POWER WAVE AC/DC - Lincoln Electric

POWER WAVE AC/DC ™

OPERATOR’S MANUAL

IM718June 2002

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers: 10849

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

ISO/IEC 60974-1

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2002 Lincoln Global Inc.

R

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

POWER WAVE AC/DC

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

Mar ‘95

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

POWER WAVE AC/DC

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

POWER WAVE AC/DC

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu 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” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

POWER WAVE AC/DC

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications - POWER WAVE AC/DC ...............................................A-1Safety Precautions.................................................................................................A-2Select Suitable Location ........................................................................................A-2

Lifting...............................................................................................................A-2Stacking ..........................................................................................................A-2

Machine Grounding ...............................................................................................A-2High Frequency Protection ....................................................................................A-2Input Connection....................................................................................................A-3Input Fuse and Supply Wire Considerations .........................................................A-3Input Voltage Changeover Procedure ...................................................................A-3Welding with Multiple Power Waves......................................................................A-4

Multiple Arc Configuration ...............................................................................A-5Electrode and Work Cable Connections................................................................A-6

Cable Inductance and its Effects on Pulse Welding........................................A-6Voltage Sensing .............................................................................................A-7

Control Cable Connections Between Power Source and Wirefeeder....................A-8Control Cable Connections Between Power Sources Run in Parallel ...................A-8Control Cable Connections between a Power Source and Phase Generator ......A-8Control Cable Specifications, Ethernet Connections.............................................A-8

External I/O Connector....................................................................................A-9High Speed Gear Box .....................................................................................A-9Dip Switch Settings and Locations...............................................................A-10Control Board Dip Switch ..............................................................................A-10Feed Head Board Dip Switch........................................................................A-10DeviceNET/Gateway Board Dip Switch, .......................................................A-11Multiple-Arc System Description ...................................................................A-12

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1Graphic Symbols that appear on this machine or in this manual...........................B-2Definiition of Welding Terms..................................................................................B-3General Description ...............................................................................................B-4Recommended Processes and Equipment ...........................................................B-4Required Equipment ..............................................................................................B-4Limitations..............................................................................................................B-4

Duty Cycle and Time Period ...........................................................................B-4Case Front Controls ........................................................................................B-5Constant Voltage Welding...............................................................................B-6Pulse Welding .................................................................................................B-7

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Equipment ...............................................................................................C-1Factory Installed..............................................................................................C-1Field Installed..................................................................................................C-1

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Routine, Periodic, Calibration Specification...........................................................D-1

________________________________________________________________________Troubleshooting ..............................................................................................Section E

How to use Troubleshooting Guide .......................................................................E-1Troubleshooting the Power Wave / Power Feed System using the Status LED ...E-2Troubleshooting Guide.............................................................................E-3 thru E-6Error Codes for the Power Wave ...................................................................E-7, E-8

________________________________________________________________________Diagrams ..........................................................................................................Section F

Wiring Diagram ......................................................................................................F-1Pin, Lead Connector, Connection Diagrams, and Dimension Print..........F-2 thru F-5

________________________________________________________________________Parts Lists ................................................................................................................P392

A-1INSTALLATION

POWER WAVE AC/DC

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE AC/DC (K1860-1)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

50/60HZ.3 PHASE

460/500/575V

OPENCIRCUIT

VOLTAGE

90VDC

INPUTVOLTAGE /

FREQUENCY50/60HZ

460V500V575V

HEIGHT38 in

965 mm

WIDTH19 in

483 mm

DEPTH33 in

838 mm

WEIGHT490 lbs.222 kg.

TYPE 75°C(SUPER LAG)OR BREAKERSIZE (AMPS)

454035

TYPE 75°CGROUND WIRE IN

CONDUIT AWG[IEC]SIZES (MM2)

10 (6)10 (6)10 (6)

TYPE 75°CCOPPER WIRE IN

CONDUIT AWG[IEC]SIZES (MM2)

8 (10)8 (10)10 (6)

PROCESS CURRENT RANGES (AC or DC)

SAW / MIG / MAGFCAWPulse

CURRENT

50-500 Average Amps 40-500 Average Amps15-725 Peak Amps

PULSEVOLTAGE

RANGE

5 - 55 VDC

AUXILIARY POWER(CIRCUIT BREAKER

PROTECTED)

40 VDC AT10 AMPS

115 VAC AT10 AMPS

PULSE ANDBACKGROUNDTIME RANGE

100 MICRO SEC. -3.3 SEC.

CURRENTRANGE

DC

20-500

PULSEFREQUENCY

0.15 - 1000 Hz

INPUTCURRENT

AMPS

31/29/25

IDLEPOWER

800 WattsMax.

POWER FACTOR@ RATED OUPUT

.95 MIN.

EFFICIENCY@ RATED OUPUT

84%

OUTPUTCONDITIONS

[email protected]%

OPERATING TEMPERATURE RANGE-20°C to +40°C

STORAGE TEMPERATURE RANGE-40°C to +40°C

LIFTING

Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave with accessories attached to it.

STACKING

Power Wave AC/DC machine cannot be stacked.

MACHINE GROUNDING

The frame of the welder must be grounded. A groundterminal marked with the symbol is located insidethe reconnect/input access door for this purpose. Seeyour local and national electrical codes for propergrounding methods.

HIGH FREQUENCY PROTECTION

Locate the Power Wave away from radio controlledmachinery.

The normal operation of the Power Wave mayadversely affect the operation of RF controlledequipment, which may result in bodily injury ordamage to the equipment.

------------------------------------------------------------------------

A-2INSTALLATION

POWER WAVE AC/DC

A-2

SAFETY PRECAUTIONSRead this entire installation section before youstart installation.

ELECTRIC SHOCK can kill.

• Only qualified personnelshould perform this installa-tion.

• Turn the input power OFF atthe disconnect switch or fusebox before working on thisequipment. Turn off the input

power to any other equipment connected to thewelding system at the disconnect switch or fusebox before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the Power Wave grounding lug(located inside the reconnect input access door)to a proper safety (Earth) ground.

-------------------------------------------------------------

SELECT SUITABLE LOCATIONDo not use Power Waves in outdoor environments. ThePower Wave power source should not be subjected tofalling water, nor should any parts of it be submerged inwater. Doing so may cause improper operation as wellas pose a safety hazard. The best practice is to keep themachine in a dry, sheltered area.

Do not mount the PowerWave over combustible sur-faces. Where there is a combustible surface directlyunder stationary or fixed electrical equipment, thatsurface shall be covered with a steel plate atleast.060" (1.6mm) thick, which shall extend not less than5.90" (150mm) beyond the equipment on all sides.

Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides and bottom. Dirt, dust, or any foreignmaterial that can be drawn into the welder should bekept at a minimum. Do not use air filters on the airintake because the air flow will be restricted. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdowns.

WARNING

CAUTION

A-3INSTALLATION

POWER WAVE AC/DC

A-3

INPUT CONNECTION

Only a qualified electrician should connect theinput leads to the Power Wave. Connectionsshould be made in accordance with all local andnational electrical codes and the connection dia-gram located on the inside of the reconnect/inputaccess door of the machine. Failure to do so mayresult in bodily injury or death.

-------------------------------------------------------------

Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe upper left case back next to the input access door.Connect L1, L2, L3 and ground according to the InputSupply Connection Diagram decal located on the

inside of the input access door or refer to Figure A.1 .

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONSRefer to the Technical Specifications at the beginningof this Installation section for recommended fuse andwire sizes. Fuse the input circuit with the recommend-ed super lag fuse or delay type breakers (also called“inverse time” or “thermal/magnetic” circuit breakers).Choose an input and grounding wire size according tolocal or national electrical codes. Using fuses or circuitbreakers smaller than recommended may result in“nuisance” shut-offs from welder inrush currents, evenif the machine is not being used at high currents.

INPUT VOLTAGE CHANGE OVER(FOR MULTIPLE INPUT VOLTAGEMACHINES ONLY)Welders are shipped connected for the highest inputvoltage listed on the rating plate. To move this con-nection to a different input voltage, see the diagramlocated on the inside of the input access door.

