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IM718
June 2002
™
POWER WAVE
AC/DC
For use with machines having Code Numbers:
10849
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
R
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
ISO/IEC 60974-1
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
POWER WAVE AC/DC
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
POWER WAVE AC/DC
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE AC/DC ...............................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Lifting...............................................................................................................A-2
Stacking ..........................................................................................................A-2
Machine Grounding ...............................................................................................A-2
High Frequency Protection ....................................................................................A-2
Input Connection....................................................................................................A-3
Input Fuse and Supply Wire Considerations .........................................................A-3
Input Voltage Changeover Procedure ...................................................................A-3
Welding with Multiple Power Waves......................................................................A-4
Multiple Arc Configuration...............................................................................A-5
Electrode and Work Cable Connections................................................................A-6
Cable Inductance and its Effects on Pulse Welding........................................A-6
Voltage Sensing .............................................................................................A-7
Control Cable Connections Between Power Source and Wirefeeder....................A-8
Control Cable Connections Between Power Sources Run in Parallel...................A-8
Control Cable Connections between a Power Source and Phase Generator ......A-8
Control Cable Specifications, Ethernet Connections.............................................A-8
External I/O Connector....................................................................................A-9
High Speed Gear Box .....................................................................................A-9
Dip Switch Settings and Locations...............................................................A-10
Control Board Dip Switch..............................................................................A-10
Feed Head Board Dip Switch........................................................................A-10
DeviceNET/Gateway Board Dip Switch, .......................................................A-11
Multiple-Arc System Description ...................................................................A-12
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Graphic Symbols that appear on this machine or in this manual...........................B-2
Definiition of Welding Terms..................................................................................B-3
General Description...............................................................................................B-4
Recommended Processes and Equipment ...........................................................B-4
Required Equipment..............................................................................................B-4
Limitations..............................................................................................................B-4
Duty Cycle and Time Period ...........................................................................B-4
Case Front Controls........................................................................................B-5
Constant Voltage Welding...............................................................................B-6
Pulse Welding .................................................................................................B-7
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Equipment...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine, Periodic, Calibration Specification...........................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to use Troubleshooting Guide .......................................................................E-1
Troubleshooting the Power Wave / Power Feed System using the Status LED ...E-2
Troubleshooting Guide.............................................................................E-3 thru E-6
Error Codes for the Power Wave ...................................................................E-7, E-8
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Pin, Lead Connector, Connection Diagrams, and Dimension Print..........F-2 thru F-5
________________________________________________________________________
Parts Lists................................................................................................................P392
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE AC/DC (K1860-1)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS
50/60HZ.
OUTPUT
INPUT
CURRENT
AMPS
POWER FACTOR
IDLE
POWER
EFFICIENCY
@ RATED OUPUT
CONDITIONS
@ RATED OUPUT
3 PHASE
460/500/575V
500A@40V.100%
31/29/25
.95 MIN.
800 Watts
Max.
84%
OUTPUT
OPEN
CIRCUIT
VOLTAGE
CURRENT
PULSE
PULSE
PULSE AND
AUXILIARY POWER
(CIRCUIT BREAKER
PROTECTED)
RANGE FREQUENCY VOLTAGE BACKGROUND
DC
RANGE
TIME RANGE
90VDC
20-500
0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. -
3.3 SEC.
40 VDC AT
10 AMPS
115 VAC AT
10 AMPS
PROCESS CURRENT RANGES (AC or DC)
CURRENT
50-500 Average Amps
40-500 Average Amps
15-725 Peak Amps
SAW / MIG / MAG
FCAW
Pulse
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG[IEC]
SIZES (MM2)
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG[IEC]
SIZES (MM2)
INPUT
VOLTAGE /
FREQUENCY
50/60HZ
460V
500V
575V
8 (10)
8 (10)
10 (6)
45
40
35
10 (6)
10 (6)
10 (6)
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
490 lbs.
222 kg.
38 in
19 in
33 in
965 mm
483 mm
838 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
STORAGE TEMPERATURE RANGE
-20°C to +40°C
-40°C to +40°C
POWER WAVE AC/DC
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
LIFTING
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.
Read this entire installation section before you
start installation.
WARNING
ELECTRIC SHOCK can kill.
STACKING
Power Wave AC/DC machine cannot be stacked.
• Only qualified personnel
should perform this installa-
tion.
