Instruction/ maintenance manual of the product POWER WAVE IM718 Lincoln Electric
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PO WER W A VE A C/DC ™ OPERA TOR’S MANUAL IM718 June 2002 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
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 RA YS can burn. 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.
FOR ELECTRICALL Y powered 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.
Thank You 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.
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE AC/DC ...............................................A-1 Safety Precautions.
A-1 INST ALLA TION POWER WAVE AC/DC A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE AC/DC (K1860-1) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 50/60HZ.
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 with accessories attached to it. ST ACKING Power Wave AC/DC machine cannot be stacked. MACHINE GROUNDING The frame of the welder must be grounded.
A-3 INST ALLA TION POWER WAVE AC/DC A-3 INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine.
A-4 INST ALLA TION POWER WAVE AC/DC A-4 WELDING WITH MUL TIPLE UNSYN- CHRONIZED POWER W A VES Special care must be taken when more than one Power Wave is welding unsynchronized on a sin- gle part. Arc blow and arc interference may occur or be magnified.
A-5 INST ALLA TION POWER WAVE AC/DC A-5 MUL TIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Wor k # 2 Se ns e # 2 Pow er Source #2 Pow er Sourc e #1 Arc # 1 Arc #2 Wor k #1 Se n.
A-6 INST ALLA TION POWER WAVE AC/DC A-6 ELECTRODE AND WORK CABLE CONNECTIONS Due to the PowerWave AC/DC ’ s ability to produce either a DC positive, DC negative or AC output the electrode and work connections do not need to be reversed for the different polarities.
VOL T AGE SENSING The best arc performance occurs when the PowerWave AC/DC has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influ- ence the voltage apparent at the studs of the welder.
CONTROL CABLE CONNECTIONS BETWEEN POWER SOURCE AND WIREFEEDER Connect the control cable between the power source and wire feeder. The wire feeder connection on the PowerWave AC/DC is located under the spring loaded output cover, on the case front. The control cable is keyed and polarized to prevent improper connect.
EXTERNAL I/O CONNECTOR The Power Wave is equipped with a terminal strip for making simple input signal connections. The terminal strip is located underneath the spring-loaded cover. It is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group.
A-10 INST ALLA TION POWER WAVE AC/DC A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave.
A-11 INST ALLA TION POWER WAVE AC/DC A-11 DEVICENET MAC ID TABLE A.5 Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3 0 0 0 0 0 0 0 Software Selectable 1000001 2000010 3000011 4000100 500010.
A-12 INST ALLA TION POWER WAVE AC/DC A-12 Bank S3 and S4.
A-13 INST ALLA TION POWER WAVE AC/DC A-13 MUL TI-ARC SYSTEM DESCRIPTION The following is a general description of how the PowerWave AC/DC can be configured in a multi-arc set-up. Each welding arc may be driven by one machine or up to four machines connected in parallel.
B-1 OPERA TION B-1 POWER WAVE AC/DC SAFETY PRECUA TIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill.
B-2 OPERA TION B-2 POWER WAVE AC/DC 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 DIRECT C.
B-3 OPERA TION B-3 POWER WAVE AC/DC DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control.
RECOMMENDED EQUIPMENT /INTERF ACE Robotic Operation All welding programs and procedures are configured through software for the robotic Power Waves. With the proper configuration, Fanuc robots equipped with RJ-3 or RJ-3iB controllers may communicate directly to the Power Wave via ArcLink or DeviceNet.
B-5 OPERA TION POWER WAVE AC/DC B-5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1 . POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors.
B-6 OPERA TION B-6 POWER WAVE AC/DC Second, find the program in the welding software that best matches the desired welding process. The stan- dard software shipped with the Power Waves encom- passes a wide range of common processes and will meet most needs.
B-7 OPERA TION B-7 CV WELDING Synergic CV: For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The nominal preprogrammed volt- age is the best average voltage for a given wire feed speed, but may be adjusted to preference.
B-8 OPERA TION B-8 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage.
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power Wave. FIELD INST ALLED OPTIONS / ACCESSORIES Required Accessories For Paralle.
D-1 MAINTENANCE D-1 POWER WAVE AC/DC 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 equipment. • Do not touch electrically hot parts.
E-1 TROUBLESHOOTING E-1 POWER WAVE AC/DC 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 Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-3 TROUBLESHOOTING E-3 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-4 TROUBLESHOOTING E-4 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
E-5 TROUBLESHOOTING E-5 POWER WAVE AC/DC 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-6 TROUBLESHOOTING E-6 POWER WAVE AC/DC USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave is equipped with a status light if a problem occurs it is important to note the condition of the status light.Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.
E-7 TROUBLESHOOTING E-7 POWER WAVE AC/DC 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 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 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 PIN, LEAD CONNECT OR SETUPS F-3 POWER WAVE AC/DC T ABLE F .5 DEVICENET CONNECT OR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L T ABLE F .2 WIRE FEEDER RECEPT ACLE S1 Pin Lead # Function A 53 Arclink L B 54 Arclink H C 67A Electrode V oltage Sense D 52 Ground(0v) E 51 +40vdc T ABLE F .
F-4 CONNECTION DIAGRAM F-4 POWER WAVE AC/DC K1796 COAXIAL WELD CABLE User supplied work lead User supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE K.
F-5 DIMENSION PRINT F-5 POWER WAVE AC/DC XA 9.45 19.16 19.83 14.62 37.46 18.80 33.08 .65 .96 34.96 L1 1656.
NOTES POWER WAVE AC/DC.
NOTES POWER WAVE AC/DC.
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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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An important point after buying a device Lincoln Electric POWER WAVE IM718 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric POWER WAVE IM718 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric POWER WAVE IM718 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric POWER WAVE IM718 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric POWER WAVE IM718 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric POWER WAVE IM718, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric POWER WAVE IM718.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric POWER WAVE IM718. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric POWER WAVE IM718 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