If the Auxiliary (A) lead is placed in the wrong position,there are two possible results. If the lead is placed in aposition higher than the applied line voltage, thewelder may not come on at all. If the Auxiliary (A) leadis placed in a position lower than the applied line volt-age, the welder will not come on, and the two circuitbreakers in the reconnect area will open. If thisoccurs, turn off the input voltage, properly connect the(A) lead, reset the breakers, and try again.

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

X

A

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 todo so will result in damage to the machine.

WARNING

A-4INSTALLATION

POWER WAVE AC/DC

A-4

WELDING WITH MULTIPLE UNSYN-CHRONIZED POWER WAVES

Special care must be taken when more than onePower Wave is welding unsynchronized on a sin-gle part. Arc blow and arc interference may occuror be magnified. Each power source requires awork lead to the work stud to the welding fixture.Do not combine all of the work leads into onelead. Performing welding in the direction awayfrom the work leads. (In a synchronized multi arcsystem the weld should go towards the workleads to minimize arc blow). Connect all of thework sense leads from each power source to thework piece at the end of the weld, such that theyare out of the path of the weld current. For addi-tional information on work voltage sense leadssee sections entitled "Voltage Sensing" and"Multiple Unsynchronized Arc Sense Lead andWork Lead Placement Guidelines".------------------------------------------------------------------------

TWO POWER WAVES

For the best results when pulse welding, set the wiresize and wire feed speed the same for all the PowerWaves. When these parameters are identical, thepulsing frequency will be the same, helping to stabilizethe arcs.

Every welding gun requires a separate shielding gasregulator for proper flow rate and shielding gas cover-age. Do not attempt to supply shielding gas for two ormore guns from only one regulator.

If an anti-spatter system is in use then each gun musthave its own anti-spatter system. (See Figure A.2.)

CAUTION

FIGURE A.2

TravelDirection

Connect All WorkSense Leads at the Endof the Joint.

Connect All WeldingWork Leads at the Beginning of the Joint.

A-5INSTALLATION

POWER WAVE AC/DC

A-5

MULTIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

Work #2Sense # 2

PowerSource

#2

PowerSource

#1

Arc #1

Arc #2

Work #1Sense #1

Work # 2 PowerSource

#2

PowerSource

#1

Arc #1

Arc #2

Work # 1

Sense #1Sense # 2

Current Flow

PowerSource

#1

PowerSource

#2

Work #1Sense #1

Work #2Sense #2

Arc #2

Arc #1

Current Flow

fl Current flow from Arc #1affects sense lead #2

fl Current flow from Arc #2affects sense lead #1

fl Neither sense lead picks upthe correct work voltage,causing starting and weldingarc instability.

BAD

fl Sense #1 is only affected by weldcurrent from Arc #1

fl Sense #2 is only affected by weldcurrent from Arc #2

fl Due to voltage drops across work piece,Arc voltage may be low, causing needfor deviation from standard procedures.

BETTER

fl Both Sense leads are out of the currentpaths.

fl Both Sense leads detect arc voltageaccurately.

fl No voltage drop between Arc and Senselead.

fl Best starts, best arcs, most reliableresults.

BEST

Current Flow

A-6INSTALLATION

POWER WAVE AC/DC

A-6

ELECTRODE AND WORK CABLECONNECTIONSDue to the PowerWave AC/DC’s ability to produce eithera DC positive, DC negative or AC output the electrodeand work connections do not need to be reversed for thedifferent polarities. Additionally no DIP switch changesare required to switch between the different polarities. Allof this is controlled internally by the Power Wave AC/DC.The following directions apply to all polarities:

Connect a work lead of sufficient size (Per Table 1) andlength between the "work" stud (located beneath thespring loaded output cover on the front of the machine)and the work. For convenience, the work lead can berouted behind the left strain relief (under the springloaded output cover), along the channels, and out theback of the machine. Be sure the connection to the workmakes tight metal-to-metal electrical contact. The workpiece connection must be firm and secure. Excessivevoltage drops caused by poor work piece connectionsoften result in unsatisfactory welding performance, espe-cially if pulse welding is planned. To avoid interferenceproblems with other equipment and to achieve the bestpossible operation, route all cables directly to the workand wire feeder. Avoid excessive lengths and do not coilexcess cable.

Connect the electrode cable between the wire feeder andthe "electrode" stud on the power source (located behindthe cover plate on the lower right side). For convenience,the cable can be routed through the oval hole in the rearof the machine before being connected to the output ter-minals. Connect the other end of the electrode cable tothe wire drive feed plate. Be sure the connection to thefeed plate makes tight metal-to-metal electrical contact.The electrode cable should be sized according to thespecifications given in (Table A.1).

Suggested Copper Cable Sizes - 100 Duty Cycle CombinedLength of Electrode and Work Cables (Table A.1)Cable Length (ft (m) Parallel Cables Cable Size0 (0) to 100 (30.4) 1 4/0 (120mm2)100 (30.4) to 200 (60.8) 2 2/0 (70mm2)200 (60.8) to 250 (76.2) 2 3/0 (95mm2)

When using inverter type power sources like thePower Wave, use the largest welding (electrode andwork) cables that are practical. When pulsing, thepulse current can reach very high levels. Voltagedrops can become excessive, leading to poor weldingcharacteristics, if undersized welding cables are used.NOTE: K1796 coaxial welding cable is recommendedto reduce the cable inductance in long cable lengths.This is especially important when Pulse welding up to350 amps.

CABLE INDUCTANCE, AND ITS EFFECTSON PULSE WELDINGFor Pulse Welding processes, cable inductance willcause the welding performance to degrade. For thetotal welding loop length less than 50 feet, traditionalwelding cables may be used without any effects onwelding performance. For the total welding loop lengthgreater than 50 feet, the K1796 Coaxial WeldingCables are recommended. The welding loop length is defined as the total of elec-trode cable length (A) + work cable length (B) + worklength (C) (See Figure A.3).

For long work piece lengths, a sliding ground shouldbe considered to keep the total welding loop lengthless than 50 feet. (See Figure A.4.)

FOR A DETAILED CONNECTION DIAGRAM USINGK1796 COAXIAL CABLE, SEE PAGE F-4.

When pulsing, the pulse current can reach veryhigh levels. Voltage drops can become excessive,leading to poor welding characteristics, if under-sized welding cables are used.------------------------------------------------------------------------

CAUTION

B

A

C

FIGURE A.3

POWERWAVE

WORK

A

C

B

POWERWAVE

FIGURE A.4

K1796 COAXIAL CABLE

MEASURE FROM ENDOF OUTER JACKET OFCABLE

C

A

B

WORK

SLIDING GROUND

VOLTAGE SENSINGThe best arc performance occurs when thePowerWave AC/DC has accurate data about the arcconditions. Depending upon the process, inductancewithin 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 arcconditions and can have a dramatic effect on perfor-mance. Sense Lead Kits (K490-series) are availablefor this purpose.

If the voltage sensing is enabled but the senseleads are missing, improperly connected, or if theelectrode polarity switch is improperly configuredextremely high welding outputs may occur.

In extremely sensitive applications requiring volt-age sense leads, it may be necessary to route thecontrol cable (67 lead) and the work voltage senselead (21 lead) away from the electrode and workwelding cables. For more information regardingthe placement of voltage sense leads, see the sec-tion entitled "Welding with Multiple IndependentPower Waves."

------------------------------------------------------------------------The ELECTRODE sense lead (67) is built into theK1795 control cable. The WORK sense lead (21) con-nects to the Power Wave at the four-pin connectorlocated underneath the output stud cover.Enable the voltage sense leads as follows:

TABLE A.2Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 leadGMAW 67 lead required 21 lead optional**GMAW-P 67 lead required 21 lead optional**FCAW 67 lead required 21 lead optional**GTAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optional

* The electrode voltage 67 sense lead is part of thecontrol cable to the wire feeder.

