Lincoln Electric INVERTEC POWER WAVE IM542-D manual

INVERTEC PO WER W A VE 450 ROBO TIC IM542-D October , 2001 For use with machines having Code Numbers: TM OPERA TOR’S MANUAL Safety Depends on Y ou 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. D[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ____________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durable flame-resistant material to protect your[...]

FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse bo x bef ore working on the equipment. 8.b . Install equipment in accordance with the U .S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U .S. National Elec[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our 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 P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circui[...]

Thank You f or selecting a QU ALITY product by Lincoln Electric. We w ant you to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to you! Read this Operators Man ual completely bef ore attempting to use this equipment. Sav e this manual and k eep it handy f or quick ref eren[...]

T ABLE OF CONTENTS vi vi Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Section A T echnical Spe[...]

vii vii Limits Overlay ................................................................................................................. ....B-12 Setup Overlay .................................................................................................................. ...B-14 Wire Feeder Setup Description .....................................[...]

viii viii 3.1.5 WIRE STICK DETECT ...........................................................................................C-3 4. POWER WA VE CIRCUITS .....................................................................................................C-3 4.1 VOL T AGE COMMAND ......................................................................[...]

ix ix Maintenance .......................................................................................................................... Section E Safety Precautions ......................................................................................................................E-1 Routine and Periodic Maintenance .........................[...]

PO WER W A VE 450 TECHNICAL SPECIFICA TIONS - POWER W A VE 450 INPUT - THREE PHASE 50/60 HZ. ONL Y Input V olta g es: 200 230 400 460 575 Input Currents @ 500A/40 VDC 87 76 44 38 32 @ 450A/38 VDC 75 65 38 32 28 RA TED OUTPUT Duty Cyc le Amps V olts at Rated Amperes 200 - 60% Duty Cycle 500 40 VDC 230/400/460 - 60% Duty Cycle 500 40 VDC 460/575 - 60[...]

Read this entire installation section before y ou start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T urn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. • Always connect the Power W [...]

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 gr ound- ing methods. S[...]

INST ALLA TION A-4 A-4 PO WER W A VE 450 2 3 1 FIGURE A.3 – FRONTP ANEL/BACK P ANEL 1 WORK TERMINAL 2 ELECTRODE TERMINAL 3 REMOTE CONTROL AMPHENOL RECEPT ACLE 4 WA TER COOLING FITTINGS (ON ACCESS P ANEL) 5 WIRE FEEDER CONNECTIONS (ON BACK P ANEL) 6 ELECTRODE TERMINAL T o r econnect your machine for the proper input volt- age, see the reconnect in[...]

INST ALLA TION A-5 A-5 PO WER W A VE 450 PO WER W A VE 450 R OBO TIC DIMENSIONS 18.76 19.50 15.50 35.82 A 16.08 29.49 32.26 35.00 38.82 M17793[...]

INST ALLA TION A-6 A-6 PO WER W A VE 450 PO WER W A VE 450 R OBO TIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIA GRAM POWER WAVE 450 ROBOTIC / SYNERGIC 7F DRIVE UNIT COMPONENTS DIAGRAM K680 K681 CONTROL TO WIRE DRIVE CABLES CUSTOMER MUST PROVIDE WIRE DEREELING METHOD SYNERGIC 7F WIRE DRIVE K679-1 (LOW SPEED) K679-2 (HIGH SPEED) DRIVE ROLLS CONSULT IM55[...]

OPERA TION B-1 B-1 PO WER W A VE 450 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS 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 gr ound. • Always[...]

QUICK ST AR T REFERENCE FOR USING THE PROCESS SELECTION OVERLA Y Read and understand the “Controls and Settings” and “Operating Overlays” sections of this manual before using the following Quick Start Reference pr ocedure to operate the Power W ave. NOTE: Selection of certain options may limit the selection of subsequent options. Step 1: Se[...]

