Lincoln Electric 11124, 11226 Bad Weld Ending Burnback Disabled, Is present Burnback Time, Gas

Page 61

E-10

 

 

TROUBLESHOOTING

 

 

 

 

 

E-10

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE

 

 

RECOMMENDED

 

 

 

(SYMPTOMS)

 

 

CAUSE

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DEVICENET-PLC CONTROLLED SYSTEM

 

 

 

 

 

Bad Weld Ending

 

1. Burnback Disabled.

 

1. From

the

DeviceNet

tab

of

the

 

 

 

 

 

 

Diagnostics Utility, select Monitor. The

 

 

 

 

 

 

Monitor window will be displayed. Verify

 

 

 

 

 

 

under the "State Enabled" that "Burnback"

 

 

 

 

 

 

is present.

 

 

 

 

 

 

2.

Burnback Time.

 

2. Using Command Center verify that

 

 

 

 

 

 

Burnback Time for the active schedule in

 

 

 

 

 

 

the main window has a value other than 0.

 

 

3.

Analog Scans Between Updates.

 

3. The DeviceNet tab of the Diagnostics

 

 

 

 

 

 

Utility displays the Power Wave’s "Analog

 

 

 

 

 

 

Scans Between Updates" and "I/O

 

 

 

 

 

 

Scans/Sec." Verify that "Analog Scans

 

 

 

 

 

 

Between Updates" is 1/4 of "I/O

 

 

 

 

 

 

Scans/Sec" value.

 

 

 

 

 

4.

Limit Error reported at the end of a weld.

 

4. Verify all welding settings for Burnback

 

 

 

 

 

 

and Crater states.

 

 

 

 

 

5.

Fan Out.

 

5. From

the

DeviceNet

tab

of

the

 

 

 

 

 

 

Diagnostics Utility, select Monitor. Verify

 

 

 

 

 

 

under "Analog Input Fan Out" that

 

 

 

 

 

 

Burnback is present for all analogs in.

 

 

 

6.

Welding set points.

 

6. Verify Burnback set points for work point,

 

 

 

 

 

 

trim, and wave values.

 

 

 

 

 

7.

Analog Hysteresis.

 

7. From

the

DeviceNet

tab

of

the

 

 

 

 

 

 

Diagnostics Utility, select Configure.

 

 

 

 

 

 

Verify in "Analog Input Channels" that the

 

 

 

 

 

 

Hysteresis settings are all 0.

 

 

 

 

 

8.

Gas.

 

8. Verify Gas is turned on.

 

 

 

 

 

 

 

 

Bad Welding

1.

Analog Scans Between Updates.

 

1. The DeviceNet tab of the Diagnostics

 

 

 

 

 

 

Utility displays the Power Wave’s "Analog

 

 

 

 

 

 

Scans Between Updates" and "I/O

 

 

 

 

 

 

Scans/Sec." Verify that "Analog Scans

 

 

 

 

 

 

Between Updates" is 1/4 of "I/O

 

 

 

 

 

 

Scans/Sec" value.

 

 

 

 

 

2.

Voltage Sense Leads.

 

2. Verify voltage sense leads are properly

 

 

 

 

 

 

connected and configured as described in

 

 

 

 

 

 

the instruction manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 Mar ‘95 SafetyElectric Shock can kill Iii Welding and Cutting Sparks can Cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Safety Thank You Table of Contents Table of Contents Specifications Installation Input and Ground Connections Input Fuse and Supply Wire ConsiderationsInput Connection Input Voltage SelectionSystem Overview System ConnectionSystem Description Single Arc Tandem Arc Triple Arc 3,4 Recommended EquipmentSystem Identifier Description Optional EquipmentElectrode 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 Connections Electrode and WorkCable INDUCTANCE, and ITS Effects on Welding Remove the front cover from the power sourceRemote Sense Lead Connections Voltage Sensing OverviewVoltage Sensing Considerations for Multiple ARC Systems Voltage Sensing for Slave machinesPower Common Equipment Connections Control Cable ConnectionsInstallation Receptacle Specification External I/O ConnectorTable A.4 RS232 Connector S3 DB-25 style Table A.5 DeviceNet Connector S5 5 pin mini styleTransmit + Table A.7 External I/O S7 12 pin terminal blockTransmit Receive +Ethernet Configuration Wire Drive Gear Ratio SettingInternal Controls Devicenet ConfigurationInternal Controls Description Feed Head Board DIP Switch S1 Control Board DIP Switch S1Ethernet Board DIP Switches S1, S2 Object Instance Off 0defaultTable A.14 Table A.15Devicenet MAC ID Table A.16 Master Master / Slave ConfigSlave Bank S4 Bank S3Definitions of Welding Modes OperationCommon Welding Abbreviations Input Power Three Phase Positive Output Negative Output Phase InverterProtective GroundRecommended Processes Product SummaryProcess Limitations Equipment LimitationsSee Figure B.4 Case Front Control DescriptionsFigure B.5 Power Wave AC/DC Case Rear Components POWER-UP SequenceDuty Cycle Common Welding ProceduresOverview of the AC/DC Submerged ARC Process Making a WeldBasic Modes of Operation Multiple ARC System ConsiderationsConstant Current CC Constant Voltage CVWeld Sequence RE-STRIKE TimerStart Options END OptionsAC Adjustments Weld Process Adjustments DC OffsetWave Balance FrequencyRecommendations PhaseKITS, Options and Accessories AccessoriesOptional Kits and Accessories Software ToolsPeriodic Maintenance MaintenanceCalibration Specification HOW to USE Troubleshooting Guide TroubleshootingRecommended SymptomsCourse of Action Qualified person should Perform this operationRecommended Symptoms ARC Quality Problems Weld Tab of the Diagnostics Utility Diagnostics Utility displays Diagnostics Utility, select MonitorDiagnostics Utility, select Changed, select Configure, Power Wave’s passive modeProduced Assembly that Gas Analog In Active Selections From the DeviceNet tabScans Between Updates and I/O Bad Weld Ending Burnback DisabledBetween Updates is 1/4 of I/O Bad Welding Analog Scans Between UpdatesManager utility Utility included on the Power Wave Submerged Arc Present. Read the error codes before the machineUtilities and Service Navigator CD’s. This is the pre Is turned offError Codes Power SOURCE- Weld ControllerError Code # Indication This error will immediately turn off the machine outputWire Drive Module 1000 DiagramsDiagrams AC Switch Wiring Diagram AC Switch Wiring Diagram Dimension Print Power Wave AC/DC Precaucion Warnung
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