MACHINE GROUNDING
• Turn the input power OFF at
the disconnect switch or fuse
box before working on this
equipment. Turn off the input
The frame of the welder must be grounded. A ground
terminal marked with the symbol
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
power to any other equipment connected to the
welding system at the disconnect switch or fuse
box before working on the equipment.
is located inside
• 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.
HIGH FREQUENCY PROTECTION
-------------------------------------------------------------
SELECT SUITABLE LOCATION
Locate the Power Wave away from radio controlled
machinery.
Do not use Power Waves in outdoor environments. The
Power Wave power source should not be subjected to
falling water, nor should any parts of it be submerged in
water. Doing so may cause improper operation as well
as pose a safety hazard. The best practice is to keep the
machine in a dry, sheltered area.
CAUTION
The normal operation of the Power Wave may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.
Do not mount the PowerWave over combustible sur-
faces. Where there is a combustible surface directly
under stationary or fixed electrical equipment, that
surface shall be covered with a steel plate atleast
.060" (1.6mm) thick, which shall extend not less than
5.90" (150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through
the case sides and bottom. Dirt, dust, or any foreign
material that can be drawn into the welder should be
kept at a minimum. Do not use air filters on the air
intake because the air flow will be restricted. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdowns.
POWER WAVE AC/DC
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A-3
A-3
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
Do not operate with covers removed
Disconnect input power before servicing
Do not touch electrically live parts
Only qualified persons should install,
use or service this equipment
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to
do so will result in damage to the machine.
INPUT CONNECTION
WARNING
Only a qualified electrician should connect the
input leads to the Power Wave. Connections
should be made in accordance with all local and
national electrical codes and the connection dia-
gram located on the inside of the reconnect/input
access door of the machine. Failure to do so may
result in bodily injury or death.
INPUT VOLTAGE CHANGE OVER
(FOR MULTIPLE INPUT VOLTAGE
MACHINES ONLY)
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this con-
nection to a different input voltage, see the diagram
located 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 a
position higher than the applied line voltage, the
welder may not come on at all. If the Auxiliary (A) lead
is placed in a position lower than the applied line volt-
age, the welder will not come on, and the two circuit
breakers in the reconnect area will open. If this
occurs, turn off the input voltage, properly connect the
(A) lead, reset the breakers, and try again.
-------------------------------------------------------------
Use a three-phase supply line. A 1.75 inch (45 mm)
diameter access hole for the input supply is located on
the upper left case back next to the input access door.
Connect L1, L2, L3 and ground according to the Input
Supply Connection Diagram decal located on the
inside of the input access door or refer to Figure A.1 .
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire 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 to
local or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
POWER WAVE AC/DC
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A-4
A-4
INSTALLATION
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the
pulsing frequency will be the same, helping to stabilize
the arcs.
WELDING WITH MULTIPLE UNSYN-
CHRONIZED POWER WAVES
CAUTION
Special care must be taken when more than one
Power Wave is welding unsynchronized on a sin-
gle part. Arc blow and arc interference may occur
or be magnified. Each power source requires a
work lead to the work stud to the welding fixture.
Do not combine all of the work leads into one
lead. Performing welding in the direction away
from the work leads. (In a synchronized multi arc
system the weld should go towards the work
leads to minimize arc blow). Connect all of the
work sense leads from each power source to the
work piece at the end of the weld, such that they
are out of the path of the weld current. For addi-
tional information on work voltage sense leads
see sections entitled "Voltage Sensing" and
"Multiple Unsynchronized Arc Sense Lead and
Work Lead Placement Guidelines".
Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas cover-
age. Do not attempt to supply shielding gas for two or
more guns from only one regulator.
If an anti-spatter system is in use then each gun must
have its own anti-spatter system. (See Figure A.2.)
------------------------------------------------------------------------
FIGURE A.2
TWO POWER WAVES
Travel
Direction
Connect All Work
Sense Leads at the End
of the Joint.
Connect All Welding
Work Leads at the
Beginning of the Joint.
POWER WAVE AC/DC
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A-5
A-5
INSTALLATION
MULTIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
Power
Source
#1
BAD
fl
Current flow from Arc #1
Work #1
affects sense lead #2
Sense 1
#
Arc #1
fl
fl
Current flow from Arc #2
affects sense lead #1
Power
Source
#2
Work #2
Sense # 2
Neither sense lead picks up
the correct work voltage,
causing starting and welding
arc instability.