GENERAL DESCRIPTION The INVERTEC Power W ave power source is a high performance, digitally controlled inverter welding power source capable of complex, high-speed wave- form control. It uses thr ee-phase input power only . The Power W ave is designed to be used as a synergic welding system in conjunction with a wire feeder . SYNERGIC WELDING The Po[...]

CONTROLS AND SETTINGS All operator controls and adjustments ar e located on the case front of the Power W ave. Refer to Figure B.1 and corresponding explanations. FIGURE B.1 – CASE FRONT CONTROLS CASE FRONT CONTR OLS Refer to Figure B.1 for the location of the following controls: 1. LCD DISPLA Y : Provides welding procedur e infor- mation and par[...]

OPERA TING OVERLA YS O VER VIEW The Power W ave is controlled by a panel of keys (key- pad) located on the front of the machine. The opera- tor can access controls by placing an overlay over the keys. An OVERLA Y is a special plastic sheet with a number of keys and symbols printed on one side and a bar code printed on the other . See Figure B.2. Th[...]

O VERLA Y TYPES Four types of overlays can be used with the Power W ave. 1. Process Overlays. These overlays are used to create, save and r ecall specific welding proce- dures by selecting and adjusting the various weld- ing settings that have been programmed into the Power W ave at the factory . 2. W eld From Memory Overlays . These overlays (also[...]

1. LCD DISPLA Y WINDOW : Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears on the display for a few seconds: LINCOLN ELECTRIC VERSION X.X This display is followed by: OVERLA Y ID NUMBER = 1 A welding procedur e is made up of seven compo- nents: process, material type, wir e diameter , [...]

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. Pr ess the ELECTRODE CLASS UP or DOWN key until the desired material type is dis- played. 4. ELECTRODE SIZE UP/DOWN: Use the ELEC- TRODE SIZE UP or DOWN keys to select from the wire diameters available for the [...]

10. RECALL FROM MEMOR Y KEY : This key is used to recall an existing pr ocedure fr om memory . Y ou can recall and use any of the pr eviously created welding procedur es that are stor ed in one of the eight memory locations. Simply press the RECALL FROM MEMOR Y key and then the appropriate MEMOR Y LOCA TION NUMBER key . If you press the RECALL FROM[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 10 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. ME[...]

3. PROGRAM LIST : The PROGRAM LIST block in the center of this overlay provides a convenient place to recor d a brief description of each welding procedur e stored in memory . A “Dry Erase” mark- er should be used for this purpose. 4. DISPLA Y RECALL KEY : T o view other information about the selected procedur e, press the DISPLA Y RECALL key .[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 4 This message is then replaced by the following message: SELECT A MEMOR Y LOCA TION 2. REC[...]

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. Press the SET LIMIT key . The present maximum and minim[...]

1. LCD DISPLA Y WINDOW: Power up the machine with this overlay in place. When the Power W ave is turned on, the following message appears in the display window for a few seconds: LINCOLN ELECTRIC V ersion X.X This display is followed by: OVERLA Y ID NUMBER = 0 This message is then replaced by the following message: POWER WA VE SETUP 2. WA TER COOLE[...]

When the “WA TER 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 pr esent polarity of wire feeder 1 is indicated by the “WIRE FEEDER 1+ POLARITY” light. If wire feeder 1 is set for positive voltage sensing polarity , [...]

O VER VIEW OF WELDING PR OCEDURES FLUX CORED ARC WELDING (FCA W) AND GMA W PROCEDURES F or each wire feed speed, a corresponding v oltage is preprogrammed into the machine b y welding e xper ts. This preprogrammed v oltage is the best a verage v olt- age f or the procedure at the given wire f eed speed. If the wire f eed speed is changed on the wir[...]

OPERA TION B-17 B-17 PO WER W A VE 450 T rigger Position Pulse GMAW FCAW WFS and WFS and Open Ar c Length T rim Preset V oltage WFS, WFS, Actual Arc Actual Arc Closed V oltage, V oltage, Actual Arc Actual Arc Current Curr ent Power W ave 450 Adjustable Pulse GMAW Parameters FCAW Wire Feed Wire Feed WFS Display Speed Speed Arc Length Preset V oltage[...]

