Lincoln Electric POWER WAVE 11124 Operator'S Manual Download Page 10 | Manualshive

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TABLE OF CONTENTS

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Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...........................................................................E-2 thru E-11
Using the Status LED to Troubleshoot System Problem .....................................E-12
Error Codes................................................................................................E-13, E-14

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Wiring Diagrams and Dimension Print ..........................................................Section F

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Parts List.................................................................................................................P-509

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Summary of Contents for POWER WAVE 11124

Page 1: ...pends 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 p...

Page 2: ...WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of...

Page 3: ...ooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders...

Page 4: ...adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent ha...

Page 5: ...opri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pa...

Page 6: ...v SAFETY v...

Page 7: ...vi SAFETY vi...

Page 8: ...pecially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the f...

Page 9: ...______________________________________________ Operation Section B Safety Precautions Definition of Welding Modes B 1 Graphic Symbols B 2 Product Summary Recommended Process Process and Equipment Limi...

Page 10: ...D to Troubleshoot System Problem E 12 Error Codes E 13 E 14 ________________________________________________________________________ Wiring Diagrams and Dimension Print Section F _____________________...

Page 11: ...C AT 10 AMPS 115 VAC AT 10 AMPS INPUT CURRENT AMPS K2344 1 K2344 2 82 79 68 69 62 62 54 55 IDLE POWER WATTS 225 POWER FACTOR RATED OUTPUT 95 EFFICIENCY RATED OUTPUT 86 OUTPUT CONDITIONS 1000A 44V 100...

Page 12: ...uipment Turn off the input power to any other equip ment connected to the welding sys tem at the disconnect switch or fuse box before working on the equip ment Do not touch electrically hot parts Alwa...

Page 13: ...d line voltage the welder will not come on and the two circuit breakers in the reconnect area will open If this occurs turn off the input voltage properly connect the aux iliary lead reset the breaker...

Page 14: ...ractical range being 10 to 100 hertz It can also control the phase angle between arcs to reduce the effects of welding related issues such as Arc Blow The arc to arc phase relationship is determined b...

Page 15: ...c PF 10A Controller Triple Arc 1 Lead Arc to System Interface Programmable Logic Controller DeviceNet compatible DeviceNet Cables Tees and Terminators 5 pin sealed mini style form a trunk style networ...

Page 16: ...acket uses mounting holes reserved for K299 Wire Reel Assembly see Wire Reel Mounting options for additional information Horizontal Lift Adjuster provides 2 51mm crank adjustment of horizontal head po...

Page 17: ...lectrode Cable s K1785 XX Wire Feeder Control Cable K1543 XX Arclink Control Cable Work Sense Lead 21 Electrode Sense Lead 67 67 Lead 21 Lead 14 Pin Connector Flux Hopper Connection Travel Carriage Co...

Page 18: ...Wire Drive 1 Connect K1543 xx ArcLink Control Cable 5 pin between Power Wave and PF10A 1 Configure Install sense leads Connect Install welding cables per recommended Output Cable Guidelines Open all...

Page 19: ...XX Wire Feeder Control Cables K1795 XX Cables Electrode Cables Arc link 5 Pin Wire Feeder 14 Pin K2282 1 K2362 1 Head K231 XXX WorkPiece 14 Pin Connector Work Studs Electrode Studs Arclink Output Work...

Page 20: ...tween Power Wave 2 and the PF10A Controller for ARC 2 1 Connect K1795 xx System Control Cables 22 pin between each Power Wave and the System Interface 2 Configure Install sense leads Connect Install w...

Page 21: ...ler 67 Lead 21 Lead 14 Pin Connector Work Cables Work Piece Work Sense Leads 21 E lectrode Cables Refer to Output Cable Guidelines for recommended cable size Head K231 XXX DeviceNet Cable Network K179...

Page 22: ...RC formerly PHASE outputs 2 Connect the System Interface and each power source to the PLC via the DeviceNet network 1 Configure Install sense leads Connect Install welding cables per recommended Outpu...

Page 23: ...12 Input S13 Output Connect to optional K2282 1 System Interface for Synchronized Multiple Arc Applications Ethernet Note Ethernet connectivity allows machines to share critical parameter information...

Page 24: ...rc system the System Interface must connected to the PLC via the DeviceNet network It must also be connected to the ARC 1 Master power source via a K1543 xx ArcLink Control Cable 5 pin Connect K1795 x...

Page 25: ...late on the lower left side For convenience the cable can be routed down through the two holes in the left cable tray before being connected to the output terminals Connect the other end of the electr...

