Lincoln Electric 11226, 11124 manual Installation

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A-2

INSTALLATION

A-2

 

 

 

SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should per- form this installation.

Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment. 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.

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LOCATION AND MOUNTING

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and front. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

LIFTING

WARNING

 

• Lift only with equipment of

 

adequate lifting capacity.

 

• Be sure machine is stable

 

when lifting.

 

• Do not lift this machine using

 

lift bail if it is equipped with a

 

heavy accessory such as trail-

 

er or gas cylinder.

FALLING

• Do not lift machine if lift bail is

EQUIPMENT can

damaged.

cause injury.

• Do not operate machine while

 

suspended from lift bail.

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Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave AC/DC 1000 with accessories attached to it.

ENVIRONMENTAL LIMITATIONS

Do not use the Power Wave AC/DC 1000 in an out- door environment. The Power Wave AC/DC 1000 power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR- FACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least

.06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

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STACKING

Power Wave AC/DC 1000 machine cannot be stacked.

ELECTROMAGNETIC COMPATIBILITY (EMC)

The EMC classification ot the Power Wave AC/DC 1000 is Industrial, Scientific and Medical (ISM) group 2, class A. The Power Wave AC/DC 1000 is for indus- trial use only.

Locate the Power Wave away from radio controlled machinery.

CAUTION

The normal operation of the Power Wave AC/DC 1000 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

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POWER WAVE® AC/DC 1000

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Contents Power Wave AC/DC Safety Mar ‘95Electric Shock can kill Welding and Cutting Sparks can Cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Safety Thank You Table of Contents Table of Contents Specifications Installation Input Fuse and Supply Wire Considerations Input and Ground ConnectionsInput Connection Input Voltage SelectionSystem Connection System OverviewRecommended Equipment System Description Single Arc Tandem Arc Triple Arc 3,4Optional Equipment System Identifier DescriptionElectrode Studs Work Studs Arclink 5 Pin Step by Step Installation Checklist Wire Reel Mountings Step by Step Installation Checklist System DeviceNet PLC Controller Installation Connection Diagram- Parallel Machines PF-10S Connections PF-10A Controlled SystemsDeviceNet PLC Controlled Systems Electrode and Work ConnectionsRemove the front cover from the power source Cable INDUCTANCE, and ITS Effects on WeldingRemote Sense Lead Connections Voltage Sensing OverviewVoltage Sensing for Slave machines Voltage Sensing Considerations for Multiple ARC SystemsPower Control Cable Connections Common Equipment ConnectionsInstallation External I/O Connector Receptacle SpecificationTable A.4 RS232 Connector S3 DB-25 style Table A.5 DeviceNet Connector S5 5 pin mini styleTable A.7 External I/O S7 12 pin terminal block Transmit +Transmit Receive +Wire Drive Gear Ratio Setting Ethernet ConfigurationDevicenet Configuration Internal ControlsInternal Controls Description Control Board DIP Switch S1 Feed Head Board DIP Switch S1Ethernet Board DIP Switches S1, S2 Off 0default Object InstanceTable A.14 Table A.15Devicenet MAC ID Table A.16 Master / Slave Config MasterSlave Bank S4 Bank S3Operation Definitions of Welding ModesCommon Welding Abbreviations Positive Output Negative Output Phase Inverter Input Power Three PhaseProtective GroundProduct Summary Recommended ProcessesProcess Limitations Equipment LimitationsCase Front Control Descriptions See Figure B.4Figure B.5 Power Wave AC/DC POWER-UP Sequence Case Rear ComponentsCommon Welding Procedures Duty CycleOverview of the AC/DC Submerged ARC Process Making a WeldMultiple ARC System Considerations Basic Modes of OperationConstant Current CC Constant Voltage CVRE-STRIKE Timer Weld SequenceStart Options END OptionsWeld Process Adjustments DC Offset AC AdjustmentsWave Balance FrequencyPhase RecommendationsAccessories KITS, Options and AccessoriesOptional Kits and Accessories Software ToolsMaintenance Periodic MaintenanceCalibration Specification Troubleshooting HOW to USE Troubleshooting GuideSymptoms RecommendedCourse of Action Qualified person should Perform this operationRecommended Symptoms ARC Quality Problems Weld Tab of the Diagnostics Utility Diagnostics Utility, select Monitor Diagnostics Utility displaysDiagnostics Utility, select Power Wave’s passive mode Changed, select Configure,Produced Assembly that Gas Analog In Active Selections From the DeviceNet tabBad Weld Ending Burnback Disabled Scans Between Updates and I/OBetween Updates is 1/4 of I/O Bad Welding Analog Scans Between UpdatesManager utility Present. Read the error codes before the machine Utility included on the Power Wave Submerged ArcUtilities and Service Navigator CD’s. This is the pre Is turned offPower SOURCE- Weld Controller Error CodesError Code # Indication This error will immediately turn off the machine outputWire Drive Module Diagrams 1000Diagrams AC Switch Wiring Diagram AC Switch Wiring Diagram Dimension Print Power Wave AC/DC Precaucion Warnung