** For consistent weld quality, work voltage sensing isrecommended.

Work Voltage SensingThe Power Waves are shipped from the factorywith the work sense lead disabled.

To use work voltage sensing, connect the (21) workvoltage sense lead from the Power Wave to the work.Attach the sense lead to the work as close to the weldas practical. Enable the work voltage sensing in thePower Wave as follows:


• Do not touch electrically live partsor electrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

-----------------------------------------------------------

1. Turn off power to the power source at the discon-nect switch.

2. Remove the front cover from the power source.

3. The control board is on the left side ofthe power source. Locate the 8-positionDIP switch and look for switch 8 of theDIP switch.

4. Using a pencil or other small object,slide the switch to the OFF position ifthe work sense lead is NOT connected.Conversely, slide the switch to the ONposition if the work sense lead is pre-sent.

5. Replace the cover and screws. The PC board will(read) the switch at power up, and configure thework voltage sense lead appropriately.

Electrode Voltage SensingEnabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead is internal to the cable to thewire feeder and always connected when a wire feederis present.

WARNING

O N1

23

45

67

8

CAUTION

A-7INSTALLATION

POWER WAVE AC/DC

A-7

CONTROL CABLE CONNECTIONSBETWEEN POWER SOURCE ANDWIREFEEDERConnect the control cable between the power sourceand wire feeder. The wire feeder connection on thePowerWave AC/DC is located under the spring loadedoutput cover, on the case front. The control cable iskeyed and polarized to prevent improper connect.

For convenience, the control cables can be routedbehind the left or right strain relief (under the springloaded output cover), along the channels of the PowerWave, out the back of the channels, and then to thewire feeder.

Excessive voltage drops at the work piece con-nection often result in unsatisfactory pulse weld-ing performance.------------------------------------------------------------------------

CONTROL CABLE CONNECTIONSBETWEEN POWER SOURCES RUNIN PARALLELThe connectors located on the rear of the machine areused for synchronizing the operation of multiplemachines. To run machines in parallel connect thecontrol cable (K1795 series) between power sourcesthat are to run in parallel. The bottom (male) connec-tor on the master connects to the top (female) connec-tor on the slave. If needed the bottom connector onthe slave machine is then used to connect to anotherslave machine. This connection scheme is duplicatedfor any additional slaves.

CONTROL CABLE CONNECTIONSBETWEEN A POWER SOURCEAND PHASE GENERATORIf multiple arcs need to be synchronized an externalphase generator is required. The phase generator isconnected to all of the master machines. A controlcable (K1795 series) should be connected betweenthe phase generator and the top (female) connectoron the rear of the master machine.

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave / Power Feed system.

The use of non-standard cables, especially inlengths greater than 25 feet, can lead to communi-cation problems (system shutdowns), poor motoracceleration (poor arc starting) and low wire dri-ving force (wire feeding problems). Use the short-est length of control cable possible. Do not coilexcess cable as this can cause communicationproblems (system shutdowns).------------------------------------------------------------------------Lincoln control cables are copper 22 conductor cablein a SO-type rubber jacket.

The K1795 series of control cables can be added inseries as needed. Do not exceed more than 100 feet(30.5 m) total control cable length.

ETHERNET CONNECTIONS

The PowerWave is equipped with an Ethernet con-nector, which is located under the spring loaded out-put cover. All Ethernet cables external to either a con-duit or an enclosure should be solid, shielded with adrain, cat 5 cable. The drain should be grounded. Donot use cat 5+, cat 5E, cat 6 or stranded cable. If con-nection failure during welding persists reroute cablesaway from any other cables that carry current or otherdevices that would create a magnetic field. See FigureA.4a.

FIGURE A.4a

CAUTION

CAUTION

A-8INSTALLATION

POWER WAVE AC/DC

A-8

POWER WAVEPOWER WAVEPOWER WAVE

POWER WAVE POWER WAVE

PHASEGENERATOR

CAT 5 CABLESOLID, SHIELDED,WITH A DRAIN(MAX LENGTH = 3 METERS)

JUNCTION BOX

CONDUIT WITH CAT 5 UTP CABLE

ENVIRONMENTALENCLOSURE

ETHERNET SWITCH

PATCH PANEL

POWER WAVE ETHERNET LAYOUT SETUP

- MAX TOTAL CABLE LENGTH IS 70 METERS (FROM POWER WAVE TO PATCH PANEL)

- SHIELDED CABLE SHOULD BE GROUNDED AT JUNCTION BOX

- REFER TO ISO / IEC 11801 FOR SPECIFICATIONS

EXTERNAL I/O CONNECTOR

The Power Wave is equipped with a terminal strip formaking simple input signal connections. The terminalstrip is located underneath the spring-loaded cover. Itis divided into three groups: Trigger group, Cold InchGroup and Shutdown Group. Because the PowerWave is a ‘slave’ on the DeviceNet network, theTrigger and Cold Inch Groups are disabled when theDeviceNet/Gateway is active.

The shutdown group is always enabled. Shutdown2 isused for signaling low flow in the water cooler.Unused shutdowns must be jumpered. Machines fromthe factory come with the shutdowns alreadyjumpered. (See Figure A.5)

A-9INSTALLATION

POWER WAVE AC/DC

A-9

D

E

F

1 2 3 4 5 6 7 8 9 10 11 12

G

H

I

A

B

C

+15

VD

C fo

r T

rigge

r G

roup

Trig

ger

Inpu

t

Dua

l Pro

cedu

re In

put

4 S

tep

Inpu

t

+15

VD

C fo

r C

old

Inch

Gro

up

Col

d In

ch F

orw

ard

Col

d In

ch R

ever

se

Gas

Pur

ge In

put

+15

for

shut

dow

n gr

oup

Shu

tdow

n1 in

put

Shu

tdow

n2 in

put (

Wat

er F

ault)

Res

erve

d fo

r fu

ture

use

FIGURE A.5

HIGH SPEED GEAR BOXChanging the ratio requires a gear change and a PCboard DIP switch change. As shipped from the facto-ry, the low speed (high torque) gear is configured. Tochange the gear ratio see the Wire Feeder InstructionManual. The High/Low DIP switch code on Wire DrivePC board can be set as follows:


• Do not touch electrically live partsor electrodes with your skin or wetclothing.

• Insulate yourself from the work andground.


-----------------------------------------------------------

1. Turn off power to the power source at the dis-connect switch.

2. Remove the front cover from the power source.

3. The wire feed head board is on the right side of thepower source. Locate the 8-position DIPswitch and look for position 8 of the DIPswitch.

4. Using a pencil or other small object, slidethe switch to the OFF position, when thelow speed gear is installed. Conversely,slide the switch to the ON position whenthe high speed gear is installed.

5. Replace the cover and screws. The PCboard will "read" the switch at power up, automati-cally adjusting all control parameters for the speedrange selected

O N1

23

45

67

8

WARNING

WARNING

A-10INSTALLATION

POWER WAVE AC/DC

A-10

DIP Switch Settings and LocationsDIP switches on the P.C. Boards allow for customconfiguration of the Power Wave. To access the DIPswitches:

• Turn off power at the disconnect switch.------------------------------------------------------------------------• Remove the top four screws securing the front

access panel.• Loosen, but do not completely remove, the bottom

two screws holding the access panel.• Open the access panel, allowing the weight of the

panel to be carried by the bottom two screws. Makesure to prevent the weight of the access panel fromhanging on the harness.

• Adjust the DIP switches as necessary.• Replace the panel and screws, and restore power.

