Lincoln Electric IM986 manual Weld and ARC Quality Problems

Page 45

E-8

 

 

TROUBLESHOOTING

 

 

E-8

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE

 

RECOMMENDED

(SYMPTOMS)

 

CAUSE

 

COURSE OF ACTION

 

 

WELD AND ARC QUALITY PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wire burns back to tip at the end of

1. Burnback Time.

 

 

 

 

1.

Reduce burnback time and/or

 

the weld.

 

 

 

 

 

 

workpoint.

 

 

Machine output shuts down during

 

 

1.Inverter or System Fault

 

 

1.

A non-recoverable inverter fault

 

 

a weld.

 

 

 

 

 

 

will interrupt welding, and open

 

 

 

 

 

 

 

 

 

 

the main contactor. This condi-

 

 

 

 

 

 

 

 

 

 

tion will also result in an alternat-

 

 

 

 

 

 

 

 

 

 

ing red and green status light on

 

 

 

 

 

 

 

 

 

 

the control panel. See the Status

 

 

 

 

 

 

 

 

 

 

Light section for more informa-

 

 

 

 

 

 

 

 

 

 

tion.

 

 

Machine wonʼt produce full output.

 

 

1. Input voltage may be too low,

 

 

1.

Make certain that the input volt-

 

 

 

 

 

 

limiting output capability of the

 

 

 

age is proper, according to the

 

 

 

 

 

 

power source.

 

 

 

Rating Plate located on the rear

 

 

 

 

 

 

 

 

 

 

of the machine.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Machine calibration.

 

 

2.

Calibrate secondary current and

 

 

 

 

 

 

 

 

 

 

voltage.

 

 

 

 

 

 

 

 

 

 

 

 

Excessively long and erratic arc.

 

 

1. Wire feed problem.

 

 

1.

Check for feeding problems.

 

 

 

 

 

 

 

 

 

 

Verify proper wire drive and gear

 

 

 

 

 

 

 

 

 

 

ratio has been selected.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Voltage sensing problem.

 

 

2.

Check sense lead connections.

 

 

 

 

 

 

 

 

 

 

Check the sense lead configura-

 

 

 

 

 

 

 

 

 

 

tion and arc polarity. Make sure

 

 

 

 

 

 

 

 

 

 

Electrode and Work connections

 

 

 

 

 

 

 

 

 

 

are not reversed.

 

 

 

 

 

 

3. Loss of, or improper Shielding

 

 

3.

Verify gas flow and type are cor-

 

 

 

 

 

 

Gas.

 

 

 

rect.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. Machine calibration.

 

 

4.

Calibrate secondary current and

 

 

 

 

 

 

 

 

 

 

voltage.

 

 

 

 

 

 

 

 

 

 

 

 

Arc loss fault on robot.

 

 

1. Possibly caused by wire feeding

 

 

1.

Check for feeding problems.

 

 

 

 

 

 

problem.

 

 

 

Verify proper wire drive and gear

 

 

 

 

 

 

 

 

 

 

ratio has been selected. For

 

 

 

 

 

 

 

 

 

 

larger diameter wire, consider

 

 

 

 

 

 

 

 

 

 

the highest torque / lowest range

 

 

 

 

 

 

 

 

 

 

gear ratio available to suit the

 

 

 

 

 

 

 

 

 

 

application.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

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.

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 Height Width Depth Weight Phase InputOperating Temperature Range Storage Temperature RangeClass EnclosureClass F K2673-23 155CSafety Precautions InstallationPower Supply Connection for the Fanuc R30iA Controller Input Fuse and Supply Wire ConsiderationsInput and Grounding Connections Input ConnectionsOptional Equipment Connection Diagrams and SystemPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM I400 TypicalTable A.1 Electrode and Work Connections General GuidelinesPercent DutyRemote Sense Lead Connections Cable INDUCTANCE, and ITS Effects on WeldingVoltage Sensing Overview Table A.2Voltage Sensing Considerations for Multiple Arc Systems Work Voltage SensingIf Sense Leads are not Used See Figure A.3Power Control Cable Connections Regarding cable placement, best results will beCommon Equipment Connections General GuidelinesOther SET-UP Issues Electric Shock can kill OperationDirect Current Input Power Three PhaseRecommended Processes and Equipment Product DescriptionCase Front Control Description Case FrontCase Back Components Description Case BackPin Leads Function 115V / 15A Duplex ReceptacleCommon Welding Procedures POWER-UP SequenceInternal Controls Internal Controls DescriptionConstant Voltage Welding Basic Welding ControlsNon Synergic CV Pulse WeldingFactory Installed AccessoriesField Installed Optional EquipmentRoutine Maintenance MaintenancePeriodic Maintenance Calibration SpecificationFigure 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 Under the Produced Assembly that Power SupplyTouch Sense command From the DeviceNet tab Passive ModeThrough the wire conduit. Verify Bad Weld Starting Wire Feed problemStrike Wire Feed Speed Ly connected and configured asAnalog In Active Selections From the DeviceNet tab Respond quicklyNeeds to be changed, select ModificationOther than Analog Scans Between Updates Bad Weld Ending Burnback Disabled From the DeviceNet tabBurnback is present Burnback Time That Burnback is present for all Analogs Welding set pointsProblems Possible Recommended Symptoms Enhanced Diagam DiagramsDimension Print Power Wave Aviso DE  Use ventilation or exhaust to Guards off
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