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2009-12-301电源前面板一、通过该测试可以快速的确定各个开关是否工作正常；二、通过该测试可以能够查看最近出现过的14个历史故障代码，并能够删除这些历史故障代码2009-12-302数显表负输出端前面板状态指示灯电压表电源开关控制电缆连接口手柄认识电源前面板4数字电压表数字电流表过热指示灯控制面板部分认识电源前面板收弧模式开关检气/焊接转换开关焊丝种类选择CO2/Ar+CO2选择开关焊丝直径选择开关收弧电流电位器收弧电压电位器电弧特性控制认识电源控制面板上的开关2009-12-306冷送丝按钮检气按钮电流调节旋钮电压调节旋钮压紧轮旋钮2009-12-30控制电路板DIP 高级功能开关PC 板在焊接电源内的位置OFFON2009-12-308DIP 功能开关的位置和顺序DIP 功能开关设在焊机主板上，面对焊机，从左手向右手数依次为1，2，3，4，5，6，7，8，该开关设置在上边为开，即ON 状态；开关打在下边位置为关，即OFF 状态。
下图为全开状态。
OFFON81234567OFF ON控制板上的DIP开关的功能1 预送气（ON启用OFF关闭）2 起始弧坑模式输出（ON启用OFF关闭）3 反复填弧坑（ON启用OFF关闭）4 测试模式5 待定6 待定7 长电缆补偿（ON启用OFF关闭）8 送丝速度校正出厂设置全部在OFF位置。
2009-12-3092009-12-30104＃开关：测试模式开关设置：第4#开关设置在ON 的位置，则启用了测试模式。
如下图所示:功能说明：这个开关设置在ON 的位置，其他开关设置在OFF 的位置时，可以测试面板的电位器旋钮和开关的好坏。
81234567OFF ON注意：在焊接的时候，该开关必须设置在OFF 的位置INVERTEC ®CV 500功能性测试及错误代码显示•面板上开关和电位器的位置：收弧开关－置于“关”位置气流调整/ 焊接开关－置于“焊接”位置焊丝直径置于位置电弧特性控制电位器－调至“最小”收弧电流电位器－调至“最小”保护气选择开关Ar/CO2 / CO2 －置于“Ar/CO2 ”位置收弧电压电位器－调至“最小”2009-12-3012送丝机上的电压旋钮－调至“最小”送丝机上的电流旋钮－调至“最小”功能性测试及错误代码显示•送丝机控制盒上开关和电位器的位置：开机过程顺时针旋转收弧电流电位器从0到10数值将从0到100变化左边电流表显示“1”（代表测试步骤1,下同），右边电压表即将显示0到100来表示电位器的位置。
林肯焊机说明书Ⅰ.机械安装1．机头安装安装应牢固以防起弧时机头移动，注意机头与工作电缆应与地绝缘。
根据需要，可装在垂直调节器/水平调节器/行走小车上，所定的机头出厂前根据用户的订购模式安装送丝比率，当改变焊丝直径时需改变送丝轮和导向管。
对不同直径的焊丝需调节随动轮压力调节螺丝，焊丝分两档0.9-2.4mm和3.0-5.6mm。
根据需要调节，对较软的焊丝，压力宜小一点。
出厂时送丝轮设为正转（如图所示方向），但安装板可转动180º，并对换校直器和导电杆，送丝轮转动方向通过改变控制箱内接线上626，627号线来实现。
一般用25kg送丝盘。
NA-3S/NA-4/NA-3SF出厂时所装焊丝校直器的焊丝直径大于2mm以上。
机头安装好后，通过校直器和送丝导向管安装焊丝（其入口处为倒圆）而出丝导向管入口处为倒角）。
2．控制箱安装控制箱在标准行走小车或其它的机架上，当装在其它机架上时，打开控制箱后盖，按照控制箱底板上的安装孔固定控制箱。
3．导电杆组件国内一般常用K231 和K226●K231 导电杆组件：一般用于600A，更高电流可能引起导电嘴磨损坏。
适用于Ф2.4-5.6mm，对不同焊丝需不同导电嘴。
对Ф2.0-2.4mm焊丝还需导电嘴选配件和导丝管。
把工件电缆控制接到导电杆上，用螺栓拧紧，不用完全校直焊丝，以保持良好的电接触。
把焊剂漏斗的软管接到锥形组件的开口处。
要注意经常更换坏的导电嘴。
●K226 压钳式导电杆：一般用于600-1000A。
K226-T 由两个锥形夹组成用于Ф2.4-3.2mm。
K226R由一个锥形夹和一个方形夹组成，用于Ф3.2-5.6mm。
导电杆装在机头的下部，注意锥形夹的斜坡应朝向工件移动方向。
压钳应与导向管对直，通过调节夹钳一侧的螺丝来调节。
Ⅱ.电气安装1．电缆连接需600W，115V/50AC（其中，350W 给送丝电机和控制电路，250W 给行走电路）●从机头到控制箱：所有的工件电缆都接到控制箱后部，每个机头都带1.2m 长电机电缆和1.2m 长焊剂斗电缆，插到控制箱一侧对应的接口内。
焊机在使用的过程中遇到的常见故障及解决方法1. 问：虽已打开电源上的空气开关，但电源指示灯不亮有什么原因？答：A：焊接电源的输入端是否加了3~380V。
B：空气开关是否打开，冷却风机是否转动。
C：电源指示灯两端有否有DC电压。
2. 问：电源指示灯亮，但不能焊接是什么原因？答：A：检查电源保险，打开焊枪查看是否送丝。
B：输出端电缆接线是否正常。
C：用万用表测量反击是否有空载输出。
3.问：焊接中（电弧产生中）输出突然停止是什么原因？答：A：异常指示灯是否显示亮。
B：有无焊丝与导电嘴相粘现象？有无顶丝现象？C：送丝轮是否与丝径一致或有无严重磨损？D：送丝软管是否堵塞？4：问：焊缝有气孔有什么原因？答：A：打开焊枪是否有气体送出。
B：检查保护氛围是否良好C：检查工件是否生锈或有油污D：检查焊枪里是否有水E：检查送丝轮是否油污严重5：问：输出无法调整（空载电压正常）有什么原因？答：A：检查是电流不可调整还是电压不可调整B：检查电流电位器跟电压电位器是否良好C：检查控制电缆是否缺相6：问：易断弧或粘导电嘴有什么原因?答：A：易断弧，检查导电嘴的大小与焊丝直径是否一致，送丝软管是否良好B：粘导电嘴，适当降低焊接电压试焊C：导电嘴，送丝软管是否合适7：问：在使用中，超过了负载持续率及额定输出功率时，异常指示灯亮。
答：A：关掉焊枪开关，电源开关仍置于“开“的位置上（冷却风扇转动）待机，当焊接电源内部温度降到规定值以下时，会自动启动，可重新开始操作。
B：指示灯灭掉之后，不要马上开始作业，等候20分钟以上，让冷却风扇一直转动，使；焊接电源内部得到充分冷却C：重新开始作业时，务必注意降低施工条件（缩短焊接时间或降低输出电流）使用，如果在相同的条件下继续作业，会再次引起同样的故障，导致焊机停止工作，作业中断。