WARNING

CONTROL BOARD DIP SWITCHSwitch Description Comments1 Object Instance LSB (see table A.3)2 Object Instance MSB (see table A.3)3 Equipment Group 1 Select4 Equipment Group 2 Select Used for ArcLink5 Equipment Group 3 Select configuration6 Equipment Group 4 Select7 Reserved for future use

Used for configuringwork sense lead(See Work VolktageSensing in Section A)

OBJECT INSTANCEswitch 2 switch 1 Instance

off off 0off on 1on off 2on on 3

TABLE A.3

(default)

FEED HEAD BOARD DIP SWITCH:Switch Description Comments1 Object Instance LSB (see table A.3)2 Object Instance MSB (see table A.3)3 Equipment Group 1 Select4 Equipment Group 2 Select Used for ArcLink Configuration5 Equipment Group 3 Select6 Equipment Group 4 Select

Used for configuring electrode polarity (see Electrode and Work

7 Cable Connection in this Section)No changes required for PowerWave AC/DCUsed for configuring wirefeeder

8 gear ratio (see High Speed GearBox in this Section)

Bank S1Switch Description Comments1 Object Instance LSB (see table A.3)2 Object Instance MSB (see table A.3)3 Equipment Group 1 Select4 Equipment Group 2 Select Used for ArcLink Configuration5 Equipment Group 3 Select6 Equipment Group 4 Select7 Reserved for future use8 Reserved for future use

Bank S2:Switch Description Comments1 DeviceNet Baud Rate2 (See Table A.4)34 Used for DeviceNet 5 DeviceNet Mac ID Configuration6 (See Table A.5)78

ETHERNET BOARD DIP SWITCH:

DeviceNet Baud Rate:switch 1 switch 2 Baud rate

off off 125Kon off 250Koff on 500Kon on Programmable value

TABLE A.4

off work sense lead not connected

on work sense lead connected8

off Electrode polarity positive (default)

on Electrode polarity negative

off Low speed gear (default)

on High speed gear

A-11INSTALLATION

POWER WAVE AC/DC

A-11DEVICENET MAC ID

TABLE A.5Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3

0 0 0 0 0 0 0 Software Selectable1 0 0 0 0 0 12 0 0 0 0 1 03 0 0 0 0 1 14 0 0 0 1 0 05 0 0 0 1 0 16 0 0 0 1 1 07 0 0 0 1 1 18 0 0 1 0 0 09 0 0 1 0 0 110 0 0 1 0 1 011 0 0 1 0 1 112 0 0 1 1 0 013 0 0 1 1 0 114 0 0 1 1 1 015 0 0 1 1 1 116 0 1 0 0 0 017 0 1 0 0 0 118 0 1 0 0 1 019 0 1 0 0 1 120 0 1 0 1 0 021 0 1 0 1 0 122 0 1 0 1 1 023 0 1 0 1 1 124 0 1 1 0 0 025 0 1 1 0 0 126 0 1 1 0 1 027 0 1 1 0 1 128 0 1 1 1 0 029 0 1 1 1 0 130 0 1 1 1 1 031 0 1 1 1 1 132 1 0 0 0 0 033 1 0 0 0 0 134 1 0 0 0 1 035 1 0 0 0 1 136 1 0 0 1 0 037 1 0 0 1 0 138 1 0 0 1 1 039 1 0 0 1 1 140 1 0 1 0 0 041 1 0 1 0 0 142 1 0 1 0 1 043 1 0 1 0 1 144 1 0 1 1 0 045 1 0 1 1 0 146 1 0 1 1 1 047 1 0 1 1 1 148 1 1 0 0 0 049 1 1 0 0 0 150 1 1 0 0 1 051 1 1 0 0 1 152 1 1 0 1 0 053 1 1 0 1 0 154 1 1 0 1 1 055 1 1 0 1 1 156 1 1 1 0 0 057 1 1 1 0 0 158 1 1 1 0 1 059 1 1 1 0 1 160 1 1 1 1 0 061 1 1 1 1 0 162 1 1 1 1 1 0 Default Setting

A-12INSTALLATION

POWER WAVE AC/DC

A-12

Bank S3 and S4

A-13INSTALLATION

POWER WAVE AC/DC

A-13

MULTI-ARC SYSTEM DESCRIPTION

The following is a general description of how thePowerWave AC/DC can be configured in a multi-arcset-up.

Each welding arc may be driven by one machine or upto four machines connected in parallel. The hardwarefor the power source has been designed so that thepower source can either operate as a master or aslave. A few DIP switches must be configured proper-ly to set the machine’s identity. Each power sourcehas a rating of 500 amps average current, with a peakcurrent of 725 amps. So, four machines are capableof driving 2000 amps of output current with up to 2900amps of peak current available. Each arc must haveone power source designated as the master. If onlyone machine is required for an arc, then it must be setup as the master. The master power source controlsthe AC switching for the arc. The slaves respond towhat the master wants

Due to the flexibility of the platform the configurationmay vary. A typical subarc system will consist of fourwelding arcs, which require ten power sources andone synchronous generator. Arc # 1 & #2 will be threemachines in parallel. Arc #3 & #4 will be two machinesconnected in parallel (each individual machine is con-nected to the ethernet hub).

The PC will function as the control center for theAC/DC system as well as the user interface. TheEthernet hub splits the Ethernet port from the PC to allthe power sources and the phase generator. The PCwill act to coordinate the welding sequence of the mul-tiple machines.

One machine will be designated the master, with therest of the machines connected in parallel consideredslaves. The master can generate it's own AC frequen-cy or it can use an external signal as a reference. Anexternal Phase Generator provides the means to syn-chronize the AC wave shape between multiple arcs.The phase angle between arcs can be adjusted toreduce "Arc Blow" and other welding related issues.An external phase control signal is required to keepthe separate wave shapes synchronized with eachother

An Ethernet-Gateway board can be used as the exter-nal Phase Generator. An Ethernet-Gateway PC boardthat can be configured to generate four phase signalsonto four differential I/O lines. The phase signals canthen be used to synchronize the four different arcs toa common carrier frequency. The frequency canrange from 10 hertz to 300 hertz, with the most practi-cal range being from 50 to 100 hertz. It may be desir-able that sync signals 2, 3, or 4 are some multiple ofthe first signal. The frequency and phase shift arecontrolled by software.

Ethernet Hub

PC

ARC#1

ARC#2

ARC#3

ARC#4

PULSE

GENERATOR

B-1OPERATIONB-1

POWER WAVE AC/DC

SAFETY PRECUATIONSRead this entire section of operating instructionsbefore operating the machine.


• Unless using cold feed feature, whenfeeding with gun trigger, the electrodeand drive mechanism are always elec-trically energized and could remainenergized several seconds after thewelding ceases.

• Do not touch electrically live parts or electrodeswith your skin or wet clothing.

• Insulate yourself from the work and ground.


FUMES AND GASES can be dan-gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fireor explosion.

• Keep flammable material away.

• Do not weld on containers that haveheld combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the begin-ning of this manual.

WARNING

B-2OPERATIONB-2

POWER WAVE AC/DC

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

GMAW

FCAW

GTAW

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVEGROUND

WARNING

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

SMAW

B-3OPERATIONB-3

POWER WAVE AC/DC

DEFINITION OF WELDING TERMS

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all weldingprocess variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity ofsingle knob control. The machine will select the cor-rect voltage and amperage based on the wire feedspeed (WFS) set by the operator.

WFS• Wire Feed Speed

CC• Constant Current

CV• Constant Voltage

GMAW (MIG)• Gas Metal Arc welding

GMAW-P (MIG)• Gas Metal Arc welding-(Pulse)

GMAW-PP (MIG)• Gas Metal Arc welding-(Pulse-on-Pulse)

GTAW (TIG)• Gas Tungsten Arc welding

SMAW (STICK)• Shielded Metal Arc welding

FCAW (INNERSHIELD)• Flux Core Arc Welding

SAW• Submerged Arc welding

RECOMMENDED EQUIPMENT/INTERFACE Robotic OperationAll welding programs and procedures are configuredthrough software for the robotic Power Waves. Withthe proper configuration, Fanuc robots equipped withRJ-3 or RJ-3iB controllers may communicate directlyto the Power Wave via ArcLink or DeviceNet. Properconfiguration and options allow other equipment suchas PLC’s or computers to interface with a PowerWave through a serial, DeviceNet, ArcLink, orEthernet interfaces. All wire welding processes requirea robotic Power Feed wire feeder.

