Lincoln Electric IM986 manual Recommended

Page 44

E-7

TROUBLESHOOTING

E-7

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

POSSIBLE

RECOMMENDED

(SYMPTOMS)

CAUSE

COURSE OF ACTION

BASIC MACHINE PROBLEMS

Auxiliary receptacle is dead.

1. Circuit breaker CB2 (near the

1. Power down and reset CB2.

115V receptacle) may have

tripped.

2. Fuse F1 (in reconnect area) may

2. Power down and replace the

have blown.

fuse.

“Real Time Clock” no longer func-

1. Control PC Board Battery.

1. Replace the battery (Type:

tioning

BS2032)

PROBLEMS

POSSIBLE

RECOMMENDED

(SYMPTOMS)

CAUSE

COURSE OF ACTION

WELD AND ARC QUALITY PROBLEMS

General degradation of weld per-

1. Wire feed problem.

1. Check for feeding problems. Check actu-

formance.

al WFS vs. preset. Verify proper wire

drive and gear ratio has been selected.

2. Cabling problems.

2. Check for bad connections, excessive

loops in cable, etc.

NOTE: The presence of heat in the exter-

nal welding circuit indicates poor connec-

tions or undersized cables.

3. Loss of, or improper Shielding Gas.

3. Verify gas flow and type are correct.

4. Verify weld mode is correct for process.

4. Select the correct weld mode for the

application.

5. Machine calibration.

5. Verify the calibration of the output current

and voltage.

6. Secondary current limit has been

6. Long term average current is limited to

reached.

450A. Adjust procedure to reduce output

demand.

Wire burns back to tip when the arc

1. Voltage sense lead problem.

1. Check sense lead connections. Check

is initiated.

the sense lead configuration and arc

polarity. Make sure Electrode and Work

connections are not reversed.

2. Wire feed problem.

2. Check for feeding problems. Verify proper

wire drive and gear ratio has been select-

ed.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE® i400

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Contents Power Wave Safety Depends on YouSafety Mar ʻ95Electric Shock can kill AUGIii JanPrécautions DE Sûreté Mar. ʻ93Electromagnetic Compatibility EMC Safety Thank You ViiTable of Contents Phase Input Height Width Depth WeightOperating Temperature Range Storage Temperature RangeEnclosure ClassClass F K2673-23 155CInstallation Safety PrecautionsInput Fuse and Supply Wire Considerations Power Supply Connection for the Fanuc R30iA ControllerInput and Grounding Connections Input ConnectionsConnection Diagrams and System Optional EquipmentPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM Typical I400Electrode and Work Connections General Guidelines Table A.1Percent DutyCable INDUCTANCE, and ITS Effects on Welding Remote Sense Lead ConnectionsVoltage Sensing Overview Table A.2Work Voltage Sensing Voltage Sensing Considerations for Multiple Arc SystemsIf Sense Leads are not Used See Figure A.3Power Regarding cable placement, best results will be Control Cable ConnectionsCommon Equipment Connections General GuidelinesOther SET-UP Issues Operation Electric Shock can killInput Power Three Phase Direct CurrentProduct Description Recommended Processes and EquipmentCase Front Case Front Control DescriptionCase Back Case Back Components DescriptionPin Leads Function 115V / 15A Duplex ReceptaclePOWER-UP Sequence Common Welding ProceduresInternal Controls Internal Controls DescriptionBasic Welding Controls Constant Voltage WeldingPulse Welding Non Synergic CVAccessories Factory InstalledField Installed Optional EquipmentMaintenance Routine MaintenancePeriodic Maintenance Calibration SpecificationCapacitor Discharge Procedure Figure D.1aTroubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Table E.1Indication Error Codes for the Power WaveError Code # Wire Drive Module Course of Action ProblemsRecommended Symptoms Observe Safety Guidelines LEDRecommended Weld and ARC Quality Problems DeviceNet PLC Controlled System Power Supply Under the Produced Assembly thatTouch Sense command From the DeviceNet tab Passive ModeBad Weld Starting Wire Feed problem Through the wire conduit. VerifyStrike Wire Feed Speed Ly connected and configured asRespond quickly Analog In Active Selections From the DeviceNet tabNeeds to be changed, select ModificationBad Weld Ending Burnback Disabled From the DeviceNet tab Other than Analog Scans Between UpdatesBurnback is present Burnback Time That Burnback is present for all Analogs Welding set pointsProblems Possible Recommended Symptoms Diagrams Enhanced DiagamDimension Print Power Wave Aviso DE Use ventilation or exhaust to Guards off