Lincoln Electric Power Wave AC/DC 1000 Operator'S Manual Download

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E-10

TROUBLESHOOTING

E-10

POWER WAVE® AC/DC 1000

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Bad Weld Ending

Bad Welding

1. Burnback Disabled.

2. Burnback Time.

3. Analog Scans Between Updates.

4. Limit Error reported at the end of a weld.

5. Fan Out.

6. Welding set points.

7. Analog Hysteresis.

8. Gas.

1. Analog Scans Between Updates.

2. Voltage Sense Leads.

From the DeviceNet tab of the

Diagnostics Utility

, select Monitor. The

Monitor window will be displayed. Verify
under the "State Enabled" that "Burnback"
is present.

2. Using

Command Center

verify 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 Waveʼs "Analog

Scans Between Updates" and "I/O
Scans/Sec." Verify that "Analog Scans
Between Updates" is 1/4 of "I/O
Scans/Sec" value.

4. Verify all welding settings for Burnback

and Crater states.

From the DeviceNet tab of the

Diagnostics Utility

, select Monitor. Verify

under "Analog Input Fan Out" that
Burnback is present for all analogs in.

6. Verify Burnback set points for work point,

trim, and wave values.

From the DeviceNet tab of the

Diagnostics Utility

, select Configure.

Verify in "Analog Input Channels" that the
Hysteresis settings are all 0.

8. Verify Gas is turned on.

1. The DeviceNet tab of the

Diagnostics

Utility

displays the Power Waveʼs "Analog

Scans Between Updates" and "I/O
Scans/Sec." Verify that "Analog Scans
Between Updates" is 1/4 of "I/O
Scans/Sec" value.

2. Verify voltage sense leads are properly

connected and configured as described in
the instruction manual.

DEVICENET-PLC CONTROLLED SYSTEM

Summary of Contents for Power Wave AC/DC 1000

Page 1: ...fety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT I NSTALL OPERATE OR REPAI R THI S EQUI PM ENT W I THOUT READ I NG THI S M ANUAL AND THE SAFETY PRECAUTI ONS CON TAI NED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11124 11226 Copyright Lincoln Global Inc IEC...

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 Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availab...

Page 3: ...cooling 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 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fumes...

Page 4: ...o 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 hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode cir...

Page 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Elo...

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

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

Page 8: ...y 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 form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www li...

Page 9: ..._______________________________________________ Operation Section B Safety Precautions Definition of Welding Modes B 1 Graphic Symbols B 2 Product Summary Recommended Process Process and Equipment Limitations B 3 Common Equipment Packages and Recommended Equipment B 3 Case Front Control Descriptions B 4 B 5 Case Rear Components B 6 Power Up Sequence B 6 Duty Cycle B 7 Common Welding Procedures B 7...

Page 10: ...ED to Troubleshoot System Problem E 12 Error Codes E 13 E 14 ________________________________________________________________________ Wiring Diagrams and Dimension Print Section F ________________________________________________________________________ Parts List P 509 ________________________________________________________________________ ...

Page 11: ...DC 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 Duty Cycle OPERATING TEMPERATURE RANGE 32 F to 104 F 0 C to 40 C STORAGE TEMPERATURE RANGE 40 F to 185 F 40 C to 85 C 1 Wire and Fuse Sizes based upon the U S National Electric Code and maximum outpu...

Page 12: ...quipment 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 Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground LOCATION AND MOUNTING Place the welder where clean cooling air can freely circul...

Page 13: ...ied 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 breakers and try again INPUT CONNECTION ELECTRIC SHOCK can kill Only a qualified electrician should connect the input leads to the Power Wave Connections should be made in accordance with all local and Nat...

Page 14: ...practical 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 by the timing of each arcʼs sync signal relative to the sync signal of ARC 1 In a typical multi arc system each arc is controlled by its own Power Feed 10A Controller The basic charac teristics of the...

Page 15: ...rc 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 network con necting PLC to each power source and the System Interface For additional information refer to the DeviceNet Cable Planning and Installation Manual Allen Bradley publication DN 6 7 2 Power Wave ...

Page 16: ...racket 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 posi tion Vertical Lift Adjuster provides 4 102mm crank adjustment of vertical head position Also provides 3 37 95mm in and out horizontal adjustment with movable stops for repeatability Wire Reel Asse...

Page 17: ...Electrode 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 Connection Refer to Output Cable Guidelines for recommended cable size WorkStuds Electrode Studs Connection Diagram Typical Single Arc System Power Feed 10A Controller ...

Page 18: ...d 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 Power Wave front panel and configure DIP switch settings per Internal Controls section Connect input power to Power Wave per recommended guidelines Turn on Power Wave and verify all system Status Lig...

Page 19: ...s 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 Sense Lead 21 Electrode Sense Lead 67 Refer to Ou tput Cable g uidel ines f or reco mmended cable s ize K1543 XX Arclink Control Cables Connection Diagram Typical Tandem Arc System Power Feed 10A Controller Arclink Input Wire Reel and Mounting...