Hard AutomationOperating the Power Wave AC/DC in a hard automa-tion application requires a PC or PLC for the userinterface. The power source communicates with thePC via Ethernet. A wire feeder can be controlledthrough Arc-link, DeviceNET or Ethernet.

SemiAutomatic OperationOperating the Power Wave AC/DC in the semi-auto-matic mode requires an Arc-Link compatible wirefeeder and user interface.

EQUIPMENT LIMITATIONS

• The Power Waves are not to be used in outdoorenvironments.

• Only Arc-Link Power Feed wire feeders may beused with standard interfaces. Other Lincoln wirefeeders or non-Lincoln wire feeders can only beused with custom interfaces.

• Operating Temperature Range is –20C to + 40C.• The Power Wave AC/DC will support a maximum

average output current of 500 Amps at 100% DutyCycle.

REQUIRED EQUIPMENT• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 10 ft), K1804-1 • Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 18 in), K1805-1• Control Cables (for use on FANUC robot arm, 22 pin to 14

pin, 18 in), K1804-2

DUTY CYCLE AND TIME PERIODThe Power Wave AC/DC is capable of welding at a100% duty cycle (continuous welding).

B-4OPERATIONB-4

GENERAL DESCRIPTIONThe Power Wave AC/DC power source is designed tobe a part of a modular welding system. Each weldingarc may be driven by a single machine or by a numberof machines in parallel. Additionally with the use of anexternal Phase Generator the phase angle and fre-quency of different machines can be synchronized.

The Power Wave AC/DC is a high performance, digi-tally controlled inverter welding power source capableof complex, high-speed waveform control. The PowerWave AC/DC is capable of producing a variable fre-quency and amplitude AC output, a DC positive out-put, or a DC negative output. The Power WaveAC/DC can support constant current, constant voltageand pulse welding modes.

The Power Wave AC/DC is designed to communicatewith other Arc-Link equipment. Additionally it can com-municate with other industrial machines viaDeviceNET. Also the Power Wave AC/DC machinesare capable of communicating by Ethernet. The resultis a highly integrated and flexible welding cell.

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSES

The Power Wave AC/DC can be set up in a number ofconfigurations, some requiring optional equipment orwelding programs. Each machine is factory prepro-grammed with multiple welding procedures, typicallyincluding SAW, GMAW, GMAW-P, FCAW, GTAW fora variety of materials, including mild steel, stainlesssteel, cored wires, and aluminum. It carries an outputrating of 500 amps, 44 volts (at 100% duty cycle).

The Power Wave AC/DC can be configured for robot-ic, hard-automation or semi-automatic use.

PROCESS LIMITATIONS

The Power Wave AC/DC is suitable only for theprocesses listed.

POWER WAVE AC/DC

B-5OPERATION

POWER WAVE AC/DC

B-5

CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave. (See Figure B.1)

1. POWER SWITCH: Controls input power to thePower Wave.

2. STATUS LIGHT: A two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated per table B1.

NOTE: The robotic PowerWaves’ status light will flashgreen, for up to 15 seconds when the machine is firstturned on. This is a normal situation as the machinegoes through a self test at power up.

TABLE B1

LightCondition

Steady Green

BlinkingGreen

A l t e r n a t i n gGreen andRed

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-ly with wire feeder and its components.

Occurs during a reset, and indicates the PW-AC/DC is mapping (identifying) each compo-nent in the system. Normal for first 1-10 sec-onds after power is turned on, or if the systemconfiguration is changed during operation.

Non-recoverable system fault. If the PSStatus light is flashing any combination ofred and green, errors are present in the PW-AC/DC. Read the error code before themachine is turned off.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red witha long pause between digits. If more thanone code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, andback on to reset. See TroubleshootingSection.

Not applicable.

Not applicable.

6. LEAD CONNECTOR S2 (SENSE LEAD)7. 5-PIN ARC LINK S18. 5-PIN DEVICENET CONNECTOR S59. I / O CONNECTOR10. NEGATIVE STUD11. INTERFACE CONNECTOR S612. POSITIVE STUD13. AUXILUARY OUTPUT14. ETHERNET CONTROLS (NOT SHOWN)

FIGURE B.1

3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled until themachine cools down. When cool, the light goes outand output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.

5. AUXILIARY POWER CIRCUIT BREAKER: Protectscase front receptacle auxiliary supply. (10 amp onnon-CE models, 5 amp on CE models.)

WELDER OPERATION

Making a WeldThe serviceability of a product or structure utilizing thewelding programs is and must be the sole responsibili-ty of the builder/user. Many variables beyond the con-trol of The Lincoln Electric Company affect the resultsobtained in applying these programs. These variablesinclude, but are not limited to, welding procedure,plate chemistry and temperature, weldment design,fabrication methods and service requirements. Theavailable range of a welding program may not be suit-able for all applications, and the build/user is and mustbe solely responsible for welding program selection.

The steps for operating the Power Wave will varydepending upon the user interface of the welding sys-tem. The flexibility of the Power Wave lets the usercustomize operation for the best performance.

First, consider the desired welding process and thepart to be welded. Choose an electrode material,diameter, shielding gas and process (GMAW, GMAW-P, SAW, etc.)

B-6OPERATIONB-6

POWER WAVE AC/DC

Second, find the program in the welding software thatbest matches the desired welding process. The stan-dard software shipped with the Power Waves encom-passes a wide range of common processes and willmeet most needs. If a special welding program isdesired, contact the local Lincoln Electric sales repre-sentative.

To make a weld, the Power Wave needs to know thedesired welding parameters. ArcLink allows full cus-tomization for exacting performance. The PowerWave can be programmed with specific values forStrike, Run-in, Crater and other parameters as need-ed.

The Power Wave supports advanced features, liketouch sensing and through-the-arc-seam tracking(TAST).

WELDING ADJUSTMENTS

All adjustments are made on through the user inter-face which can vary. Because of the different configu-ration options your system may not have all of the fol-lowing adjustments. Regardless of availability, all con-trols are described below.

GENERAL WELDING ADJUSTMENTS

1. WFS / AMPS:In synergic welding modes (synergic CV, pulseGMAW) WFS (wire feed speed) is the dominantcontrol parameter, controlling all other variables.The user adjusts WFS according to factors such asweld size, penetration requirements, heat input, etc.The Power Wave then uses the WFS setting toadjust its output characteristics (output voltage, out-put current) according to pre-programmed settingscontained in the Power Wave. In non-synergicmodes, the WFS control behaves more like a con-ventional CV power source where WFS and voltageare independent adjustments. Therefore to maintainthe arc characteristics, the operator must adjust thevoltage to compensate for any changes made to theWFS.

2. VOLTS / TRIM:In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAWonly) the user can change the Trim setting to adjustthe arc length. It is adjustable from 0.500 to 1.500.A Trim setting of 1.000 is a good starting point formost conditions.

3. WELDING MODE:May be selected by name (CV/MIG, CC/Stick Crisp,Gouge, etc.) or by a mode number (10, 24, 71,etc.). Selecting a welding mode determines the out-put characteristics of the Power Wave powersource

4. ARC CONTROL:Also known as Inductance or Wave Control. Allowsoperator to vary the arc characteristics from "soft" to"harsh" in all weld modes. It is adjustable from -10.0to +10.0, with a nominal setting of 0.0.

B-7OPERATIONB-7

CV WELDING

Synergic CV:For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The nominal preprogrammed volt-age is the best average voltage for a given wire feedspeed, but may be adjusted to preference. With syner-gic programs, when the wire feed speed changes thePower Wave will automatically adjust the voltage cor-respondingly to maintain similar arc characteristicsthroughout the WFS range.

Non Synergic CV:This type of CV mode behaves more like a conven-tional CV power source. Voltage and WFS are inde-pendent adjustments. Therefore to maintain the arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS.

