Lincoln Electric IM839 User Manual

Page 1
DEVICENET MODULE
RETURN TO MAIN MENU
Safety Depends on You
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.
IM839
July, 2003
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
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i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 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.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
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1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
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1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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SAFETY
ii
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. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
ARC RAYS 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.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
vapors
Mar ‘95
to
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iii
SAFETY
iii
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.
materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY 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.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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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 suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
Page 6
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
vv
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Module Installation Instructions. ...........................................................................................A-1
DeviceNet Module Setup......................................................................................................A-1
Power Wave Setup...............................................................................................................A-1
DeviceNet Dip Switches .......................................................................................................A-2
DeviceNet Mac ID...................................................................................................A-2 thru A-4
DeviceNet Mac ID – ON=1, OFF =0: (Table 3) ...................................................................A-5
DeviceNet Module Board Figure A.3....................................................................................A-6
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Trouble Shooting............................................................................................................Section B
How To Use Troubleshooting Guide ......................................................................B-1
Troubleshooting Guide ............................................................................B-2 Thru B-4
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Page 8
A-1
FIGURE A.1
ITEMS CONTAINED IN HARDWARE BAG
Plastic LED lens (1)
Locknut (6)
Rubber Ring (1)
# 10 Hardware (Washer, Lockwasher,Nut
(1 Each)
INSTALLATION
MODULE INSTALLATION INSTRUCTIONS
REQUIRED TOOLS
3/8 Wrench or nut Driver Short Phillips Screw Driver
A-1
Remove the "optional" portion of the Communication Interface Module decal on the top door assembly and discard; apply the DeviceNet decal as shown in the DECAL MOUNTING detail.
DISCARD
OPTIONAL TOOLS
Serial Cable (Radio Shack Cat. Num. 26-269) Microsoft Windows compatible computer.
DEVICENET MODULE DESCRIPTION
This module adds DeviceNet communication capabili­ty to a Power Wave “M” type power source. It has a 5­pin sealed mini connector per ANSI B93.55M-1981.
THIS MANUAL COVERS:
• The setup and installation of the DeviceNet Module in a Power Wave “M” type power source.
• The installation of the software on a PC and its con­nection to a Power Wave.
• How to connect the Power Wave to a DeviceNet net­work.
• How to get the Power Wave up and running on the DeviceNet network.
WARNING
• ELECTRIC SHOCK CAN KILL.
DEVICENET DECAL
DECAL MOUNTING
Remove the screws in the door assembly. Lower door as shown in Figure A.1. Do not lean against the door assembly during installation, hinge damage may occur.
J16
1
D
4
A
• Do not touch electrically live part or electrode with skin or wet cloth­ing.
• Insulate yourself from work and ground.
• Turn off input power using the disconnect switch at the fuse box before working on the equip­ment..
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Locate the hardware bag and review its contests. Some items in the HARDWARE BAG will not be used.
C
3
F
2
Place the DeviceNet Interface Module (ITEM 1) onto the self-clinching studs.
Fasten the module to the door assembly using three of the supplied locknuts (ITEM 2).
Install the plastic LED lens through the open hole in the front of the door assembly and roll the rubber ring onto lens from the rear of the door assembly (ITEM 3).
Seat the status LED into the lens from the rear of the door assembly.
DEVICENET MODULE
Page 9
A-2
FIGURE A.2
INSTALLATION
A-2
Install the DeviceNet bulkhead connector by removing the plastic plug covering the circular hole (ITEM 4) in the front lower panel assembly. Install the 5-pin con­nector and mounting plate over the mounting studs as shown in (Figure A.1). Fasten with two of the supplied locknuts.
If a Wire Drive Interface Module is not installed (Figure A.1), locate the 6-pin to 4-pin interconnect. Insert the interconnect between J73 on the DeviceNet module and J16 in the machine harness. Discard the 4-pin to 4-pin interconnect and proceed to the next section.
If a Wire Drive Interface Module is installed (Figure A.2), locate the 4-pin to 4-pin interconnect. Insert the interconnect between J73 on the DeviceNet module and J81 on the Wire Drive Interface Module. Discard the 6-pin to 4-pin interconnect.
