Lincoln ElectricメーカーPOWER WAVE 11124の使用説明書/サービス説明書
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• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
iii SAFETY iii FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1.
v SAFETY v.
vi SAFETY vi.
vii vii T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
viii viii T ABLE OF CONTENTS Page I nstallation .......................................................................................................................... Section A Specifications .......................................................
ix T ABLE OF CONTENTS ix Troubleshooting ..............................................................................................Section E How to Use Troubleshooting Guide .......................................................................E-1 Troubleshooting Guide.
A-1 SPECIFICA TIONS POWER WAVE® AC/DC 1000 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® AC/DC 1000 (K2344-1, K2344-2) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERA TURE.
LIFTING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave AC/DC 1000 with accessories attached to it. ENVIRONMENT AL LIMIT A TIONS Do not use the Power Wave AC/DC 1000 in an out- door environment.
INPUT AND GROUND CONNECTIONS MACHINE GROUNDING The frame of the welder must be grounded. A ground terminal marked with the symbol shown is located inside the reconnect / input access door for this pur- pose. See your local and national electrical codes for proper grounding methods.
A-4 INST ALLA TION POWER WAVE® AC/DC 1000 A-4 SYSTEM CONNECTION System Overview The Power Wave AC/DC 1000 power source is designed to be a part of a modular welding system typically controlled by a Power Feed 10A Controller or customer supplied Programmable Logic Controller (PLC) .
A-5 INST ALLA TION A-5 RECOMMENDED EQUIPMENT System Identifier Power Source Weld Cables Head Torch Power Source to Head Control Cable User Interface ArcLink Digital Communication Cable PLC (w/ User Interface) DeviceNet Cables and Accessories System Interface System Interface to Power Source Control Cable Part No .
A-6 INST ALLA TION POWER WAVE® AC/DC 1000 A-6 OPTIONAL EQUIPMENT System Identifier Ethernet Network Equipment Personal Computer Travel Carriage Travel Carriage (High Capacity) Controller Mounting Bra.
A-7 INST ALLA TION POWER WAVE® AC/DC 1000 A-7 Wi re Feeder (14 Pin) A rc lin k (5 Pin) Arclink Conn ect io n K 236 2-1 Wire Reel and Mou nt ing Wor k Piece K 231- XXX Head * Wor k Cable(s) * Electr o.
A-8 INST ALLA TION POWER WAVE® AC/DC 1000 A-8 STEP BY STEP INST ALLA TION CHECKLIST SINGLE ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE) (as shown in the Connection Diagram "Typical Single Arc System") Place Power Wave in suitable operating location.
A-9 INST ALLA TION POWER WAVE® AC/DC 1000 A-9 A A R R C C 2 2 A A R R C C 1 1 A A R R C C 1 1 A A R R C C 2 2 A A R R C C 1 1 A A R R C C 2 2 A A R R C C 1 1 A A R R C C 2 2 S S Y Y S S T T E E M M I.
A-10 INST ALLA TION POWER WAVE® AC/DC 1000 A-10 STEP BY STEP INST ALLA TION CHECKLIST TANDEM ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE PER ARC) (as shown in the Connection Diagram "Typical Tandem Arc System”) Place Power Waves in suitable operating location.
A-11 INST ALLA TION POWER WAVE® AC/DC 1000 A-11 A A R R C C 1 1 A A R R C C 2 2 A A R R C C 2 2 A A R R C C 3 3 A A R R C C 1 1 A A R R C C 3 3 A A R R C C 1 1 A A R R C C 2 2 A A R R C C 3 3 S S Y Y.
A-12 INST ALLA TION POWER WAVE® AC/DC 1000 A-12 STEP BY STEP INST ALLA TION CHECKLIST TRIPLE ARC SYSTEM CHECKLIST – (DEVICENET PLC CONTROLLED, 1 POWER SOURCE PER ARC) (as shown in the Connection Diagram "Typical Triple Arc System”) Place Power Waves in suitable operating location.
A-13 INST ALLA TION POWER WAVE® AC/DC 1000 A-13 M M A A S S T T E E R R S S L L A A V V E E K 179 5- XX C abl es Connecti on Diagram - Parallel M achines (Example depicts a sin gle arc grouping, and may be repeated for each arc in th e syste m) Connect additional SLAVE machines as required to reach desired capacity.