PULSE WELDING Some people hav e trouble getting used to the beha vior of the pulsing arc. The parameters progr ammed into the P ower W av e ha ve been thoroughly tested f or their ability to deliv er a sound weld with good appearance. There are, ho we ver , a fe w things to keep in mind when pulse welding. Spatter levels are often very low with the[...]

1. INTERF A CE DESCRIPTION This interf ace is designed for a P ower W av e 450 and a F anuc robot using ArcT ool software (V1.30P) with touch sensing and through arc trac king. The interf ace responds to all of the ArcT ool welding inputs and out- puts e xcept wire fault and wire stic k alar m. All of the circuitr y f or touch sensing is inter nal [...]

2.3 T OUCH SENSE SIGNAL This is an activ e low input to the robot controller which indicates that the welding electrode has touched the work piece. T o star t touch sensing the touch sensing command must be held lo w by the robot controller . Then the P ower Wa v e mon- itors the current through the electrode to deter- mine if it is touching the wo[...]

2.17 DU AL PR OCEDURE SWITCH COM- MAND This is an activ e low output from the robot con- troller used to activate the dual procedure s witch. When the P ower W av e is running a dual proce- dure ov erlay this output is used to s witch between procedures. If the output is held high by the robot controller then procedure A is activ e, and if the outp[...]

ting and clearing the miscellaneous output #4. 4.4 ARC DETECT The arc detect signal is generated from the v oltage and current signals on the control board. The arc detect cir- cuit is calibrated to detect a minimum arc of 15V and 30A. The signal is isolated from the control ground and tied to the robot controller welding input 2 (WDI2). 4.5 GAS F [...]

5. R OBO T CONTR OLLER SETUP 5.1 WELD SYSTEM SETUP MONIT ORING FUNCTIONS 1 Arc loss ENABLED 2 Gas shor tage DISABLED 3 Wire shor tage DISABLED 4 Wire stick ENABLED 5 P ower supply f ailure ENABLED 6 Coolant shor tage ENABLED WELD REST ART FUNCTION 7 Retur n to path DISABLED 8 Overlap distance 0mm 9 Retur n to path speed 200mm/s SCRA TCH ST AR T FUN[...]

ROBOTIC INTERF ACE C-6 C-6 PO WER W A VE 450 6. CONNECTIONS 6.2 ARCT OOL WELDING INPUTS AND OUTPUTS J101-1 +Serial loop CTRL J27-1 J101-2 High speed sense 1 P83-K J101-3 High speed sense 2 P83-L J101-4 -Serial loop CTRL J27-4 J104-1 V oltage signal CTRL J21-4 J104-2 Current signal CTRL J21-7 J104-3 Water PWR D .K. J16-4 J104-4 +output signal SNUB J[...]

W A TER COOLER USA GE The P ower W av e is equipped with an optional internal water cooler . We recommend using the water cooler when welding abov e 300 amps with argon blends on a regular basis. The gun heating from pulsing abov e 300 amps av erage current is often e xcessiv e and leads to reduced consumable lif e, reduced gun life , and opera- to[...]

ACCESSORIES D-2 D-2 PO WER W A VE 450 1.00 6.25 6.75 4.67 REMOTE A 6.67 7.16 7.50 1.72 3.18 .25 .25 .281 7.00 11.25 1.44 TYP. OUTLET 1.31 .81 1.00 8.06 .87 INLET INPUT 3.36 6.21 GAS FITTING MOUNTING WIRE FEED UNIT) (10 HOLES FOR CONNECTOR CLOSED TRIGGER CONNECTOR CONNECTOR GAS FITTING DIRECTION WIRE FEED TOP VIEW CLEARANCE ENVELOPE OF QUICK RELEASE[...]