All CV Modes:Wave control adjusts the inductance of the waveshape. (This adjustment is often referred to as "pinch".Inductance is inversely proportional pinch.)Increasing wave control greater than 0.0 results in acrispier, colder arc while decreasing the wave controlto less than 0.0 provides a softer, hotter arc.(See Figure B.2 for CURRENT WAVE FORM (CV)

POWER WAVE AC/DC

Wave Control 0.00

Wave Control +10.0

Wave Control -10.0

FIGURE B.2

Current

Time

B-8OPERATIONB-8

PULSE WELDING

Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. Theexact voltage for a given wire feed speed can only bepredicted when all the pulsing waveform parametersare known. Using a preset voltage becomes impracti-cal, and instead the arc length is set by adjusting"trim".

Trim adjusts the arc length and ranges from 0.50 to1.50, with a nominal value of 1.00. Trim values greaterthan 1.00 increase the arc length, while values lessthan 1.00 decrease the arc length.

Most pulse welding programs are syngeric. As thewire feed speed is adjusted, the Power Wave willautomatically recalculate the waveform parameters tomaintain similar arc properties.

POWER WAVE AC/DC

Wave Control 0.0

Wave Control +10.0

Wave Control -10.0

The Power Wave utilizes "adaptive control" to com-pensate for changes in electrical stick-out while weld-ing. (Electrical stick-out is the distance from the con-tact tip to the work piece.) The Power Wave wave-forms are optimized for a 0.75" (19mm) stick-out.The adaptive behavior supports a range of stickoutsfrom 0.50" (13mm) to 1.25" (32mm). At very low orhigh wire feed speeds, the adaptive range may beless due to reaching physical limitations of the weldingprocess.

Wave control in pulse programs usually adjusts thefocus or shape of the arc. Wave control values greaterthan 0 increase the pulse frequency while decreasingthe background current, resulting in a tight, stiff arcbest for high speed sheet metal welding. Wave con-trol values less than 0 decrease the pulse frequencywhile increasing the background current, for a soft arcgood for out-of-position welding. (See Figure B.3)

FIGURE B.3

Current

Time

C-1ACCESSORIESC-1

OPTIONAL EQUIPMENT

FACTORY INSTALLEDThere are no factory installed options available for thePower 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 to14 pin, 10 ft), K1804-1

• Control Cables (for use on FANUC robot arm, 14 pin to22 pin, 18 in), K1805-1

• Control Cables (for use on FANUC robot arm, 22 pin to14 pin, 18 in), K1804-2

Optional Accessories

• Work Voltage Sense Lead Kit K940• Gas Guard Regulator, K659-1• Coaxial welding Cable, K1796

Compatible Lincoln equipment

• PF-10/R Wire Feeder, K1780-1• Any arc-link compatible wire feeding equipment

POWER WAVE AC/DC

D-1MAINTENANCED-1

POWER WAVE AC/DC

SAFETY PRECAUTIONS


• Only Qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE Routine maintenance consists of periodicallyblowing out the machine, using a low pressureairstream, to remove accumulated dust and dirtfrom the intake and outlet louvers, and the cool-ing channels in the machine.

PERIODIC MAINTENANCECalibration of the Power Wave AC/DC is critical toits operation. Generally speaking the calibrationwill not need adjustment. However, neglected orimproperly calibrated machines may not yield sat-isfactory weld performance. To ensure optimalperformance, the calibration of output Voltageand Current should be checked yearly.

CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at thefactory. Generally speaking the machine calibrationwill not need adjustment. However, if the weld per-formance changes, or the yearly calibration checkreveals a problem, contact the Lincoln ElectricCompany for the calibration software utility.

The calibration procedure itself requires the useof a grid, and certified actual meters for voltageand current. The accuracy of the calibration willbe directly affected by the accuracy of the mea-suring equipment you use. Detailed instructionsare available with the utility.

WARNING

E-1TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


POWER WAVE AC/DC

Observe all Safety Guidelines detailed throughout this manual

CAUTIONIf 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.

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.

Input fuses keep blowing, or inputbreaker keeps tripping.

Machine will not power up (nolights, no fan, etc.)

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.

1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.

2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.

3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.

1. Make certain that the PowerSwitch (SW1) is in the “ON”position.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset. Also, check input volt-age selection, below.

3. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.

If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.


POWER WAVE AC/DC



PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMSThermal LED is lit.

Machine won’t weld, can’t get anyoutput. (CR1 will not pull in.)

1. Machine ’s thermostat hasopened. Check for proper fanoperation. There are two mainfans in the PowerWave AC/DC.One machine is located in thelower portion of the machinewhich should be running when-ever the machine is on. Theother fan is located in the upperportion of the machine and onlyruns when the machine is trig-gered. Check for material block-ing intake or exhaust louvers, orfor excessive dirt clogging coo-ing channels in machine.

2. DC Bus PC board thermostathas opened check for excessiveload on 40VDC supply.

3. Be sure process does notexceed duty cycle limit of themachine.

1. Input voltage is too low or toohigh. Make certain that inputvoltage is proper, according tothe Rating Plate located on therear of the machine.

2. If the Thermal LED is also lit,see “Yellow Thermal LED is Lit”section.

3.Primary current limit has beenexceeded. Possible short in out-put circuit. Turn machine off.Remove all loads from the outputof the machine. Turn back on. Ifcondition persists, turn power off,and contact an authorizedLincoln Electric Field Servicefacility.

4. This problem will normally beaccompanied by an error code.Error codes are displayed as aseries of red and green flashesby the status l ight. See"Troubleshooting the PowerWave / Power Feed SystemUsing the Status LED" sectionof this text.



POWER WAVE AC/DC



PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure

Auxiliary receptacle is “dead” — noauxiliary voltage .

The Power Wave is triggered toweld, but there is no output.

1. Secondary current limit hasbeen exceeded, and themachine has phased back toprotect itself. Adjust procedureor reduce load to lower cur-rent draw from the machine.

1. Circuit breaker CB2 (on casefront) may have opened.Reset.

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.

1. Check for fault signals fromthe I/O connector. Possiblefaults are lack of water flow

2. Circuit breaker CB4 (in recon-nect area) may have opened.Reset.



POWER WAVE AC/DC



CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)


General degradation of the weldperformance.

The Power Wave is triggered toweld, but there is no output.

The feeder will not cold inch wire

Excessively long and erratic arc.

Arc loss fault on robot

1. Check for feeding problems, badconnections, excessive loops incabling, etc..

2. Verify weld mode is correct forprocesses.

3. The power source may requirecalibration.• Check the current calibration• Check the voltage calibration• Check the WFS calibration

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow / water flowturned off.

1. Check for fault signals from theI/O connector. Possible faults arelack of water flow / water coolerturned off.

1. Check for proper configurationand implementation of voltagesensing circuits.

1. Possibly caused by wire feedingproblem.

2. Possible causes/solutions are:

• Problem - Conduit leading to thewire feeder has bends or twists,which can reduce the wire feedspeed.

• Solution - Remove bends andtwists from conduit.

• Problem – Conduit leading up tothe wire feeder from the wire reelis too long.

• Solution – Use a shorter length ofconduit

If all recommended possible areas ofmisadjustments have been checkedand the problem persists, contactyour local Lincoln AuthorizedField Service Facility.

OUTPUT PROBLEMS


POWER WAVE AC/DC

USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS

The Power Wave is equipped with a status light if aproblem occurs it is important to note the condition ofthe status light.Therefore, prior to cycling power to thesystem, check the power source status light for errorsequences as noted below.

Included in this section is information about the powersource Status LED, and some basic troubleshootingcharts for both machine and weld performance.

Troubleshooting the Power Wave Using the StatusLED

The STATUS LIGHT is a two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated in the followingchart.

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

System OK. Power source communicating normallywith wire feeder and its components.

Occurs during a reset, and indicates the Power Waveis mapping (identifying) each component in the system.Normal for first 1-10 seconds after power is turned on,or if the system configuration is changed during opera-tion

Non-recoverable system fault. If the PS Status light isflashing any combination of red and green, errors arepresent in the Power Wave. Read the error codebefore the machine is turned off.

Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off, and back onto reset.

Not applicable.

Not applicable.


POWER WAVE AC/DC



CAUTION

ERROR CODES FOR THE POWERWAVEThe 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 #

31 Primary overcurrent error.

32 Capacitor "A" under voltage (Left side facing machine)

33 Capacitor "B" under voltage (Right side facing machine)

34 Capacitor "A" over voltage (Left side facing machine)

35 Capacitor "B" over voltage (Right side facing machine)

36 Thermal error

37 Softstart error

41 Secondary overcurrent error

43 Capacitor delta error

49 Single phase error

Other

Indication

Excessive Primary current present. May be related to a switch board oroutput rectifier failure.

Low voltage on the main capacitors. May be caused by improper inputconfiguration, or an open/short circuit in the primary side of themachine.

Excess voltage on the main capacitors. May be caused by improperinput configuration, , excessive line voltage, or improper capacitor bal-ance (see Error 43)

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cycle limitof the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.

The secondary (weld) current limit has been exceeded. When thisoccurs the machine output will phase back to 100 amps, typically result-ing in a condition refered to as "noodle welding" NOTE: For the PowerWave AC/DC the secondary limit is 500

The maximum voltage difference between the main capacitors hasbeen exceeded. May be accompanied by errors 32-35. May be causedby an open or short in the primary or secondary circuit(s).

Indicates machine is running on single phase input power. Usuallycaused by the loss of the middle leg (L2).

Error codes that contain three or four digits are defined as fatal errors.These codes generally indicate internal errors on the Power SourceControl Board. If cycling the input power on the machine does not clearthe error, contact the Service Department.

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2B

TO C

ONT

ACTO

RL3

A

L1A

A.0

1

W R41

H5 (5

00)

H4 (4

40-4

60)

H3

(380

-415

)

H1

6H5

A

3 14

H3A

2

H4A

H2 (2

20-2

30)

(115

V)

H2A

H1A

H6 (5

50-5

75)

5H6

AP5

0

TO S

4,CB

2,AU

X. F

AN

350 352

8

147

98

1

1216

7

10

8

CON

NEC

TOR

CAV

ITY

NUM

BERI

NG

SEQ

UEN

CE

(VIE

WED

FR

OM

CO

MPO

NEN

T SI

DE O

F BO

ARD

)

1

1 6

5

61

3

56

4

41

1

J10A

, J10

B,

J2VS

, J7

21

34

1 2

J2,J

5,J1

1,J4

1,J4

6,J7

2J7

3,J7

6,J8

1J8

2

J1VS

,J9,

J14,

J40,

J42,

J50,

J75,

J83,

J711

J8,

J47,

J60

J84,

J712

J1AD

,J3

J61,

J77,

J79,

J86

J4,J

13,

J43,

J71

J1,J

6,J7

J10,

J70,

J85

J87

250

0

J81

741

743

4321

2.7

10W

2.7

10W

2.7

10W 2.7

10W

847

8

TO CB1

J41

J82

S1

TO

SO

LID

ST

AT

E R

ELA

YX

3ATO F

AN

X1

R(1

15V)

N(2

4V)

X4H

2AH3A

H1H2

H3H4

H4A

X2U

(51V

)

X3W

X3 X5

W

H5A

H5

H6A

H6

.022

800V

.022

800V

.022

800V

.022

800V

1816 14 17 13

TO J

6

TO J

6

AUXI

LIAR

Y TR

ANSF

OR

MER

#1

J6

12

16

C6

18

C7

+

NEG

+ C17

NEG

C15

N.B

.C

URRE

NT

TRAN

SFO

RM

ER#2N

.B.

CUR

REN

TTR

ANSF

OR

MER

#1

R5

SID

E O

F CT

TO

TH

E SW

ITCH

BO

ARD

. THE

AR

ROW

ON

THE

CT

SHO

ULD

POIN

T FR

OM

THE

SW

ITC

H BO

ARD

TO

TH

E TR

ANSF

OR

MER

.N

.B.

CTs

MUS

T BE

OR

IENT

ED IN

THE

PR

OPE

R DI

REC

TIO

N. T

RANS

FORM

ER L

EADS

SHO

ULD

GO

FR

OM

TRA

NSF

ORM

ER T

HRO

UGH

TH

E DO

TTED

TO C

T #1

TO C

T #2

830

TO J4 J11

R5

262

220

292A

TO

AU

X#1

+3RT

O3W

J7

X3A

TP

444

4

TO

FA

N

34

-

SO

LID

ST

AT

ER

ELA

Y

21

518

WH

ITE

514

RED

POS

NEG

32135

035

233

A4

262

268

268A

R5

DC

BUS

THER

M

TO

4

32 33

1 6

33A

2(2

30V)

E

G40

48

115/

230V

AC

SW

ITC

HR

EC

EP

TA

CLE

S8

TO J2VS J73

J47

CB1

L5

TO J84

J2VS

J83

TO J4 J1AD

TO J47 TO C3

TO J4 J43

TO J46

POW

ER B

D R

ECT

TO J4 J6 J40

J42

J50

TO S8

TO J10B

TO J10A

TO A

UX #

1

TO A

UX #

2

HA

RM

ON

ICF

ILT

ER

L6

J1AD

18

J710

352A

AUX.

FAN

352A

3 421 5 6 7 8 9 10 11 12

J77

1 32 987654 10

J79

1 32 987654 10

CB2

AUX

2TO

32

115V

REC

EPTA

CLE

S4

31

CB2

10A

CIR

CUI

TBR

EAKE

RTO S4 AU

X 2

31 33

TO

886

880

DIO

DE

J83

D6

+40V

DC

ACAC

32A

AUX

FAN

J710

J712

J1AD

1 2 3 4 5

301

225

622

5A7

403

406

8 9 10

222

503

506

222A

302

4 5 61 32 7 8 4 5 61 32 7 8

1211

414

RED

418

WH

ITE

16

733

734

TO J3 J6 J7

771

772

773

774

775

776

777

778

779

711

TO S9

712

713

714

715

716

717

718

281

282

285

286

778

S9

774

776

J77

771

TO J77

773

775

777

772

779

285A

BLU

E28

6A B

LACK

(BLU

E)

733

YELL

OW

734

BLAC

K (Y

ELLO

W)

285B

YEL

LOW

286B

BLA

CK

(YEL

LOW

)

711

BLUE

211A

WHI

TE21

2A B

LACK

(WHI

TE)

224A

240

TO J8 J712

J7

717

WHI

TE

216A

GRE

EN

718

BLAC

K (W

HITE

)

712

BLAC

K (B

LUE)

714

BLAC

K (G

REE

N)71

3 G

REEN

716

BLAC

K (R

ED)

715

RED

H4

440-

460V

H5 (5

00)

H4 (4

40-4

60)

H3 (3

80-4

15)

H1H2 (2

20-2

30)

H6 (5

50-5

75)

N.E.

N.F

.N.

G.

N.G

.

N.G

.

N.G

.

N.E

. CO

NN

ECT

TO 2

06B

OU

TPU

T ST

UD

ON

AC

SW

ITCH

N.F

. C

ON

NEC

T TO

DC

PO

SITI

VE C

HO

PPER

BO

AR

D O

N A

C S

WIT

CH

N.G

. CO

NN

ECT

TO R

ECTI

FIER

ON

AC

SW

ITCH

(FO

UR P

LAC

ES)

N.D

. C

ON

NEC

T TO

202

C O

UTP

UT

RES

ISTO

R O

N A

C S

WIT

CH

224

J73

N.J

. C

ON

NEC

T TO

PO

WER

REC

EPTA

CLE

ON

AC

SW

ITCH

AC

SW

ITCH

CO

NN

ECTI

ON

S

N.J.

TO S4

TO AUX2

202A

224A

N.E.

CO

NNE

CTI

ON

J5 TO

N.D

.

N.K

. P

IN N

EARE

ST T

HE

FLAT

ED

GE

OF

LED

LEN

S (A

NO

DE)

ALI

GN

S W

ITH

BLAC

K LE

AD O

F LE

D S

OCK

ET.

