Lincoln Electric 11226, 11124 manual HOW to USE Troubleshooting Guide

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E-1	TROUBLESHOOTING	E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

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This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP- TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE 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 Authorized Field Service Facility.

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® 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-10A Controlled Systems PF-10S ConnectionsDeviceNet 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 ConfigurationInternal Controls Devicenet ConfigurationInternal Controls Description Feed Head Board DIP Switch S1 Control 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 S3Definitions of Welding Modes OperationCommon 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 ToolsPeriodic Maintenance 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