ACCESSORIES D-3 D-3 PO WER W A VE 450 MOUNTING THE WIRE FEED UNIT Mount the wire f eed unit by means of the insulated mounting brac ket attached to the bottom of the gear- bo x. See L9777 Dimension Pr int f ollowing, to find the size and location of the mounting holes . The gearbo x assembly is electrically “ hot ” when the gun or nozzle is ene[...]

ACCESSORIES D-4 D-4 PO WER W A VE 450 Standard 4-Roll Kits (KP655 and KP656) 1) T urn off welding power source . 2) Release both quick release le vers b y sliding the le vers side wa ys into the open positions. 3) Remov e clamping screw & clamping collar from the drive shaft closest to the incoming side of the f eeder . 4) Install drive roll on[...]

ACCESSORIES D-5 D-5 PO WER W A VE 450 Idle Roll Pressure Setting The idle roll pressure is set at the f actor y , back ed out three turns from full pressure on 4-roll feeders. This is an appro ximate setting. F or small wire sizes and alu- minum wire up to 9 or 10 turns out may be required to minimize “ birdnesting ” . The optimum idle roll pre[...]

ACCESSORIES D-6 D-6 PO WER W A VE 450 7) T o remov e 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 remov e adapter from the spindle. T o Mount 10 to 44 lb (4.5-20kg) Spool (12 ” /300mm Diameter): (For 8 ” (200mm) spools, a K468 spindle adapter [...]

ACCESSORIES D-7 D-7 PO WER W A VE 450 4) Tighten the cover as m uch as possible b y hand. DO NO T hammer on the spinner nut ar ms. 5) Cut and remo ve only the tie wire holding the free end of the coil. Inser t the free end into one of the holes in the cov er and secure it by bending it bac k. Cut and remov e the remaining tie wires. Alwa ys be sure[...]

ACCESSORIES D-8 D-8 PO WER W A VE 450 Routine Maintenance of Wire Feed Unit Drive Rolls and Guide T ubes After f eeding ev er y coil of wire, inspect the driv e roll section. Clean it as necessary . Do not use a solvent f or cleaning the idle roll because it may w ash the lubri- cant out of the bearing. The driver roll and guide tubes are stamped w[...]

ACCESSORIES D-9 D-9 PO WER W A VE 450 Gun Cable Connector Requirements to P ermit Pr oper Connection to Wire Feed Units Connector must be insulated in this area Style "A" 1.25 max (31.7) 2.00 (51.0) 1.25 (31.7) 1.00 (25.4) .252 (6.40) .260 (6.60) .295 (7.49) .290 (7.36) "A" DIA HOLE .062R (1.5R) .03 x 45 ° (.76 x 45 ° ) .749 ([...]

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • T ur n 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 once every six[...]

5. Locate two sets of two r esistors on the left side of the machine and three sets of two r esistors on the right side of the machine. See Figure D.1. Do not touch the resistors or any other internal machine component. Using a DC voltmeter , check for any DC voltage that may be present acr oss the termi- nals of each resistor and fr om each resist[...]

6. Locate the #9 and #12 terminals, identified by the “Dischar ge” labels, on each of the four Switch Boards. See Figur e 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 . 8. Car eful[...]

PREVENTIVE MAINTENANCE Perform the following preventive maintenance pr oce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance r ecor d; a r ecord tag attached to the machine works best. 1. Remove the hex head scr ews from the sides and top of the machine. Remove the handle bar and the machine wrap-around c[...]

MAINTENANCE E-5 E-5 PO WER W A VE 450 RECOMMENDED T OOLS FOR INST AL- LA TION OR SER VICE OF COOLER: • absorbent towels • alcohol wipe • 3 mm allen wrench (G3503 only) • sock et wrench • 4 inch long minimum soc ket e xtension • 1/4, 5/16, and 3/8 he x standard depth sock ets • 5/32 allen sock et • medium blade slotted scre wdriver ?[...]