FRO

M A

C S

WIT

CH

21 3 54 6 87

282A

282B

281A

281B

285A

285B

286A

286B

P7A

281A

BRO

WN

282A

BLA

CK

(BRO

WN)

281B

RED

282B

BLA

CK (R

ED)

213A

BLA

CK (G

REEN

)

TO AC SWITCH TO AC SWITCH

733A

734A

292A

224B

224

224B

220

292A

F-2DIAGRAMSF-2

POWER WAVE AC/DC

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

TM

LEF

T S

IDE

OF

MA

CH

INE

N.C

. C

ON

NEC

T TO

206

A IN

PO

WER

SO

URC

E (V

OLT

AG

E FE

EDB

ACK

)

RIG

HT

SID

E O

F M

AC

HIN

E

N.A

. C

ON

NEC

T TO

TRA

NSF

ORM

ER L

EAD

S FR

OM

PO

WER

SO

URCE

NO

TES:

REAR OF MACHINE

FRONT OF MACHINE

282B

281B

733

734

285A

286B

711

718

224A

240

722

211A

712

N.B

. C

ON

NEC

T TO

OU

TPUT

REC

TIFI

ER H

EATS

INK

IN P

OW

ER S

OU

RCE

CHO

PPER

D

RECT

IFIE

R2.

710

W

2.7

10W

2.7

10W 2.7

10W

.022

800V

.022

800V.0

2280

0V

.022

800V

N.A.

N.A.N.A

.

N.A.

286DB8

285D

281D

282D

286C

285C

281C

282C

N.B.

3433

34 3335

3738

211216

1234

212213

CENTERTAPCHOKE

36

40

38

3635

40

39

C1

TP1

OU

TPU

T ST

UD

S

N.C

.

32 4

350A

352B

33B

1

N P R S T U V W XA B C D E F G H I J K L M

717A

714A

718A

722A

713A

N P R S T U V W XA B C D G H I J K L M73

373

4C

GN

D

722

MASTER / SLAVE INPUT S12 MASTER / SLAVE OUTPUT S13

717

212A

216A

714

713

213A

716

282A

281A

285B

286A

715

711

718

717

712

714

713

716

715

715A

716A

713A

714A

722A

718A

717A

716A

715A

S8 POWERRECEPTACLE

31 2 5 67 84 9

282B

281B

285A

286B

721

282A

281A

285B

286A

S11

282D

281D

285C

286D

282C

281C

285D

286C

31 2 5 6 7 84 9

240

212A

213A

224A

211A

216A

S10

324

212

213

320

211

216

350B

FAN

AUXI

LIAR

Y TR

ANSF

ORM

ER

brow

n

blue

1

4 5 8763

6

230

VAC

230

VAC

( vio

let)

2118

VAC

( whi

te)

18 V

AC(g

reen

)

18 V

AC( y

ello

w)

18 V

AC( r

ed)

633

2

1633

3

133

0

1133

1

230

VAC

(ora

nge)

S23

352C

350C

S22

SNUB

BER

# 2

SNUB

BER

# 1 1 2

J133

233

3320

321

Ther

mos

tat

324

323

321

322

Ther

mos

tat

323

322 Ther

mos

tat

206B

345

50W

346

341

344

N.D

.

N.D

. C

ONN

ECT

TO O

UTP

UT

STU

D IN

PO

WER

SO

URC

E (C

ENTE

RTA

P C

ON

NEC

TIO

N)

202C

CIRC

UIT

BREA

KER

734B

734C

734

342

347

50W

348

343

N.E.

N.E

. C

ONN

ECT

TO P

OW

ER R

ESEP

TACL

E IN

PO

WER

SO

URC

E

C

G40

76-2

CHO

PPER

B

CHO

PPER

CC

HOPP

ER A

+ -

B3, B

6

B2, B

5

B1, B

4

3

12

4317

315

318

316

J2

E F

+-

B3, B

6

B2, B

5

B1, B

4

+-

B3, B

6

B2, B

5

B1, B

4

+ -

B3, B

6

B2, B

5

B1, B

4

TOP

BOTT

OM

TOP

BOTT

OM

CUR

REN

TTR

ANSD

UCER

J15

Ther

mos

tat

1 2J1

330

331

3

12

4313

311

314

312

J2

39

37

314

311

312

313

317

316315

318

345

344

31 2 4S14

352B

350B

352C

350C

B7

B8

B7

B8

B7

B8

B7

TO ETHERNET BOARD

721

TO CONTROL BOARD

DRAI

N

DRAI

N

TO CONTROL BOARD

F-3PIN, LEAD CONNECTOR SETUPSF-3

POWER WAVE AC/DC

TABLE F.5 DEVICENET CONNECTOR S5

Pin Lead # Function2 894 +24vdc Devicenet3 893 Commom Devicenet+4 892 Devicenet H5 891 Devicenet L

TABLE F.2 WIRE FEEDER RECEPTACLE S1

Pin Lead # FunctionA 53 Arclink LB 54 Arclink HC 67A Electrode Voltage SenseD 52 Ground(0v)E 51 +40vdc

TABLE F.6 EXTERNAL I/O S7

Pin Lead # Function1 851 +15vdc for Trigger group2 852 Trigger input3 853 Dual procedure input4 854 4 Step input5 855 +15vdc for cold inch group6 856 cold inch forward7 857 cold inch reverse8 858 gas purge input9 859 +15vdc for shutdown group10 860 shutdown1 input11 861 shutdown2 input12 862 input B

TABLE F.4 RS232 CONNECTOR S3

Pin Lead # Function2 253 RS232 Receive3 254 RS232 Transmit4 # S3 Pin55 # S3 Pin46 ## S3 Pin2020 ## S3 Pin67 251 RS232 Common

TABLE F.3 VOLTAGE SENSE RECEPTACLE S2

Pin Lead # Function3 21A Work Voltage Sense

Pin Robotic Interface Connector (S6) Master / Slave Input(S12) Master / Slave Output(S13)

A +15vdc Tach voltage Reserved for future use Reserved for future useB Tach common Reserved for future use Reserved for future useC Tach 1A differential signal Sync In Reserved for future useD Tach 1B differential signal Sync In Reserved for future useE Tach 2A differential signal Ready In Ready InF Tach 2B differential signal Ready In Ready InG Single Tach Input Polarity Out Polarity OutH Reserved for future use Polarity Out Polarity OutI Voltage sense lead GroundJ Motor "+" Reserved for future use Reserved for future useK Motor "-" Reserved for future use Reserved for future useL Reserved for future use +40v (COM) Reserved for future useM Reserved for future use +40v ("+") Reserved for future useN +40vdc for solenoid Reserved for future use Reserved for future useP solenoid input Reserved for future use Reserved for future useR Reserved for future use Reserved for future use Reserved for future useS Reserved for future use Reserved for future use Reserved for future useT Shield ground to case Drain (ethernet) Drain (ethernet)U Reserved for future use Kill Out Kill OutV Reserved for future use Kill Out Kill OutW Reserved for future use Reserved for future use Reserved for future useX Reserved for future use Reserved for future use Reserved for future use

Table F.1 INTERFACE CONNECTOR WIRING

F-4CONNECTION DIAGRAMF-4

POWER WAVE AC/DC

K1796 COAXIAL WELD CABLE

User suppliedwork lead

User suppliedelectrode lead

- +

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE ORK1804-2 AND ANY K1795 CONTROL CABLE

User suppliedwork lead

User suppliedelectrode lead

CONTROL CABLE K1805-1

Robotic Set Up, Electrode Positive, CV/PulseConfiguration

F-5DIMENSION PRINTF-5

POWER WAVE AC/DC

XA

9.45

19.1

6

19.8

3

14.6

2

37.4

6

18.8

033

.08

.65

.96

34.9

6

L116

56

NOTES

POWER WAVE AC/DC

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

POWER WAVE AC/DC - Lincoln Electric

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