Arc #2
Power
Source
#2
BETTER
Arc #1
Power
fl
fl
fl
Source
#1
Sense #1 is only affected by weld
current from Arc #1
Sense #2 is only affected by weld
current from Arc #2
Work #2
Sense #2
Arc #2
Due to voltage drops across work piece,
Arc voltage may be low, causing need
for deviation from standard procedures.
Work #1
Sense #1
Power
Source
#1
BEST
fl
fl
fl
fl
Both Sense leads are out of the current
paths.
Work # 1
Arc #1
Both Sense leads detect arc voltage
accurately.
Power
Source
#2
Work # 2
No voltage drop between Arc and Sense
lead.
Arc #2
Best starts, best arcs, most reliable
results.
Sense #1
Sense # 2
POWER WAVE AC/DC
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A-6
A-6
INSTALLATION
CABLE INDUCTANCE, AND ITS EFFECTS
ELECTRODE AND WORK CABLE
CONNECTIONS
ON PULSE WELDING
For Pulse Welding processes, cable inductance will
cause the welding performance to degrade. For the
total welding loop length less than 50 feet, traditional
welding cables may be used without any effects on
welding performance. For the total welding loop length
greater than 50 feet, the K1796 Coaxial Welding
Cables are recommended.
The welding loop length is defined as the total of elec-
trode cable length (A) + work cable length (B) + work
length (C) (See Figure A.3).
Due to the PowerWave AC/DC’s ability to produce either
a DC positive, DC negative or AC output the electrode
and work connections do not need to be reversed for the
different polarities. Additionally no DIP switch changes
are required to switch between the different polarities. All
of 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) and
length between the "work" stud (located beneath the
spring loaded output cover on the front of the machine)
and the work. For convenience, the work lead can be
routed behind the left strain relief (under the spring
loaded output cover), along the channels, and out the
back of the machine. Be sure the connection to the work
makes tight metal-to-metal electrical contact. The work
piece connection must be firm and secure. Excessive
voltage drops caused by poor work piece connections
often result in unsatisfactory welding performance, espe-
cially if pulse welding is planned. To avoid interference
problems with other equipment and to achieve the best
possible operation, route all cables directly to the work
and wire feeder. Avoid excessive lengths and do not coil
excess cable.
FIGURE A.3
POWER
WAVE
A
C
WORK
B
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length
less than 50 feet. (See Figure A.4.)
FIGURE A.4
POWER
WAVE
Connect the electrode cable between the wire feeder and
the "electrode" stud on the power source (located behind
the cover plate on the lower right side). For convenience,
the cable can be routed through the oval hole in the rear
of the machine before being connected to the output ter-
minals. Connect the other end of the electrode cable to
the wire drive feed plate. Be sure the connection to the
feed plate makes tight metal-to-metal electrical contact.
The electrode cable should be sized according to the
specifications given in (Table A.1).
A
A
C
WORK
C
B
B
SLIDING GROUND
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
FOR A DETAILED CONNECTION DIAGRAM USING
K1796 COAXIAL CABLE, SEE PAGE F-4.
Suggested Copper Cable Sizes - 100 Duty Cycle Combined
Length of Electrode and Work Cables (Table A.1)
Cable Length (ft (m)
0 (0) to 100 (30.4)
100 (30.4) to 200 (60.8)
200 (60.8) to 250 (76.2)
Parallel Cables
Cable Size
CAUTION
2
1
2
2
4/0 (120mm )
2
2/0 (70mm )
When pulsing, the pulse current can reach very
high levels. Voltage drops can become excessive,
leading to poor welding characteristics, if under-
sized welding cables are used.
2
3/0 (95mm )
When using inverter type power sources like the
Power Wave, use the largest welding (electrode and
work) cables that are practical. When pulsing, the
pulse current can reach very high levels. Voltage
drops can become excessive, leading to poor welding
characteristics, if undersized welding cables are used.
NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long cable lengths.
This is especially important when Pulse welding up to
350 amps.
------------------------------------------------------------------------
POWER WAVE AC/DC
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A-7
A-7
INSTALLATION
Work Voltage Sensing
VOLTAGE SENSING
The Power Waves are shipped from the factory
with the work sense lead disabled.
The best arc performance occurs when the
PowerWave AC/DC has accurate data about the arc
conditions. Depending upon the process, inductance
within the electrode and work lead cables can influ-
ence the voltage apparent at the studs of the welder.
Voltage sense leads improve the accuracy of the arc
conditions and can have a dramatic effect on perfor-
mance. Sense Lead Kits (K490-series) are available
for this purpose.
