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Welder
Lincoln Electric
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F-3
AC SWITCH WIRING DIAGRAM
F-3
POWER WAVE® AC/DC 1000
Contents
Main
POWER WAVE AC/DC 1000
OPERATORS MANUAL
IM848-A
IEC 60974-1
Safety Depends on You
FOR ENGINE powered equipment.
i
Mar 95
i
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
Refer to http://www.lincolnelectric.com/safetyfor additional safety information.
WELDING a nd CUTTING SPARKScan cause fire or explosion.
Jan 09
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
Page
Page
viivii
TThhaannkk YYoouufor selecting a QUALITYproduct by Lincoln Electric. We want you
Please Examine Carton and Equipment For Damage Immediately
On-Line Product Registration
viii viii TABLE OF CONTENTS
TABLE OF CONTENTS
A-1
SPECIFICATIONS
CSA
A-1
}
WELDING PROCESSES
*
LIFTING
ENVIRONMENTAL LIMITATIONS
ELECTROMAGNETIC COMPATIBILITY (EMC)
A-2
LOCATION AND MOUNTING
INPUT AND GROUND CONNECTIONS
A-3
A-3 I
NPUT FUSE AND SUPPLY WIRE CONSIDERATIONS
INPUT VOLTAGE SELECTION
A-4
A-4 SYSTEM CONNECTION
A-5
RECOMMENDED EQUIPMENT
System Identifier
Part No.
Single Arc
Tandem Arc
OPTIONAL EQUIPMENT
System Identifier
Part No.
Description
A-7
Connection Diagram- Typical Single Arc System (Power Feed 10A Controller)
A-7
K231-XXX
Wire Feeder (14 Pin)
Arclink (5 Pin)
A-8
A-9
Arclink Input
21 Lead
AARRCC 22
Connection Diagram- Typical Tandem Arc System ( Power Feed 10A Controller)
Wire Reel and Mountings
A-10
A-11
Connection Diagram- Typical Triple Arc System (DeviceNet PLC Controller)
A-12
A-13
Ethernet Switch
Electrode
K1795-XX Cables
Connection Diagram - Parallel Machines
SLAVE machines per MASTER
S12 (Input)
Ethernet
Work
A-14
A-15
Common Connection Diagram
ELECTRODE AND WORK CONNECTIONS
A-16
A-16 CABLE INDUCTANCE, AND ITS EFFECTS ON WELDING
REMOTE SENSE LEAD CONNECTIONS
A-17
1 2 3 4 5 6 7 8
A-18
A-19
A-19 CONTROL CABLE CONNECTIONS
COMMON EQUIPMENT CONNECTIONS
A-20
A-21
A-21 EXTERNAL I/O CONNECTOR
RECEPTACLE SPECIFICATION
A-22
A-23
WIRE DRIVE GEAR RATIO SETTING
ETHERNET CONFIGURATION
A-24
S2
S4 S3
INTERNAL CONTROLS
INTERNAL CONTROLS DESCRIPTION
CONTROL BOARD DIP SWITCH (S1):
}
FEED HEAD BOARD DIP SWITCH (S1):
ETHERNET BOARD DIP SWITCHES (S1, S2):
A-25
{
Page
A-27
DEVICENET MAC ID TABLE A.16
A-28
(DEFAULT)
ETHERNET BOARD DIP SWITCHES (S3, S4):
MASTER
MASTER
Page
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL
U0 U1 U2 I1 I2
B-3
PRODUCT SUMMARY
RECOMMENDED PROCESSES
PROCESS LIMITATIONS
EQUIPMENT LIMITATIONS
B-4
B-4 CASE FRONT CONTROL DESCRIPTIONS
Page
B-6
POWER-UP SEQUENCE
CASE REAR COMPONENTS DESCRIPTION (See Figure B.6)
B-7
B-7 DUTY CYCLE
AC/DC Submerged Arc Process
B-8
B-8 MULTIPLE ARC SYSTEM CONSIDERATIONS
-
-+
BASIC MODES OF OPERATION
Weld Sequence
B-10
B-10 WELD PROCESS ADJUSTMENTS
AC ADJUSTMENTS
WAVE BALANCE
Wave Balance
DC Offset
Frequency
B-11
B-11 MULTIPLE ARC AC ADJUST MENTS FOR SYSTEMS EQUIPPED WITH K2282-1 SYSTEM INTERFACE
Phase Relationship
BAD GOOD BAD
C-1
ACCESSORIES
C-1 KITS, OPTIONS AND ACCESSORIES
D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
ROUTINE MAINTENANCE
HOW TO USE TROUBLESHOOTING GUIDE
E-2
E-3
E-4
WELD AND ARC QUALITY PROBLEMS
(SYMPTOMS) POSSIBLE
E-5
WELD AND ARC QUALITY PROBLEMS
(SYMPTOMS) POSSIBLE
E-6
(SYMPTOMS) POSSIBLE
E-7
(SYMPTOMS) POSSIBLE
E-8
E-9
(SYMPTOMS) POSSIBLE
E-10
(SYMPTOMS) POSSIBLE
E-11
ETHERNET
E-12
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS
E-13
POWER SOURCE- WELD CONTROLLER
E-13
E-14
WIRE DRIVE MODULE
COMMUNICATION MODULE
F-1
DIAGRAMS
F-1
F-2
DIAGRAMS
F-2
Page
Page
F-5
DIMENSION PRINT
L12302
F-5
A.01
Page
AVISO DE PRECAUCION ATTENTION WARNUNG ATENO
AVISO DE PRECAUCION ATTENTION WARNUNG ATENO