Page 26: ...g outputs may occur Electrode Voltage Sensing The remote ELECTRODE sense lead 67 is built into the wire feeder control cable K1785 and accessible at the wire drive It should always connected to the wi...

Page 27: ...mation see the Work Voltage Sensing section of this document VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS Special care must be taken when more than one arc is welding simultaneously on a si...

Page 28: ...l applications connect all work leads on one side of the weld joint and all of the work volt age sense leads on the opposite side such that they are out of the current path POWER SOURCE 2 POWER SOURCE...

Page 29: ...In a tandem or multi arc system each arc requires its own dedicated Power Feed 10A PF 10A The 5 pin ArcLink control cable connects the power source to the PF 10A If there is more than one power source...

Page 30: ...5E cat 6 or stranded cable is not recommended For best results route Ethernet cables away from weld cables wire drive control cables or any other current carrying device that can create a fluctuating...

Page 31: ...3 On later machines pin 12 has been redefined as a gear ratio selection input See Setting the Wire Drive Gear Ratio for further information FIGURE A 3 D E F 1 2 3 4 5 6 7 8 9 10 11 12 G H I A B C 15 V...

Page 32: ...r Slave Output Optional System Interface S12 S13 ARC1 ARC2 ARC3 ARC4 A Reserved for future use Reserved for future use B Reserved for future use Reserved for future use C Sync In Reserved for future u...

Page 33: ...ers for the speed range selected WARNING WARNING S1 S1 FE FEE EDHE DHEA AD D P P C C BOA BOAR RD D EX EXT TE ER RN NAL I O AL I O C CO ON NN NE ECTOR CTOR FIGURE A 3a ETHERNET CONFIGURATION Ethernet c...

Page 34: ...e the panel and screws and restore power CONTROL P C BOARD S1 S1 ETHERNET P C BOARD S1 S2 S4 S3 FEEDHEAD P C BOARD FIGURE A 4 DEVICENET CONFIGURATION For systems controlled via DeviceNet The MAC ID an...

Page 35: ...O N OBJECT INSTANCE GROUP SELECT RESERVED DEFAULT SETTINGS SHOWN 1 2 3 4 5 6 7 8 O N BAUD RATE 125K DEVICENET MAC ID 62 DEFAULT SETTINGS SHOWN LSB Least Significant Bit MSB Most Significant Bit Switch...

Page 36: ...000 A 26 TABLE A 14 OBJECT INSTANCE switch 2 switch 1 Instance off off 0 default off on 1 on off 2 on on 3 TABLE A 15 Switch 1 Switch 2 Baud Rate off off 125K default on off 250K off on 500K on on Pro...

Page 37: ...0 0 21 0 1 0 1 0 1 22 0 1 0 1 1 0 23 0 1 0 1 1 1 24 0 1 1 0 0 0 25 0 1 1 0 0 1 26 0 1 1 0 1 0 27 0 1 1 0 1 1 28 0 1 1 1 0 0 29 0 1 1 1 0 1 30 0 1 1 1 1 0 31 0 1 1 1 1 1 32 1 0 0 0 0 0 33 1 0 0 0 0 1...

Page 38: ...HERNET BOARD DIP SWITCHES S3 S4 MASTER Internal Synchronization Signal for systems without K2282 1 System Interface BANK S4 Master Slave Config BANK S3 I O Termination BANK S3 I O Termination BANK S3...

Page 39: ...ous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that ha...

Page 40: ...OSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING or CAUTI...

Page 41: ...ne is fac tory preprogrammed with multiple welding procedures to support all types of submerged arc welding The Power Wave AC DC 1000 carries an output rating of 1000 amps 44 volts at 100 duty cycle I...

Page 42: ...ication RS 232 B 4 OPERATION B 4 CASE FRONT CONTROL DESCRIPTIONS See Figure B 4 1 Power Switch Controls input power to the Power Wave 2 Status Lights A two color light that indicates sys tem errors No...

Page 43: ...B 5 OPERATION B 5 POWER WAVE AC DC 1000 8 12 7 11 9 10 4 5 13 14 6 15 FIGURE B 5...

Page 44: ...become steady green con sult the troubleshooting section of this manual for fur ther instruction POWER WAVE AC DC 1000 1 2 9 8 3 4 5 7 6 FIGURE B 6 CASE REAR COMPONENTS DESCRIPTION See Figure B 6 1 In...

