Lincoln Electric POWER WAVE IM718 Operator's Manual
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Lincoln Electric POWER WAVE IM718 Operator's Manual

Lincoln Electric POWER WAVE IM718 Operator's Manual

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POWER WAVE
For use with machines having Code Numbers:
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. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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.lincolnelectric.com
RETURN TO MAIN MENU
™
10849
R
ISO/IEC 60974-1
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
AC/DC
Copyright © 2002 Lincoln Global Inc.
IM718
June 2002

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Summary of Contents for Lincoln Electric POWER WAVE IM718

  • Page 1 POWER WAVE For use with machines having Code Numbers: 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.
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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. Protegez-vous contre la secousse électrique: a.
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    Installation ...Section A Technical Specifications - POWER WAVE AC/DC ...A-1 Safety Precautions...A-2 Select Suitable Location ...A-2 Lifting...A-2 Stacking ...A-2 Machine Grounding ...A-2 High Frequency Protection ...A-2 Input Connection...A-3 Input Fuse and Supply Wire Considerations ...A-3 Input Voltage Changeover Procedure ...A-3 Welding with Multiple Power Waves...A-4 Multiple Arc Configuration ...A-5 Electrode and Work Cable Connections...A-6...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - POWER WAVE AC/DC (K1860-1) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS OUTPUT CONDITIONS 50/60HZ. 3 PHASE 460/500/575V 500A@40V.100% OPEN CURRENT PULSE CIRCUIT RANGE FREQUENCY VOLTAGE 90VDC 20-500 0.15 - 1000 Hz PROCESS CURRENT RANGES (AC or DC) SAW / MIG / MAG FCAW Pulse...

  • Page 9: Safety Precautions

    SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified should perform this installa- tion. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

  • Page 10: Input Connection

    FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install, use or service this equipment NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do so will result in damage to the machine.
  • Page 11 WELDING WITH MULTIPLE UNSYN- CHRONIZED POWER WAVES CAUTION 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. Each power source requires a work lead to the work stud to the welding fixture.
  • Page 12 MULTIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Arc #1 Arc #2 Arc #1 Power Source Work #1 Sense #1 Arc #1 Arc #2 Sense #1 Sense # 2 INSTALLATION Power Source fl Work #1 Sense #1 fl Power Work #2 Source...

  • Page 13: Electrode And Work Cable Connections

    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. Additionally no DIP switch changes are required to switch between the different polarities.

  • Page 14: Voltage Sensing

    VOLTAGE 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. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on perfor- mance.

  • Page 15: Control Cable Connections Between Power Source And Wirefeeder

    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.

  • Page 16: External I/O Connector

    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. Because the Power Wave is a ‘slave’...

  • Page 17: Dip Switch Settings And Locations

    A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches: WARNING • Turn off power at the disconnect switch. ------------------------------------------------------------------------ • Remove the top four screws securing the front access panel.
  • Page 18 A-11 Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3 INSTALLATION DEVICENET MAC ID TABLE A.5 POWER WAVE AC/DC A-11 Software Selectable Default Setting...
  • Page 19 A-12 A-12 INSTALLATION Bank S3 and S4 POWER WAVE AC/DC...

  • Page 20: Multiple-Arc System Description

    A-13 MULTI-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. The hardware for the power source has been designed so that the power source can either operate as a master or a slave.

  • Page 21: Operation

    SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Observe additional guidelines detailed in the begin- ning of this manual.

  • Page 22: Graphic Symbols That Appear On This Machine Or In This Manual

    GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPERATION POWER WAVE AC/DC SMAW GMAW FCAW GTAW OPEN CIRCUIT...

  • Page 23: Definiition Of Welding Terms

    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. The machine will select the cor- rect voltage and amperage based on the wire feed speed (WFS) set by the operator.

  • Page 24: General Description

    GENERAL DESCRIPTION The Power Wave AC/DC power source is designed to be a part of a modular welding system. Each welding arc may be driven by a single machine or by a number of machines in parallel. Additionally with the use of an external Phase Generator the phase angle and fre- quency of different machines can be synchronized.

  • Page 25: Case Front Controls

    Many variables beyond the con- trol of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
  • Page 26 Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative. To make a weld, the Power Wave needs to know the desired welding parameters.
  • Page 27 OPERATION 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.

  • Page 28: Pulse Welding

    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. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known.

  • Page 29: Accessories

    OPTIONAL EQUIPMENT FACTORY INSTALLED There are no factory installed options available for the Power Wave. FIELD INSTALLED OPTIONS / ACCESSORIES Required Accessories For Paralleling machines • Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100 In Robotic Applications • Control Cables (for use on FANUC robot arm, 22 pin to 14 pin, 10 ft), K1804-1 •...

  • Page 30: Maintenance

    Generally speaking the machine calibration will not need adjustment. However, if the weld per- formance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current.

  • Page 31: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 32 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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 33 (CR1 will not pull in.) 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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 34 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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) General degradation of the weld performance. The Power Wave is triggered to weld, but there is no output. The feeder will not cold inch wire Excessively long and erratic arc. Arc loss fault on robot 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.
  • Page 36 USING THE STATUS 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.

  • Page 37: Troubleshooting The Power Wave / Power Feed System Using The Status Led

    Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the Power Wave AC/DC can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED"). Error Code # Primary overcurrent error.

  • Page 38: Diagrams

    DIAGRAMS ENHANCED DIAGRAM REAR OF MACHINE SWITCH SWITCH MACHINE FRONT POWER WAVE AC/DC...
  • Page 39 RECEPTACLE POWER DIAGRAMS MACHINE REAR INPUT BOARD ETHERNET BOARD CONTROL BOARD CONTROL 282C 281C 285C 286C MACHINE FRONT POWER WAVE AC/DC SLAVE MASTER OUTPUT SLAVE MASTER...
  • Page 40 PIN, LEAD CONNECTOR SETUPS Table F.1 INTERFACE CONNECTOR WIRING Robotic Interface Connector (S6) +15vdc Tach voltage Tach common Tach 1A differential signal Tach 1B differential signal Tach 2A differential signal Tach 2B differential signal Single Tach Input Reserved for future use Voltage sense lead Motor "+"...
  • Page 41 Robotic Set Up, Electrode Positive, CV/Pulse Configuration CONTROL CABLE K1805-1 CONTROL CABLE K1805-1 User supplied User supplied electrode lead electrode lead User supplied User supplied work lead work lead WORK SENSE LEAD K940 CONNECTION DIAGRAM K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE DEVICENET CABLE K1796 COAXIAL WELD CABLE POWER WAVE AC/DC...
  • Page 42 DIMENSION PRINT POWER WAVE AC/DC...
  • Page 43 NOTES POWER WAVE AC/DC...
  • Page 44 NOTES POWER WAVE AC/DC...
  • Page 45 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 46 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 47 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 48 • World's Leader in Welding and Cutting Products • • 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.lincolnelectric.com...

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