltageWFS, WFS,Actual Arc Actual ArcClosed V

PULSE WELDINGSome people have trouble getting used to the behaviorof the pulsing arc. The parameters programmed intothe Power Wave have been thoroughl

1. INTERFACE DESCRIPTIONThis interface is designed for a Power Wave 450 and aFanuc robot using ArcTool software (V1.30P) withtouch sensing and throug

2.3 TOUCH SENSE SIGNALThis is an active low input to the robot controllerwhich indicates that the welding electrode hastouched the work piece. To sta

2.17 DUAL PROCEDURE SWITCH COM-MANDThis is an active low output from the robot con-troller used to activate the dual procedure switch.When the Power W

ting and clearing the miscellaneous output #4.4.4 ARC DETECTThe arc detect signal is generated from the voltage andcurrent signals on the control boar

5. ROBOT CONTROLLER SETUP5.1 WELD SYSTEM SETUPMONITORING FUNCTIONS1 Arc loss ENABLED2 Gas shortage DISABLED3 Wire shortage DISABLED4 Wire stick ENABLE

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

ROBOTIC INTERFACEC-6 C-6POWER WAVE 4506. CONNECTIONS6.2 ARCTOOL WELDING INPUTS ANDOUTPUTSJ101-1 +Serial loop CTRL J27-1J101-2 High speed sense 1 P83-K

WATER COOLER USAGEThe Power Wave is equipped with an optional internalwater cooler. We recommend using the water coolerwhen welding above 300 amps wit

ACCESSORIESD-2 D-2POWER WAVE 4501.006.256.754.67REMOTEA6.677.167.501.723.18.25.25.2817.0011.251.44 TYP.OUTLET1.31.811.008.06.87INLETINPUT3.366.21GAS F

ACCESSORIESD-3 D-3POWER WAVE 450MOUNTING THE WIRE FEED UNITMount the wire feed unit by means of the insulatedmounting bracket attached to the bottom o

ACCESSORIESD-4 D-4POWER WAVE 450Standard 4-Roll Kits (KP655 and KP656)1) Turn off welding power source.2) Release both quick release levers by slidi

ACCESSORIESD-5 D-5POWER WAVE 450Idle Roll Pressure SettingThe idle roll pressure is set at the factory, backed outthree turns from full pressure on 4-

ACCESSORIESD-6 D-6POWER WAVE 4507) To remove Readi-Reel from Adapter, depressretaining spring tab with thumb while pulling theReadi-Reel cage from th

ACCESSORIESD-7 D-7POWER WAVE 4504) Tighten the cover as much as possible by hand.DO NOT hammer on the spinner nut arms.5) Cut and remove only the ti

ACCESSORIESD-8 D-8POWER WAVE 450Routine Maintenance of Wire FeedUnitDrive Rolls and Guide TubesAfter feeding every coil of wire, inspect the drive rol

ACCESSORIESD-9 D-9POWER WAVE 450Gun Cable Connector Requirementsto Permit Proper Connection to WireFeed UnitsConnector must beinsulated in this areaSt

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.• Only Qualified personnel shouldperform this maintenance.• Turn the input power OFF at thedisconnect s

5. Locate two sets of two resistors on the left side ofthe machine and three sets of two resistors on theright side of the machine. See Figure D.1.

6. Locate the #9 and #12 terminals, identified by the“Discharge” labels, on each of the four SwitchBoards. See Figure D.2.7. Using insulated, needle

PREVENTIVE MAINTENANCEPerform the following preventive maintenance proce-dures at least once every six months. It is good prac-tice to keep a prevent

MAINTENANCEE-5 E-5POWER WAVE 450RECOMMENDED TOOLS FOR INSTAL-LATION OR SERVICE OF COOLER:• absorbent towels• alcohol wipe• 3 mm allen wrench (G3503 on

MAINTENANCEE-6 E-6G3503-[ ] COOLER PERIODIC MAINTENANCE1. Preparation:• Always switch off the Power Wave machine power.• Always disconnect the Power W

MAINTENANCEE-7 E-7POWER WAVE 450FIGURE D.4 – GENERAL COMPONENT LOCATIONS1 DISPLAY BOARD (BACK OF PANEL)2 POWER SWITCH3 MAIN TRANSFORMER4 AUXILIARY

TROUBLESHOOTINGF-1 F-1POWER WAVE 450HOW TO USE TROUBLESHOOTING GUIDEThis Troubleshooting Guide is designed to be used by the machine Owner/Operator. U

Major physical or electrical dam-age is evident when the sheetmetal cover(s) are removed.Machine is dead – no output – nofans – no displays.Machine ha

Machine has no output – no fans –no display. Main input fuses areopen, indicating excessive inputcurrent draw.Machine has no output – no dis-play – fa

Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much p

Machine has no output – fans run– display is on.Machine regularly overheats – yel-low light (LED) on the front panelglows, indicating a thermal over-l

The voltage and/or wire feedspeed will not adjust to user satis-faction.The voltage and/or wire feedspeed can be adjusted on the wirefeeder but the ch

Machine does not respond to keysbeing pressed, or the machine hasimproper displays.Machine display reads “ErrorInvalid Overlay,” or it displays aninco

The Beeper (Piezoelectric Buzzer) cannot beheard – machine operating normally.The welding parameters that weresaved in memory are differentwhen recall

Machine loses output while weld-ing. Fans and display are function-ing properly.For no apparent reason the weldcharacteristics have changed.Machine of

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TABLE OF CONTENTSvi viPageSafety...

vii viiLimits Overlay........B-12Setup Ov

viii viii3.1.5 WIRE STICK DETECT.......................C-34. POWER WAVE CIRCUITS..