MAINTENANCE E-6 E-6 G3503-[ ] COOLER PERIODIC MAINTENANCE 1. Preparation: • Alwa ys s witch off the P ower Wa ve machine po wer . • Always disconnect the P ower Wa ve machine from ser vice input power . • Do not remove the pump relief v alve ’ s 3/4 in. acor n he x nut or attempt to adjust the relief valv e setting. 2. Remove the G3503-[ ] [...]

MAINTENANCE E-7 E-7 PO WER W A VE 450 FIGURE D.4 – GENERAL COMPONENT LOCA TIONS 1 DISPLA Y BOARD (BACK OF P ANEL) 2 POWER SWITCH 3 MAIN TRANSFORMER 4 AUXILIAR Y TRANSFORMER 5 INPUT RECTIFIER 6 HEA T SINK FINS 7 OUTPUT TERMINALS 8 OVERLA Y BAR CODE SENSORS 9 TERMINAL STRIP (LOCA TION) 9 4 6 3 7 2 8 1 5[...]

TROUBLESHOOTING F-1 F-1 PO WER W A VE 450 HOW TO USE TROUBLESHOOTING GUIDE This T roubleshooting Guide is designed to be used b y the machine Owner/Operator . Unauthor ized repairs per-f or med on this equipment may result in danger to the technician and machine oper ator and will inv alidate your f actor y warranty . For y our saf ety , please obs[...]

Major physical or electrical dam- age is evident when the sheet metal cover(s) are r emoved. Machine is dead – no output – no fans – no displays. Machine has no output – fans are running – display is on – a “click- ing” sound is heard coming fr om the machine. 1. Contact your local authorized Lincoln Electric Field Service Facility [...]

Machine has no output – no f ans – no displa y . Main input fuses are open, indicating e xcessive input current dra w . Machine has no output – no dis- pla y – fans run. Machine has no output – no dis- pla y – fans run – circuit breaker (5-amp) repeatedly trips. 1. Chec k for proper input v oltage connections. 2. Mak e cer tain the re[...]

Machine has no output – fans run – display is on. Machine regularly overheats – yel- low light (LED) on the front panel glows, indicating a thermal over- load. The fans run and the display is on. 1. Make sure that the machine was powered up with a pr operly installed overlay . (With no overlay on the machine or an invalid over- lay , the mach[...]

The voltage and/or wire f eed speed will not adjust to user satis- f action. The voltage and/or wire f eed speed can be adjusted on the wire f eeder but the changes are not shown on the P ower Wa v e. The Dual Procedure ov erlay is installed. The user cannot change from procedure “ A ” to procedure “ B, ” or vice versa. The displa y can not[...]

Machine does not respond to ke ys being pressed, or the machine has improper displa ys. Machine displa y reads “ Error Inv alid Ov er la y , ” or it displays an incorrect ov erlay ID number on pow er-up. Machine displa ys “ ERR OR: S.L. NO T INITIALIZED ” on pow er-up. 1. Each time an o verla y is changed make certain that the machine is po[...]

The Beeper (Piezoelectric Buzzer) cannot be heard – machine operating normally . The welding parameters that w ere sav ed in memor y are diff erent when recalled. The water cooler does not turn on. The machine beeps without the ke ys being pressed. 1. Bac kground noise ma y be too loud for user to hear beeper . 1. Mak e cer tain that a remote con[...]

Machine loses output while weld- ing. F ans and display are function- ing properly . F or no apparent reason the weld characteristics hav e changed. Machine often “ noodle welds ” with a par ticular procedure. 1. Chec k for proper input v oltages (per machine nameplate). 2. Chec k for balanced three-phase input supply voltage . 3. Chec k electr[...]

Now A vailab le ...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of previous editions pub lished since 1933, the Procedure Handbook is considered by man y to be the “ Bible ” of the arc welding industry . This printing will go fast so don ’ t dela y . Place your order now using the coupon belo w . The hardboun[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P or tuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P AR[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P or tuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fum[...]

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