D：如果反复在超过负载持续率和额定输出的状态下使用，会导致内部元件的绝缘降低，使用寿命缩短，进而到时焊机故障及烧毁事故的发生。
埋弧焊常见缺陷的产生原因及其防止方法林肯PowerPlus 系列焊机说明 (2010/07/12 16:45)（引用地址：未提供）目录： 公司动态浏览字体：大 中 小1PowerPlus 系列焊机 DIP 开关功能说明在处理客诉和回访时，发现很多客户对这些功能不太了解，有些客户在不了解的情况下 设置了这些开关，造成了设备使用上的故障。
这里对DIP 开关的功能作进一步说明。
一、位置和顺序复气 孔1、 焊剂未清理干净2、 焊剂潮湿3、 焊剂中有垃圾4、 焊剂覆盖层厚度不当或焊剂斗阻塞5、 焊丝表面清理不够6、 电压过高防止：1、接头必须清理干净 2．焊剂按规定烘干3．焊剂必须过筛、吹灰、烘干4．调节焊剂覆盖层高度，疏通焊剂斗 5．焊丝必须清理清理后应尽快使用 6．调整电压裂 纹1、 焊件焊丝焊剂等材料配合不当2、 焊丝中含碳、硫量较高3、 焊接区冷却速度过快而致热影响区硬化4、 多层焊的第一道焊缝截面过小5、 焊缝成形系数太小6、 焊接顺序不合理防止：1、合理选配焊接材料 2．选用合格焊丝3．适当降低焊速以及焊前预热和焊后缓冷4．调整工艺参数和改变极性 5．合理安排焊接顺序DIP 功能开关设在焊机主板上，面对焊机，从右手向左手数依次为1，2，3，4，5，6，7，8，该开关设置在上边为关，即OFF 状态；开关打在下边位置为开，即ON 状态。
下图为全关状态。
二、出厂设置1．PowerPlus 355/505 的标准出厂设置：DIP 开关从1 到8 分别为：关，关，关，开，开，开，关，关。
8 ONOFF7 6 5 4 3 2 18 ONOFF7 6 5 4 3 2 12该标准设置下的程序图如图1：2．PowerPlus II 的标准出厂设置：DIP 开关从1 到8 分别为：关，关，关，开，开，关，开，关。
注意：如果中继电缆长度小于10米应关闭第七个开关。
标准设置见下：8 ONOFF7 6 5 4 3 2 1焊枪开关ONOFFON送气输出电压ON送丝速度焊接电流OFFOFF焊接收弧回烧图1 焊接时序图（４步）3该标准设置下的焊接时序图如图2：三、注意事项每次重设DIP 开关时，要先关闭机器。
林肯DC1000焊机中文说明书IDEALARC DC-1000 IM420-A配合以下代码的机器使用：9919-9925 和10293注意安全，重在自己林肯电弧焊接和切割设备是以安全第一为准则进行设计和制造的。
但是，正确安装和操作更有利于保障您的人身安全。
禁止在没有通读此手册和所包含的安全规章情况下安装，使用或维修此设备。
更重要的是，客户在进行上述操作之前应考虑得当。
1安全！警告请确保所有的安装，操作，维护以及修理过程均由合格人员执行。
1.h. 为了防止烫伤，当发动机仍然热时严禁打开散热器压力盖！内燃机类设备1.a.在排除故障和维修前，应关闭发动机，除非维修工作需要它运转。
1.b.在开放，通风良好的地方操作发动机，或者将废气排到室外。
1.c.禁止在焊接电弧附近或当发动机运转时添加燃料。
在添加燃料前应使发动机停止转动并使其冷却，防止溅出的燃料挥发与热态的发动机部件接触而燃烧。
若燃料溅出，需擦净后才能启动发动机。
1.d.应使所有设备的安全防护罩，盖子和装置在适当位置并检修正常。
当起动，使用或维修设备时，手，头发，衣物和工具应远离V型皮带，齿轮，风扇和所有其它运动部件。
1.e.有些情况，需要拆除防护罩进行必要的维修。
切记只有在必要时才能拆下防护罩并且当维修结束后请迅速将其复原。
在运动部件附近工作时要格外小心。
1.f.禁止用手接近风扇。
当发动机工作时，禁止不顾调速器或空转轮而强行推动节气阀控制杆。
1.g.在维修时，当转动发动机或焊接电源时，为了防止意外起动汽油发电机，请断开火花塞接线，点火分配器顶盖或电磁发动机接线及其它。
电磁场对人体有害2.a.流过任何导体的电流会产生电磁场(EMF) 。
焊接电流在焊接电缆和焊机附近将产生EMF。
2.b. 在EMF区内心脏起搏器会受到干扰，带有心脏起搏器的焊工在焊接前应向医生咨询。
2.c.在焊接时暴露于EMF区情况下将对身体健康产生其它未知影响。
2.d. 所有焊工需执行下述步骤以减小焊接回路EMF区的暴露程度。
L T -7 TRACTOR TROUBLESHOOTINGIM279-TSJUNE 1995Safety Depends on YouLincoln 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 MAN-UAL AND THE SAFETY PRE-CAUTIONS CONTAINED THROUGHOUT.And, most importantly, think before you act and be careful.Mar ‘95TABL E OF CONTENTSivivGENERAL DESCRIPTIONThe LT-7 tractor is a compact, lightweight, DC, single arc tractor.It is capable of operating with 3/32”through 3/16”electrode with a current carrying capacity of 1000 amps.The LT-7 has a travel range from 6 to 70 inches per minute.FIGURE E.1 - 115VAC INPUT POWER CIRCUITSINPUT POWER CIRCUITSThe LT7 is powered by 115VAC which is usually sup-plied from the welding power source.The 115VAC isapplied to the travel board.This voltage is also coupledto the control box circuitry through the on/off powerswitch