Page 20: ...etween 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 welding cables per recommended Output Cable Guidelines Open all Power Wave front panels and configure DIP switch settings per Internal Controls section Connect input power to Power Waves per recommend...

Page 21: ...Work Piece Work Sense Leads 21 E lectrode Cables Refer to Output Cable Guidelines for recommended cable size Head K231 XXX DeviceNet Cable Network K1795 XX Cables K1543 XX Arclink Control Cable K1785 XX Wir e Feeder Control Cables Arclink Input Wire Feeder 14 Pin Arclink 5 Pin Work Studs Electrode Studs Wire Reel and Mountings PLC Controller Electrode Sense Lead 67 Master Input S1 2 Con nects to S...

Page 22: ...ARC 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 Output Cable Guidelines Open all Power Wave front panels and configure DIP switch settings including the DeviceNet MAC ID and Baud Rate settings per Internal Controls section Connect input power to Power ...

Page 23: ...13 Output Connect to optional K2282 1 System Interface for Synchronized Multiple Arc Applications Ethernet Note Ethernet connectivity allows machines to share critical parameter information Proper configuration requires the use of the Weld Manager and SubarcCellConfigsoftware utilities Common bus connections recommended for excessive cable length applications Locate close to power sources Electrod...

Page 24: ...arc 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 xx System Control Cables 22 pin between the Master and Slaves of each arc grouping per the Parallel Machines Connection Diagram Connect Install welding cables per the recommended Output Cable Guidelin...

Page 25: ...plate 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 electrode cable to the wire drive feed plate on the wire feeder Be sure the connection to the feed plate makes tight metal to metal electrical contact For parallel applications with excessive electrode cab...

Page 26: ...ng 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 wire drive feed plate when a wire feeder is present Enabling or disabling electrode voltage sensing is application specific and automatically configured through software Work Voltage Sensing For most a...

Page 27: ...rmation 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 single part Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads but they are strong ly recommended If Sense Leads ARE NOT Used Avoid common current paths Cur...

Page 28: ...al 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 1 POWER SOURCE 1 POWER SOURCE 2 POWER SOURCE 2 POWER SOURCE 1 ...

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 per arc it connects from the PF 10A to the power source designated as the Master for that arc The control cable consists of two power leads one twisted pair for digital communication and one lead fo...

Page 30: ...t 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 magnetic field For additional guidelines refer to ISO IEC 11801 Failure to follow these recommendations can result in an Ethernet connection failure during welding NOTE See Ethernet Configuration se...

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 VDC for Trigger Group Trigger Input Dual Procedure Input 4 Step Input 15 VDC for Cold Inch Group Cold Inch Forward Cold Inch Reverse Gas Purge Input 15 for shutdown group Shutdown1 input Shutdown2 inp...

Page 32: ...er 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 use Sync Out D Sync In Reserved for future use Sync Out E Ready In Ready In F Ready In Ready In G Polarity Out Polarity Out H Polarity Out Polarity Out I Ground J Reserved for future use Reserved for ...

Page 33: ... control parameters for the speed range selected WARNING WARNING S1 S1 FE FEEDHE DHEAD P P C BOA BOARD EX EXTERNAL I O AL I O CONNECTOR CTOR FIGURE A 3a ETHERNET CONFIGURATION Ethernet capability is provided for data monitoring or to enable parallel machine operation To utilize these features the network settings of each Power Wave AC DC 1000 must be properly configured This is accomplished throug...

Page 34: ...ce 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 and baud rate must be properly configured see the Internal Controls section of this document Other information regarding basic system integration of the Power Wave AC DC 1000 with a DeviceNet PLC is pr...

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 Description 1 Object Instance LSB see table A 14 2 Object Instance MSB see table A 14 3 Equipment Group 1 Select default OFF 4 Equipment Group 2 Select default OFF 5 Equipment Group 3 Select default...

Page 36: ...1000 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 Programmable value DeviceNet Baud Rate ...

Page 37: ...1 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 34 1 0 0 0 1 0 35 1 0 0 0 1 1 36 1 0 0 1 0 0 37 1 0 0 1 0 1 38 1 0 0 1 1 0 39 1 0 0 1 1 1 40 1 0 1 0 0 0 41 1 0 1 0 0 1 42 1 0 1 0 1 0 43 1 0 1 0 1 1 44 1 0 1 1 0 0 45 1 0 1 1 0 1 46 1 0 1 1 1 0 47 1...

Page 38: ...THERNET 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 I O Termination MASTER External Synchronization Signal for systems with K2282 1 System Interface BANK S4 Master Slave Config SLAVE BANK S4 Master Slave Config DEFAULT ...

Page 39: ... 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 have held com bustibles ARC RAYS can burn Wear eye ear and body protection Observe additional guidelines detailed in the beginning of this manual WARNING DEFINITIONS OF WELDING MODES NON SYNERGIC WELDING M...

Page 40: ...POSITIVE 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 CAUTION Explosion Dangerous Voltage Shock Hazard GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U0 U1 U2 I1 I2 ...