ONLY FOR MACHINES WITH A DEVICENET MODULE
AND A WIRE DRIVE INTERFACE MODULE
4-pin to 4-pin interconnect
switch 3 = Equipment Group 1 Select (Default = Off) switch 4 = Equipment Group 2 Select (Default = Off) switch 5 = Reserved for future use switch 6 = Reserved for future use switch 7 = Reserved for future use switch 8 = Reserved for future use
Bank S2
switch 1 = DeviceNet Baud Rate (Default = OFF) (See Table 2) switch 2 = DeviceNet Baud Rate (Default = OFF) (See Table 2)
DeviceNet Baud Rate (Table 2)
Switch 1 Switch 2 Baud Rate
Off Off 125K On Off 250K On On 500K On On Programmable Value
switch 3 = DeviceNet Mac ID (Default = Off) (See Table 3)
Wire Drive Module
DeviceNet Baud rate: The default Baud rate is 125K. If another Baud rate is desired, see table 2 in this sec­tion and set switches 1 and 2 of bank S2. Every device on a DeviceNet network must have the same Baud Rate.
DeviceNet Module DIP Switches:
Bank S1
switch 1 = Object Instance LSB (Default = OFF) (See Table 1) switch 2 = Object Instance MSB (Default = OFF) (See Table 1)
Object Instance (Table 1)
Switch 2 Switch 1 Instance
Off Off 0 Off On 1 On Off 2 On On 3
switch 4 = DeviceNet Mac ID (Default = On) (See Table 3)
switch 5 = DeviceNet Mac ID (Default = On) (See Table 3)
switch 6 = DeviceNet Mac ID (Default = On) (See Table 3)
switch 7 = DeviceNet Mac ID (Default = On) (See Table 3)
switch 8 = DeviceNet Mac ID (Default = On) (See Table 3)
DeviceNet MAC ID:
The default Mac ID is 62. Every device on the DeviceNet network should have a unique ID. If anoth­er MAC ID is desired, refer to Table 3.
Complete Board Installation
Close door assembly insuring not to cut or pinch any wires.
Reinstall the screws in door assembly. Re-apply power and verify the appropriate
status lights on the Power Wave are green. Discard any remaining hardware.
DEVICENET MODULE
Page 10
A-3
INSTALLATION
A-3
Software Installation
Insert the supplied CD into the PC. The PC should automatically start the software install of the programs.
If the PC does not automatically start the soft­ware installation then you will have to manual­ly start the software installation.
Open Windows Explorer From the software CD run "setup.exe" The installation program will guide you
through the rest of the software setup process.
DeviceNet Network Installation
For wiring the DeviceNet network to the Power Wave, see the document "DeviceNet Cabling Planning and Installation manual", Allen Bradley Publication DN-6.7.2. This doc­ument can be downloaded from the Allen Bradley web site. Connect the Power Wave to the trunk or drop using a female sealed-mini style connector. Avoid routing the DeviceNet control cables in close proximity to the weld­ing output leads. The Power Wave has no internal DeviceNet bus termination.
Some DeviceNet scanners require an EDS file be install before they can connect to the device. If your DeviceNet scanner does not require an EDS files to be installed, this step can be skipped. The EDS files for the Power Wave are located on the CD that was shipped with the DeviceNet Module.
Power Wave Product Code EDS File to USE
1 Undefined - Contact
Lincoln Electric 2 PW455 5 PW655 8 PW AC/DC 9 F355i
Configure the DeviceNet scanner to talk to the Power Wave.
Verify that the DeviceNet scanner can see the Power Wave.
Connect PC to Power Wave
With a standard 9 pin to 25 pin RS232 serial cable (Radio Shack cat no. 26-269), make a connection with the Power Wave and a PC.
Turn on the Power Wave Verify that no other application is using the
serial port. This includes any Hot Sync Application.
DeviceNet Software Settings
With the PC connected to the Power Wave, double click on the Power Wave Utilities on the Desktop to run the Power Wave PC appli­cation Launching program.
From the Applications tab select DeviceNet Observer. This will run Power Wave Observer.
Select the appropriate communication port and click OK.
To find the correct EDS file to install, go to the DeviceNet Configuration screen in Observer (complete Installation Software). The bottom left of this lists the Product Code and Vendor Revision. Based on these settings, pick the appropriate EDS file, see the table below for more information on which EDS file to use. Note that the product code that the DeviceNet reports back is based on software that is loaded into the control board.
DEVICENET MODULE
Note 1: MAC ID
Using bank S2, and switches 3 to 8, set the DeviceNet MAC ID on the gateway board. Note that every device on a DeviceNet net­work must have a unique MAC ID. Use table 3 in this section of the report to set the correct MAC ID. Changes to the DeviceNet MAC ID or Baud Rate require a cycle of power in order for them to take effect.
Page 11
A-4
Configuration Verification
From the file menu select Device Net and then Configuration. The configuration window will open up and allow you to verify that the set MAC ID and baud rate are correct.