Page 45: ...cial welding pro gram is desired contact the local Lincoln Electric sales representative To make a weld the Power Wave AC DC 1000 needs to know the desired welding parameters Waveform Control Technolo...

Page 46: ...BASIC MODES OF OPERATION CONSTANT CURRENT CC Operator presets Current and desired Voltage The Power Source Goal is to maintain a constant arc length Drives a constant Current Synergically Controls WFS...

Page 47: ...and Burnback parameters are used to define the end of the weld sequence Downslope determines the amount of time it takes to ramp from the Weld parameters to the Crater parameters The transition is lin...

Page 48: ...ve Balance to control the penetration and deposition of a given process DC OFFSET Refers to shift of the current waveform with respect to the zero crossing Use Offset to control the penetration and de...

Page 49: ...he system ARC 1 Recommendations For balanced waveforms a phase relationship of 90 should be maintained between adjacent arcs ARC 1 ARC2 ARC3 ARC 4 2 Arc System 0 90 X X 3 Arc System 0 90 180 X 4 Arc S...

Page 50: ...Name Purpose Weld Manager Setup Ethernet address information and apply security settings Command Center AC DC system tool to observe and log welding operation verify DeviceNet welding configuration an...

Page 51: ...calibrated machines may not yield satisfactory weld performance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output V...

Page 52: ...SSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gene...

Page 53: ...ocedure requiring output levels in excess of machine rating 3 Major physical or electrical damage is evident when the sheet metal covers are removed 1 No Input Power 2 Circuit breaker CB4 in recon nec...

Page 54: ...ut Chopper board thermostat 3 DC Bus PC board thermostat 4 Open thermostat circuit 1 Make certain that input voltage is proper according to the Rating Plate located on the rear of the machine 2 See Th...

Page 55: ...1 Wire feed problem 2 Cabling problems 3 Verify weld mode is correct for process 4 Machine calibration 1 Voltage sense lead problem 2 Wire feed problem 1 Burnback Time 1 Power down and reset CB2 2 Pow...

Page 56: ...calibration 1 Voltage sensing problem 2 Machine calibration 1 Verify Ethernet board DIP Switch settings 2 If major physical or electrical damage is evident when the sheet metal cover is removed from...

Page 57: ...ard The current value of the baud rate setting can be viewed on the DeviceNet tab of the Diagnostics Utility 3 Verify the DeviceNet MAC ID is correct The Mac ID is set via dip switch on the Ethernet P...

Page 58: ...Diagnostics Utility displays these values 1 From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be dis played Verify under the Produced Assembly that Trigger is h...

Page 59: ...wire can be pulled easily through the wire conduit Verify Contact tip is not blocked 2 Verify the Strike Wire Feed Speed set correctly 3 Verify the correct weld schedule is selected 4 Verify voltage s...

Page 60: ...Updates is 1 4 of I O Scans Sec value 2 From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the required channels are set active 3 From the DeviceN...

Page 61: ...fy that Burnback Time for the active schedule in the main window has a value other than 0 3 The DeviceNet tab of the Diagnostics Utility displays the Power Wave s Analog Scans Between Updates and I O...

Page 62: ...point values are within limits 5 Verify Gas remains on until after the weld is complete 6 Verify welding set points for work point trim and wave values 1 Verify that the correct patch cable or cross o...

Page 63: ...Blinking Red System OK Power source is operational and is com municating normally with all healthy peripheral equip ment connected to its ArcLink network Occurs during power up or a system reset and i...

Page 64: ...put con figuration excessive line voltage or improper capacitor balance see Error 43 Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed d...

Page 65: ...ector S7 COMMUNICATION MODULE Error Code 118 DeviceNet connection error 119 DeviceNet de allocation error 133 Write ArcLink action failure 145 Duplicate MAC ID error 146 DeviceNet Bus off 147 DeviceNe...

Page 66: ...y It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible writ...

Page 67: ...y It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible writ...

Page 68: ...F 3 AC SWITCH WIRING DIAGRAM F 3 POWER WAVE AC DC 1000...

Page 69: ...F 4 AC SWITCH WIRING DIAGRAM F 4 POWER WAVE AC DC 1000...

Page 70: ...F 5 DIMENSION PRINT F 5 POWER WAVE AC DC 1000 L12302 A 01 19 70 19 16 9 56 18 84 40 94 43 44 33 00 34 34 14 62...

Page 71: ...NOTES POWER WAVE AC DC 1000...

Page 72: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 73: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 74: ...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 World s Leader in Welding and Cutting Pr...

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