A-14 INST ALLA TION POWER WAVE® AC/DC 1000 A-14 STEP BY STEP INST ALLA TION CHECKLIST EXTRA CAPACITY PARALLEL CONNECTION (as shown in the Connection Diagram "Parallel Machines”) Follow all steps of Single, Tandem, or Triple Arc checklists. Be sure input power is disconnected prior to following the remaining steps.
A-15 INST ALLA TION POWER WAVE® AC/DC 1000 A-15 ELECTRODE AND WORK CONNECTIONS General Guidelines The unique switching structure of the Power Wave AC/DC 1000 allows it to produce DC positive, DC negative or AC output waveforms without reposition- ing the work and electrode leads.
A-16 INST ALLA TION POWER WAVE® AC/DC 1000 A-16 CABLE INDUCT ANCE, AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area.
A-17 INST ALLA TION POWER WAVE® AC/DC 1000 A-17 c . Locate the 8-position DIP switch on the control board and look for switch 8 of the DIP switch. d . Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected .
A-18 INST ALLA TION POWER WAVE® AC/DC 1000 A-18 • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work volt- age sense leads on the opposite side, such that they are out of the current path.
A-19 INST ALLA TION POWER WAVE® AC/DC 1000 A-19 CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communica- tion and power needs of the Power Wave / Power Feed systems.
A-20 INST ALLA TION POWER WAVE® AC/DC 1000 A-20 Connections Between Multiple Power Sources Run in Parallel (K1795 - Control Cable). To increase the output capacity for a given arc, the output studs of multiple Power Wave AC/DC 1000 machines can be connected in parallel.
A-21 INST ALLA TION POWER WAVE® AC/DC 1000 A-21 EXTERNAL I/O CONNECT OR The Power Wave AC/DC 1000 is equipped with a ter- minal strip for making simple input signal connections. (See Figure A.2a) The terminal strip is located under- neath the spring-loaded cover, and divided into three groups: FIGURE A.
A-22 INST ALLA TION POWER WAVE® AC/DC 1000 A-22 Table A.7 External I/O S7 (12 pin – terminal block) PIN Lead # Function 1 851 +15vdc for Trigger group 2 852 Trigger input 3 853 Dual procedure input.
A-23 INST ALLA TION POWER WAVE® AC/DC 1000 A-23 WIRE DRIVE GEAR RA TIO SETTING Changing the wirefeeder gear ratio re quires a gear change in the wire drive, and a configuration change at t he power source. The P ower Wave AC/DC 1000 can be configured to support up to 4 unique gear ratios.
A-24 INST ALLA TION POWER WAVE® AC/DC 1000 A-24 ELECTRIC SHOCK can kill. • Do not touch electric ally live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ----------------------------------------------------------- 1.
Switch Description 1 Object Instance LSB* (see table A.14) 2 Object Instance MSB** (see table A.14) 3 Equipment Group 1 Select (default OFF) 4 Equipment Group 2 Select (default OFF) 5 Equipment Group .
A-26 INST ALLA TION POWER WAVE® AC/DC 1000 A-26 TABLE A.14 OBJECT INST ANCE switch 2 switch 1 Instance off off 0(default) off on 1 on off 2 on on 3 TABLE A.15 Switch 1 Switch 2 Baud Rate off off 125K (default) on off 250K off on 500K on on Programmable value.
A-27 INST ALLA TION POWER WAVE® AC/DC 1000 A-27 DEVICENET MAC ID TABLE A.16 Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3 0 0 0 0 0 0 0 Software Selectable 1 000001 2000010 3000011 40001.
A-28 INST ALLA TION POWER WAVE® AC/DC 1000 A-28 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 O N 1 2 3 4 5 6 7 8 O N ETHERNET BOARD DIP SWITCHES (S3.
B-1 OPERA TION B-1 POWER WAVE® AC/DC 1000 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill.
B-2 OPERA TION POWER WAVE® AC/DC 1000 B-2 INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE D.
B-3 OPERA TION B-3 POWER WAVE® AC/DC 1000 PRODUCT SUMMAR Y The Power Wave AC/DC 1000 is a high performance, digitally controlled inverter welding power source. It is capable of producing a variable frequency and ampli- tude AC output, DC positive output, or DC negative output without the need for external reconnection.
(See Figure B.5) 4. 10 Amp Wire Feeder Circuit Breaker: Protects 40 volt DC wire feeder power supply. 5 . 115 VAC Auxiliary Power Circuit Breaker: Protects case front receptacle auxiliary supply. (10 amps) 6. 21 Work Sense Lead Connector(4-Pin) 7. Arclink Connector (5-Pin) 8.