If the DeviceNet scanner will not be commanding the Power Wave then refer under the DeviceNet Configuration section of the Power Wave Observer Manual for proper setup. If the DeviceNet scanner does not support explicit messages, then refer to all of the following sections in the Power Wave Observer User Manual: Additional Weld Schedule Variables and DeviceNet Configuration Section to properly setup the Power Wave.
From the file menu select Device Net and then Monitor. The DeviceNet Monitor (shown below) will display the status of the connection and its data. If everything is operating correctly, the "Polled IO Cnx State" will display "Established" and the IO Scans/Sec will have a non-zero value.
INSTALLATION
A-4
DEVICENET MODULE
Page 12
A-5
INSTALLATION
DeviceNet Mac ID – ON=1, OFF =0: (Table 3)
Mac ID Switch 8 Switch 7 Switch 6 Switch 5 Switch 4 Switch 3
000000 0 100000 1 200001 0 300001 1 400010 0 500010 1 600011 0 700011 1 800100 0
900100 1 1000101 0 1100101 1 1200110 0 1300110 1 1400111 0 1500011 1 1601000 0 1701000 1 1801001 0 1901001 1 2001010 0 2101010 1 2201011 0 2301011 1 2401100 0 2501100 1 2601101 0 2701101 1 2801110 0 2901110 1 3001111 0 3101111 1 3210000 0 3310000 1 3410001 0 3510001 1 3610010 0 3710010 1 3810011 0 3910011 1 4010100 0 4110100 1 4210101 0 4310101 1 4410110 0 4510110 1 4610111 0 4710111 1 4811000 0 4911000 1 5011001 0 5111001 1 5211010 0 5311010 1 5411011 0 5511011 1 5611100 0 5711100 1 5811101 0 5911101 1 6011110 0 6111110 1 6211111 0
A-5
DEVICENET MODULE
Page 13
A-6
INSTALLATION
FIGURE A.3
A-6
DEVICENET MODULE
Page 14
B-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
__________________________________________________________________________
B-1
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled PROBLEM (SYMP­TOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.
CAUTION
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.
DEVICENET MODULE
Page 15
B-2
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
B-2
Device does not go on line.
1. 24v bus power
2. Baud rate
3. MAC address
4. Termination
5. Wiring
1. Verify that LED 2 on the Power Waves DeviceNet Module is on when the DeviceNet network is powered. This should be done with the power on the Power Wave turned off.
2. Verify the Baud rate setting on the
Power Wave and on the DeviceNet Master are the same. The Configuration section of Observer displays the Power Waves baud rate.
3. Verify the Device Net MAC
address is correct. The Configuration section of Observer displays the Power Waves MAC address.
4. Verify that the Device Net bus is
terminated correctly.
5. Verify the wiring of all multi-port
taps and field attachable ends.
6. EDS files
6. Verify that the correct EDS files
are being used if they are needed. The Configuration section of the Observer application displays the current Product Code and Vendor Revision of the Power Wave.
CAUTION
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.
DEVICENET MODULE
Page 16
B-3
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
B-3
1. Current Interference
2. Termination
3. Shield
Device goes off line during welding
4. Power Supply
5. Expected Packet Rate
For more trouble shooting of a DeviceNet network the following references should be used.
1. Verify that cables are not run
along current carrying conductors. This would include the welding cables.
2. Verify that the DeviceNet bus is
terminated correctly.
3. Verify that the cable shielding is
correctly grounded at the bus power supply. The shield should be tied into the bus ground at only one point.
4. Verify that the power supply can
supply more than enough current for the devices in the network.
5. Verify that 1000/(Expected Packet
Rate) (scans per seconds). The Monitor section of the Observer application displays these values.
Allen-Bradley Cat. Num. DN-6.7.2 Rockwell Automation Document 8842 ODVA web site (www.odva.org)
CAUTION
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.
DEVICENET MODULE
Page 17
NOTES
DEVICENET MODULE
Page 18
WARNING
Spanish
AVISO DE
PRECAUCION
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
No toque las partes o los electrodos
bajo carga con la piel o ropa moja­da.
Aislese del trabajo y de la tierra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molha­da.
Isole-se da peça e terra.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 19
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
Turn power off before servicing.
Do not operate with panel open or
guards off.
WARNING
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
Desconectar el cable de ali-
mentación de poder de la máquina antes de iniciar cualquier servicio.
Débranchez le courant avant
l’entretien.
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
Não toque as partes elétricas nuas.
No operar con panel abierto o
guardas quitadas.
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de protection enlevés.
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 20
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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