Page 41: ...ine 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 If higher currents are required machines can be easily paral leled PROCESS LIMITATIONS The Power Wave AC DC 1000 is suitable only for the processes listed Do not use Power Wave AC DC 1000 for pipe tha...

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 Normal operation is a steady green light Error conditions are indicated in the Troubleshooting Section NOTE The robotic PowerWavesʼ status light will flash green for up to 15 seconds when the machine is...

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 Input Contactor Connection point for incoming 3 Phase power see Recommended Input Wire and Fuse Size chart in this document 2 Case Ground The frame of the welder must be grounded to earth at this termi...

Page 45: ...ecial 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 Technology allows full customization of Strike Run in Crater and other parameters for exact ing performance OVERVIEW OF THE AC DC SUBMERGED ARC PROCESS The Power Wave AC DC 1000 combines the advan tages of A...

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 to Maintain Voltage at the desired Set point Arc Length is proportional to Voltage Traditionally used for larger diameter wires and slower travel speeds CONSTANT VOLTAGE CV Operator presets Wire Fee...

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 linear and may be up or down depending on the relationship between the Weld and Crater settings Crater parameters are typically used to fill the crater at the end of the weld and include both time and o...

Page 48: ...ave 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 deposition of a given process FREQUENCY POWER WAVE AC DC 1000 can produce Output Frequencies from 10 100Hz Use Frequency to fine tune stability Higher frequencies in multiple arc setups can help reduce...

Page 49: ...the 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 System 0 90 180 270 For unbalanced waveforms Avoid switching at same time Break up long periods of unchanged polarity relative to adjacent arcs POWER WAVE AC DC 1000 Phase Relationship 500 500 0 Use P...

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 and facilitate quality analysis Submerged Arc Cell Configuration Used to configure and verify a multi arc or parallel connected power source more than one Power Wave per arc systems Production Monitori...

Page 51: ...glected or improperly 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 Voltage and Current are calibrated at the factory Generally speaking the machine calibration will not need adjustment However if the weld per formance changes or the yearly calibra...

Page 52: ...OSSIBLE 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 generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Au...

Page 53: ...r Weld Procedure 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 nect area may have tripped Power Down and Reset CB4 3 Input voltage selection made improperly 1 Contact your local authorized Lincoln Electric Field Service facility for technical assistance 1 M...

Page 54: ...r AC Output 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 Thermal LED is ON sec tion 3 Possible short in output circuit Turn machine off Remove all loads from the output of the machine Turn back on and acti vate output If condition persists turn power...

Page 55: ...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 Power down and reset CB3 or CB4 1 Check for feeding problems Make sure proper gear ratio has been selected 2 Check for bad connections excessive loops in cable etc NOTE The presence of heat in the external weld...

Page 56: ...e 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 the AC Switch lower sec tion of the machine Contact your local authorized Lincoln Electric Field Service facility for technical assistance 1 Adjust procedure or reduce load to lower current draw from...

Page 57: ...oard 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 PC Board The current value of the MAC ID can be viewed on the DeviceNet tab of the Diagnostics Utility 4 Verify that the DeviceNet bus is ter minated correctly 5 Verify the wiring of all multi port ta...

Page 58: ...e 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 highlight ed 2 From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be dis played Verify under the Produced Assembly that Touch Sense is NOT highlighted 3 The Devic...

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 sense leads are properly connected and config ured as described in the instruc tion manual 5 The DeviceNet tab of the Diagnostics Utility displays the Power Waveʼs Analog Scans Between Updates and I O...

Page 60: ...n 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 DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the Hysteresis settings are all 0 4 The DeviceNet tab of the Diagnostics Utility displays the Power Waveʼs pass...

Page 61: ...ify 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 Waveʼs Analog Scans Between Updates and I O Scans Sec Verify that Analog Scans Between Updates is 1 4 of I O Scans Sec value 4 Verify all welding settings for Burnback and Crater states 5 From the DeviceNet tab of the Diagnostics Utility selec...

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 over cable is being used refer to local IT department for assis tance Verify the cables are fully inserted into the bulk head connector LED 10 will be lit when the board is connected to another networ...

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 indi cates the Power Wave AC DC 1000 is mapping identi fying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operat...

Page 64: ...nput 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 duty cycle limit of the machine Capacitor pre charge failed Usually accompanied by codes 32 35 The long term average secondary weld current limit has been exceeded This error will cause the machine ou...

Page 65: ...nector 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 DeviceNet polled I O error 149 DeviceNet I O data error 169 Ethernet Connection Time out 171 Ethernet Socket Time out 172 Ethernet Watch Dog Time out 194 Ethernet Send Problem 195 Ethernet Problem 197 Ethern...

Page 66: ...ly 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 write to the Service Department for a replacement Give the equipment code number ...

Page 67: ...ly 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 write to the Service Department for a replacement Give the equipment code number ...

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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 73: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant lʼen tretien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 74: ...s 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 Products ...

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