Lincoln Electric 11124, 11226 Present. Read the error codes before the machine, Is turned off

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TROUBLESHOOTING

E-12

 

 

 

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave AC/DC 1000 is equipped with three externally mounted status lights, one for the power source, and each module contained in the power source. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.

Included in this section is information about the power source, Wire Drive Module, and Communication Module Status LED’s, and some basic troubleshoot- ing charts for both machine and weld performance.

The STATUS LIGHTS are dual-color LED’s that indi- cate system errors. Normal operation for each is steady green. Error conditions are indicated in the fol- lowing chart.

 

Troubleshooting the Power Wave AC/DC 1000 Using the External Status LED’s

 

 

 

 

 

Steady Green

System OK. Power source is operational, and is com-

 

 

municating normally with all healthy peripheral equip-

 

 

ment connected to its ArcLink network.

 

 

 

 

 

Blinking Green

Occurs during power up or a system reset, and indi-

 

 

cates the Power Wave AC/DC 1000 is mapping (identi-

 

 

fying) each component in the system. Normal for first 1-

 

 

10 seconds after power is turned on, or if the system

 

 

configuration is changed during operation.

 

 

 

 

 

Fast Blinking Green

Indicates Auto-mapping has failed

 

 

 

 

Alternating Green and Red

Non-recoverable system fault. If the Status lights are

 

 

flashing any combination of red and green, errors are

 

 

present. Read the error code(s) before the machine

 

 

is turned off.

 

 

Error Code interpretation through the Status light is

 

 

detailed in the Service Manual. Individual code digits

 

 

are flashed in red with a long pause between digits. If

 

 

more than one code is present, the codes will be sepa-

 

 

rated by a green light. Only active error conditions will

 

 

be accessible through the Status Light.

 

 

Error codes can also be retrieved with the Diagnostics

 

 

Utility (included on the Power Wave Submerged Arc

 

 

Utilities and Service Navigator CD’s). This is the pre-

 

 

ferred method, since it can access historical informa-

 

 

tion contained in the error logs.

 

 

To clear the active error(s), turn power source off, and

 

 

back on to reset.

Steady Red

Not applicable.

Blinking Red

Not applicable.

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 Voltage Selection Input Fuse and Supply Wire ConsiderationsInput and Ground Connections Input ConnectionSystem 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-10S Connections PF-10A Controlled SystemsDeviceNet PLC Controlled Systems Connections Electrode and WorkVoltage Sensing Overview Remove the front cover from the power sourceCable INDUCTANCE, and ITS Effects on Welding Remote Sense Lead ConnectionsVoltage Sensing Considerations for Multiple ARC Systems Voltage Sensing for Slave machinesPower Common Equipment Connections Control Cable ConnectionsInstallation Table A.5 DeviceNet Connector S5 5 pin mini style External I/O ConnectorReceptacle Specification Table A.4 RS232 Connector S3 DB-25 styleReceive + Table A.7 External I/O S7 12 pin terminal blockTransmit + TransmitEthernet Configuration Wire Drive Gear Ratio SettingDevicenet Configuration Internal ControlsInternal Controls Description Control Board DIP Switch S1 Feed Head Board DIP Switch S1Ethernet Board DIP Switches S1, S2 Table A.15 Off 0defaultObject Instance Table A.14Devicenet MAC ID Table A.16 Bank S4 Bank S3 Master / Slave ConfigMaster SlaveOperation Definitions of Welding ModesCommon Welding Abbreviations Ground Positive Output Negative Output Phase InverterInput Power Three Phase ProtectiveEquipment Limitations Product SummaryRecommended Processes Process LimitationsSee Figure B.4 Case Front Control DescriptionsFigure B.5 Power Wave AC/DC Case Rear Components POWER-UP SequenceMaking a Weld Common Welding ProceduresDuty Cycle Overview of the AC/DC Submerged ARC ProcessConstant Voltage CV Multiple ARC System ConsiderationsBasic Modes of Operation Constant Current CCEND Options RE-STRIKE TimerWeld Sequence Start OptionsFrequency Weld Process Adjustments DC OffsetAC Adjustments Wave BalanceRecommendations PhaseSoftware Tools AccessoriesKITS, Options and Accessories Optional Kits and AccessoriesMaintenance Periodic MaintenanceCalibration Specification HOW to USE Troubleshooting Guide TroubleshootingQualified person should Perform this operation SymptomsRecommended Course of ActionRecommended Symptoms ARC Quality Problems Weld Tab of the Diagnostics Utility Diagnostics Utility displays Diagnostics Utility, select MonitorDiagnostics Utility, select Analog In Active Selections From the DeviceNet tab Power Wave’s passive modeChanged, select Configure, Produced Assembly that GasBad Welding Analog Scans Between Updates Bad Weld Ending Burnback DisabledScans Between Updates and I/O Between Updates is 1/4 of I/OManager utility Is turned off Present. Read the error codes before the machineUtility included on the Power Wave Submerged Arc Utilities and Service Navigator CD’s. This is the preThis error will immediately turn off the machine output Power SOURCE- Weld ControllerError Codes Error Code # IndicationWire Drive Module 1000 DiagramsDiagrams AC Switch Wiring Diagram AC Switch Wiring Diagram Dimension Print Power Wave AC/DC Precaucion Warnung
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