and a 3 amp circuit breaker.The input power isthen applied to the the variable voltage board and,through resistor R1, to the control board.The 115VACis rectified and regulated by the control board whichsupplies 24VDC to the logic board.Upon receiving commands from the user operated switches or potentiomenters the logic board sends the appropriate signal to the control board which then dri-ves the wire feed motor to the correct speed and direc-tion.When the start signal is received by the control board the power source contact relay(1CR) is ener-gized as well as the travel relay(2CR) and the wire drive motor.When weld current closes reed switch 3CR the logic board directs the control board to change the wire feed speed from the preset inch speed to the welding feed speed set by the wire speed control potentiome-ter.Reed switch 4CR protects the internal grounding wire circuitry.In the event that abnormally high currentwas to flow in the grounding lead system the 4CR reed switch would close, signaling the logic board to stop the welding procedure.The inch up switch, which is cou-pled directly to the control board, dictates that the wire drive motor reverse direction and back the electrode wire away from the work piece.T ravel speed, direction and mode (either manual or auto) are determined by the settings of the three con-trols connected to the travel board.The travel board then applies the correct voltage and polarity to the trav-el motor to satisfy the control settings.CONTROL,LOGIC AND TRAVEL BOARDSFIGURE E.2 - CONTROL LOGIC AND TRAVEL BOARDSArc voltage is monitored by the voltmeter and variable voltage board.When the LT7 tractor is being operated in the constant current mode the variable voltage board is essential in the control of the wire feed speed. As the arc length changes the arc voltage will also change.The variable voltage board recognizes this change and signals the logic board to either increase or decrease the wire feed speed.This function is neces-sary to maintain a constant electrode arc length and a stable and high quality weld.The variable voltage board also generates a low volt-age which is applied to the electrode during the inch down mode.When the electrode makes contact with the work piece this low voltage is “loaded down”thus signaling the control circuitry to stop the wire feed motor.This feature allows the operator to utilize “work touch sensing”.FIGURE E.3 - VARIABLE VOLT AGE BOARD VARIABLE VOL TAGE BOARDA-4NOTES A-4If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.Call 216-383-2531 or 1-800-833-9353.Service and Repair should only be performed by L incoln 