To use work voltage sensing, connect the (21) work
voltage sense lead from the Power Wave to the work.
Attach the sense lead to the work as close to the weld
as practical. Enable the work voltage sensing in the
Power Wave as follows:
WARNING
ELECTRIC SHOCK can kill.
CAUTION
If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured
extremely high welding outputs may occur.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
In extremely sensitive applications requiring volt-
age sense leads, it may be necessary to route the
control cable (67 lead) and the work voltage sense
lead (21 lead) away from the electrode and work
welding cables. For more information regarding
the placement of voltage sense leads, see the sec-
tion entitled "Welding with Multiple Independent
Power Waves."
• 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.
------------------------------------------------------------------------
The ELECTRODE sense lead (67) is built into the
K1795 control cable. The WORK sense lead (21) con-
nects to the Power Wave at the four-pin connector
located underneath the output stud cover.
Enable the voltage sense leads as follows:
TABLE A.2
3. The control board is on the left side of
the power source. Locate the 8-position
DIP switch and look for switch 8 of the
DIP switch.
4. Using a pencil or other small object,
slide the switch to the OFF position if
the work sense lead is NOT connected.
Conversely, slide the switch to the ON
position if the work sense lead is pre-
sent.
Process Electrode Voltage
Sensing 67 lead *
Work Voltage
Sensing 21 lead
21 lead optional**
21 lead optional**
21 lead optional**
GMAW 67 lead required
GMAW-P 67 lead required
FCAW 67 lead required
GTAW Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional
5. Replace the cover and screws. The PC board will
(read) the switch at power up, and configure the
work voltage sense lead appropriately.
* The electrode voltage 67 sense lead is part of the
control cable to the wire feeder.
Electrode Voltage Sensing
** For consistent weld quality, work voltage sensing is
recommended.
Enabling or disabling electrode voltage sensing is
automatically configured through software. The 67
electrode sense lead is internal to the cable to the
wire feeder and always connected when a wire feeder
is present.
POWER WAVE AC/DC
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A-8
A-8
INSTALLATION
CONTROL CABLE CONNECTIONS
BETWEEN POWER SOURCE AND
WIREFEEDER
Connect the control cable between the power source
and wire feeder. The wire feeder connection on the
PowerWave AC/DC is located under the spring loaded
output cover, on the case front. The control cable is
keyed and polarized to prevent improper connect.
CAUTION
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communi-
cation problems (system shutdowns), poor motor
acceleration (poor arc starting) and low wire dri-
ving force (wire feeding problems). Use the short-
est length of control cable possible. Do not coil
excess cable as this can cause communication
problems (system shutdowns).
For convenience, the control cables can be routed
behind the left or right strain relief (under the spring
loaded output cover), along the channels of the Power
Wave, out the back of the channels, and then to the
wire feeder.
------------------------------------------------------------------------
Lincoln control cables are copper 22 conductor cable
in a SO-type rubber jacket.
The K1795 series of control cables can be added in
series as needed. Do not exceed more than 100 feet
(30.5 m) total control cable length.
CAUTION
Excessive voltage drops at the work piece con-
nection often result in unsatisfactory pulse weld-
ing performance.
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 a
drain, cat 5 cable. The drain should be grounded. Do
not use cat 5+, cat 5E, cat 6 or stranded cable. If con-
nection failure during welding persists reroute cables
away from any other cables that carry current or other
devices that would create a magnetic field. See Figure
A.4a.
CONTROL CABLE CONNECTIONS
BETWEEN POWER SOURCES RUN
IN PARALLEL
The connectors located on the rear of the machine are
used for synchronizing the operation of multiple
machines. To run machines in parallel connect the
control cable (K1795 series) between power sources
that 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 on
the slave machine is then used to connect to another
slave machine. This connection scheme is duplicated
for any additional slaves.
FIGURE A.4a
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
CONTROL CABLE CONNECTIONS
BETWEEN A POWER SOURCE
AND PHASE GENERATOR
- REFER TO ISO / IEC 11801 FOR SPECIFICATIONS
CAT 5 CABLE
SOLID, SHIELDED,
WITH A DRAIN
(MAX LENGTH =
3 METERS)
If multiple arcs need to be synchronized an external
phase generator is required. The phase generator is
connected to all of the master machines. A control
cable (K1795 series) should be connected between
the phase generator and the top (female) connector
on the rear of the master machine.
