Lincoln Electric IM986 manual Using the Status LED to Troubleshoot System Problems, Table E.1

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E-2

TROUBLESHOOTING

E-2

USING THE STATUS LED TO

TROUBLESHOOT SYSTEM PROBLEMS

The POWER WAVE® i400 is equipped with two exter- nally mounted status lights, one for the power source, and one for the wire drive module contained in the power source. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.

Included in this section is information about the power source and Wire Drive Module Status LEDʼs, and some basic troubleshooting charts for both machine and weld performance.

The STATUS LIGHTS are dual-color LEDʼs that indi- cate system errors. Normal operation for each is steady green. Error conditions are indicated in the fol- lowing Table E.1.

 

TABLE E.1

Light

Meaning

Condition

 

Steady Green

System OK. Power source is operational, and is communicating normally with all healthy

 

peripheral equipment connected to its ArcLink network.

 

 

Blinking Green

Occurs during power up or a system reset, and indicates the POWER

 

WAVE® i400 is mapping (identifying) each component in the system. Normal

 

for first 1-10 seconds after power is turned on, or if the system configuration is

 

changed during operation.

 

 

Fast Blinking Green

Under normal conditions indicates Auto-mapping has failed.

 

Also used by the Diagnostics Utility (included on the POWER WAVE® Utilities

 

and Service Navigator CDʼs or available at www.powerwavesoftware.com) to

 

identify the selected machine when connecting to a specific IP address.

 

 

Alternating Green and Red

Non-recoverable system fault. If the Status lights are flashing any combination

 

of red and green, errors are present. Read the error code(s) before the

 

machine is turned off.

 

Error Code interpretation through the Status light is detailed in the Service

 

Manual. Individual code digits are flashed in red with a long pause between

 

digits. If more than one code is present, the codes will be separated by a

 

green light. Only active error conditions will be accessible through the Status

 

Light.

 

Error codes can also be retrieved with the Diagnostics Utility (included on the

 

POWER WAVE® Utilities and Service Navigator CDʼs or available at

 

www.powerwavesoftware.com). This is the preferred method, since it can

 

access historical information contained in the error log.

 

To clear the active error(s), turn power source off, and back on to reset.

Steady Red

Not applicable.

Blinking Red

Not applicable.

POWER WAVE® i400

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Contents Safety Depends on You Power WaveMar ʻ95 SafetyAUG Electric Shock can killJan IiiMar. ʻ93 Précautions DE SûretéElectromagnetic Compatibility EMC Safety Vii Thank YouTable of Contents Storage Temperature Range Phase InputHeight Width Depth Weight Operating Temperature RangeK2673-23 155C EnclosureClass Class FSafety Precautions InstallationInput Connections Input Fuse and Supply Wire ConsiderationsPower Supply Connection for the Fanuc R30iA Controller Input and Grounding ConnectionsOptional Equipment Connection Diagrams and SystemPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM I400 TypicalDuty Electrode and Work Connections General GuidelinesTable A.1 PercentTable A.2 Cable INDUCTANCE, and ITS Effects on WeldingRemote Sense Lead Connections Voltage Sensing OverviewSee Figure A.3 Work Voltage SensingVoltage Sensing Considerations for Multiple Arc Systems If Sense Leads are not UsedPower General Guidelines Regarding cable placement, best results will beControl Cable Connections Common Equipment ConnectionsOther SET-UP Issues Electric Shock can kill OperationDirect Current Input Power Three PhaseRecommended Processes and Equipment Product DescriptionCase Front Control Description Case Front115V / 15A Duplex Receptacle Case BackCase Back Components Description Pin Leads FunctionInternal Controls Description POWER-UP SequenceCommon Welding Procedures Internal ControlsConstant Voltage Welding Basic Welding ControlsNon Synergic CV Pulse WeldingOptional Equipment AccessoriesFactory Installed Field InstalledCalibration Specification MaintenanceRoutine Maintenance Periodic MaintenanceFigure D.1a Capacitor Discharge ProcedureHOW to USE Troubleshooting Guide TroubleshootingTable E.1 Using the Status LED to Troubleshoot System ProblemsError Codes for the Power Wave Error Code #Indication Wire Drive Module Problems Recommended SymptomsCourse of Action LED Observe Safety GuidelinesRecommended Weld and ARC Quality Problems DeviceNet PLC Controlled System Passive Mode Power SupplyUnder the Produced Assembly that Touch Sense command From the DeviceNet tabLy connected and configured as Bad Weld Starting Wire Feed problemThrough the wire conduit. Verify Strike Wire Feed SpeedModification Respond quicklyAnalog In Active Selections From the DeviceNet tab Needs to be changed, selectThat Burnback is present for all Analogs Welding set points Bad Weld Ending Burnback Disabled From the DeviceNet tabOther than Analog Scans Between Updates Burnback is present Burnback TimeProblems Possible Recommended Symptoms Enhanced Diagam DiagramsDimension Print Power Wave Aviso DE  Use ventilation or exhaust to Guards off