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.This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions.Simply follow the three step procedure below.Step 1.LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMPTOMS)”.This column describes possible symptoms that the machinery may exhibit.Find the listing that best describes the symptom that the machine is exhibiting.Symptoms are grouped according to:function problems and travel problems.Step 2.PERFORM EXTERNAL TESTS.The second column labeled “FIELD COURSE OF ACTION”lists the basic possibilities that may contribute to the machine symptom.Perform these tests/checks in the order listed.Step 3.PERFORM COMPONENT TESTS.The last column labeled “RECOMMENDED SHOP COURSE OF ACTION”lists the most likely components that may have failed in your machine.It also specifies the appropriate test procedure to verify that the subject component is either bad or good.If there are a number of possible components,check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.All the necessary test specifications and repair procedures are described in detailfollowing the troubleshooting guide.All electrical test points, terminal strips,junctions, etc., can be found on the electrical wiring diagrams and schematicsin the Electrical Diagram Section.How To Use Troubleshooting GuideT able B.1 P.C.Board Status LightsON* INDICA TES LIGHT IS DIMT able B.2 P.C.Board Status Light DefinitionsB-22TROUBL ESHOOTING AND REPAIR B-22 ArrayFIGURE B.1 Logic P.C.Board LED LocationsFIGURE B.3 Control P.C.Board LED LocationsB-23NOTES B-231.Remove the wire feed motor connector from the LT7 control box.ing the ohmmeter measure the motor resistances per Table B.3.Also see Figure B.43.If the motor resistance test is good pro-ceed to the Motor Applied Voltage T est.MOTOR APPLIED VOLTAGE TEST 1.Carefully connect the 110VDC supply (SUPPL Y TURNED OFF) to pins C and D on the motor connector.2.Carefully connect the variable 0 to 90VDC supply (SUPPL Y TURNED OFF) to pins A and B on the motor connector.(See T able B.3)3.Apply field voltage first(pins C and D) to the motor.Then slowly apply the arma-ture voltage on pins A and B.(See T able B.3)4.The motor should run and the speed should vary with changes to the armature voltage.5.If the motor does NOT run and change speed correctly the motor or gear box may be faulty.6.To stop motor REMOVE ARMATURE VOLT AGE FIRST .(Pins A and B)T ABLE B.3TEST PROCEDUREWIRE DRIVE MOTOR TEST (continued)FIGURE B.4 - Wire Drive Motor Connector PinsTEST PROCEDURE1.Remove the travel motor connector fromthe LT7 control box.ing the ohmmeter measure the motorresistances per Table B.4.Also see Figures B.5.and B.6*3.If the motor resistance test is good pro-ceed to the Motor Applied Voltage T est. MOTOR APPLIED VOLTAGE TEST1.