B-5 OPERA TION B-5 POWER WAVE® AC/DC 1000 8 12 7 11 9 10 4 5 13 14 6 15 FIGURE B.5.
B-6 OPERA TION B-6 9. AC Switch Assembly W/Impeller Fan 10. Optional CE Filter Assembly (not shown): CE compliance filter connects in series with input con- nection. Available for K2344-2 only. POWER-UP SEQUENCE When power is applied to the Power Wave AC/DC 1000, the status lights will flash green, for up to 15 seconds.
B-7 OPERA TION B-7 DUTY CYCLE The Power Wave AC/DC is capable of welding at a 100% duty cycle (continuous welding). COMMON WELDING PROCEDURES MAKING A WELD The serviceability of a product or structure utiliz- ing the welding programs is and must be the sole responsibility of the builder/user.
B-8 OPERA TION B-8 MUL TIPLE ARC SYSTEM CONSIDERA TIONS Large scale SAW applications often employ multiple arcs to increase deposition rates. In multiple arc sys- tems, magnetic forces created by like and opposing weld currents of adjacent arcs can result in arc inter- action that can physically push or pull the arc columns together.
B-9 OPERA TION B-9 WELD SEQUENCE: The weld sequence defines the weld procedure from beginning to end. The Power Wave AC/DC 1000 not only provides adjustment of basic welding parameters, but also allows the operator to fine tune the start and finish of each weld for superior performance.
B-10 OPERA TION B-10 WELD PROCESS ADJUSTMENTS Depending on the weld mode, there are a number of adjustments that can be made, including but not limit- ed to Current, Voltage and WFS. These adjustments apply to either AC or DC processes, and control the basic parameters of the weld.
B-11 OPERA TION B-11 MU L TI PLE ARC AC ADJ UST ME NTS FO R SYSTEMS EQUIPPED WITH K2282-1 SYSTEM INTERF ACE Phase The phase relationship between the arcs helps to minimize the magnetic interaction between adjacent arcs.
C-1 ACCESSORIES C-1 KITS, OPTIONS AND ACCESSORIES OPTIONAL KITS AND ACCESSORIES K2282-1 Power Wave System Interface The optional Power Wave System Interface provides the means to synchronize the AC wave shapes of up to four different arcs to a common carrier frequency.
D-1 MAINTENANCE D-1 POWER WAVE® AC/DC 1000 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equip- ment.
E-1 TROUBLESHOOTING E-1 POWER WAVE® AC/DC 1000 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.
E-2 TROUBLESHOOTING E-2 POWER WAVE® AC/DC 1000 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.
E-3 TROUBLESHOOTING E-3 POWER WAVE® AC/DC 1000 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.
E-4 TROUBLESHOOTING E-4 POWER WAVE® AC/DC 1000 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.
E-5 TROUBLESHOOTING E-5 POWER WAVE® AC/DC 1000 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.
E-6 TROUBLESHOOTING E-6 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-7 TROUBLESHOOTING E-7 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-8 TROUBLESHOOTING E-8 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-9 TROUBLESHOOTING E-9 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-10 TROUBLESHOOTING E-10 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-11 TROUBLESHOOTING E-11 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
E-12 TROUBLESHOOTING E-12 POWER WAVE® AC/DC 1000 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.
E-13 TROUBLESHOOTING E-13 POWER WAVE® AC/DC 1000 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.
E-14 TROUBLESHOOTING E-14 POWER WAVE® AC/DC 1000 Observe all Safety Guidelines detailed throughout this manual 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.
F-1 DIAGRAMS F-1 POWER WAVE® AC/DC 1000 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement.
F-2 DIAGRAMS F-2 POWER WAVE® AC/DC 1000 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement.
F-3 AC SWITCH WIRING DIAGRAM F-3 POWER WAVE® AC/DC 1000.
F-4 AC SWITCH WIRING DIAGRAM F-4 POWER WAVE® AC/DC 1000.
F-5 DIMENSION PRINT F-5 POWER WAVE® AC/DC 1000 L 12 30 2 A .0 1 19.70 19.16 9.56 18.84 40.94 43.44 33.00 34.34 14.62.
NOTES POWER WAVE® AC/DC 1000.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER ’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
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