Lincoln Electric 11124, 11226

NOTES

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