*Carefully connect the 110VDC supply(SUPPL Y TURNED OFF) to pins C and D on the travel motor connector.See FigureB.62.Carefully connect the variable 0 to 90VDCsupply (SUPPL Y TURNED OFF) to pins A and B on the travel motor connector.3.*Apply field voltage first (pins C and D) tothe motor.See Figure B.6 and T able B.44.Slowly apply the armature voltage on pinsA and B.(See T able B.4)5.The motor should run and the speedshould vary with changes to the armature voltage.6.If the travel motor does NOT run andchange speed correctly the motor or gear box may be faulty.7.*To stop motor REMOVE ARMATUREVOLT AGE FIRST.(Pins A and B)*DENOTES OLDER UNITS WITH FIELD WINDING*DENOTES OLDER UNITS WITH FIELD WINDINGFIGURE B.5 T ravel Motor Connector PinsFIGURE B.6 T ravel Motor Connector Pins (OlderUnits with Powered Field.)B-29NOTES B-29MOTOR REMOVAL PROCEDURE:1.Remove the wire drive motor cable fromthe LT7 control box.ing the 1/2”wrench remove the boltholding the flux hopper(if used) to the bumper handle assembly.e the large slot head screwdriver toremove the two slot head screws holding the bumper handle assembly to the gear box housing.e the 5/32”Allen type wrench to removethe socket head cap screw from the gear box housing and motor end bracket.5.Locate and remove the four small slothead screws holding the inspection cover plate to the gear box housing.Note place-ment of rubber gasket and cable strain clamp.6.Locate and remove the two socket headcap screws mounting the motor to the gear box housing.Note:The inspection cover plate has to be remove (Step #5) to gain access to the two socket head cap screws.7.Carefully remove the motor(with piniongear) from the gear box assembly.MOTOR REPLACEMENT PROCEDURE: 1.Carefully install the replacement motor(with pinion gear) and mount to the gear box housing using the two socket head caps screws.ing the four small slot head screwsinstall the inspection cover plate along with the rubber gasket and cable clamp.3.Install the bumper handle assembly withthe socket head cap screw and the two larger slot head screws.4.Install the flux hopper (if used) to thebumper handle assembly and secure with the hex head bolt.5.Attach the wire drive motor cable to theLT7 control box receptacle.WIRE DRIVE MOTOR REMOVAL PROCEDURE (continued)CONNECTION SCHEMATIC - M15342T h i s d i a g r a m i s p r o v i d e d f o r r e f e r e n c e o n l y .I t m a y n o t b e t o t a l l y a p p l i c a b l e t o a l l m a c h i n e c o d e s .CONTROL BOX WIRING DIAGRAM- L7460It may not be totally applicable to all machine codes.C-3NOTES C-3World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors。