POWER WAVE
POWER WAVE
JUNCTION BOX
PHASE
GENERATOR
ENVIRONMENTAL
ENCLOSURE
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
POWER WAVE
POWER WAVE
POWER WAVE
ETHERNET SWITCH
PATCH PANEL
CONDUIT WITH CAT 5 UTP CABLE
POWER WAVE AC/DC
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A-9
A-9
INSTALLATION
HIGH SPEED GEAR BOX
EXTERNAL I/O CONNECTOR
Changing the ratio requires a gear change and a PC
board DIP switch change. As shipped from the facto-
ry, the low speed (high torque) gear is configured. To
change the gear ratio see the Wire Feeder Instruction
Manual. The High/Low DIP switch code on Wire Drive
PC board can be set as follows:
The Power Wave is equipped with a terminal strip for
making simple input signal connections. The terminal
strip is located underneath the spring-loaded cover. It
is divided into three groups: Trigger group, Cold Inch
Group and Shutdown Group. Because the Power
Wave is a ‘slave’ on the DeviceNet network, the
Trigger and Cold Inch Groups are disabled when the
DeviceNet/Gateway is active.
WARNING
ELECTRIC SHOCK can kill.
The shutdown group is always enabled. Shutdown2 is
used for signaling low flow in the water cooler.
Unused shutdowns must be jumpered. Machines from
the factory come with the shutdowns already
jumpered. (See Figure A.5)
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
FIGURE A.5
• Always wear dry insulating gloves.
-----------------------------------------------------------
WARNING
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 the
power source. Locate the 8-position DIP
switch and look for position 8 of the DIP
switch.
4
9
10
11
7
8
1
3
6
2
5
12
4. Using a pencil or other small object, slide
the switch to the OFF position, when the
low speed gear is installed. Conversely,
slide the switch to the ON position when
the high speed gear is installed.
A
D
G
B
E
H
5. Replace the cover and screws. The PC
board will "read" the switch at power up, automati-
cally adjusting all control parameters for the speed
range selected
C
F
I
POWER WAVE AC/DC
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A-10
A-10
INSTALLATION
FEED HEAD BOARD DIP SWITCH:
DIP Switch Settings and Locations
DIP switches on the P.C. Boards allow for custom
configuration of the Power Wave. To access the DIP
switches:
Switch
Description
Comments
1
2
3
4
5
6
Object Instance LSB (see table A.3)
Object Instance MSB (see table A.3)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Used for ArcLink Configuration
WARNING
Used for configuring electrode
polarity (see Electrode and Work
Cable Connection in this Section)
No changes required for Power
Wave AC/DC
Used for configuring wirefeeder
gear ratio (see High Speed Gear
Box in this Section)
off Electrode polarity positive (default)
on Electrode polarity negative
• 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.
7
8
off Low speed gear (default)
on High speed gear
• Open the access panel, allowing the weight of the
panel to be carried by the bottom two screws. Make
sure to prevent the weight of the access panel from
hanging on the harness.
• Adjust the DIP switches as necessary.
• Replace the panel and screws, and restore power.
ETHERNET BOARD DIP SWITCH:
Bank S1
Switch
Description
Comments
1
2
3
4
5
6
7
8
Object Instance LSB (see table A.3)
Object Instance MSB (see table A.3)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Reserved for future use
Used for ArcLink Configuration
Reserved for future use
Bank S2:
Switch
Description
Comments
1
2
3
4
5
6
7
8
DeviceNet Baud Rate
(See Table A.4)
Used for DeviceNet
Configuration
DeviceNet Mac ID
(See Table A.5)
DeviceNet Baud Rate:
switch 1 switch 2
CONTROL BOARD DIP SWITCH
Baud rate
Switch
Description
Comments
off
on
off
on
off
off
on
on
125K
250K
500K
1
2
3
4
5
6
7
Object Instance LSB (see table A.3)
Object Instance MSB (see table A.3)
Equipment Group 1 Select
Equipment Group 2 Select
Equipment Group 3 Select
Equipment Group 4 Select
Reserved for future use
Used for ArcLink
configuration
Programmable value
TABLE A.4
Used for configuring
work sense lead
(See Work Volktage
Sensing in Section A)
off
work sense lead not connected
work sense lead connected
8
on
OBJECT INSTANCE
switch 2 switch 1
Instance
(default)
off
off
on
on
off
on
off
on
0
1
2
3
TABLE A.3
POWER WAVE AC/DC
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A-11
A-11
INSTALLATION
DEVICENET MAC ID
TABLE A.5
Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3
0
1
2
3
4
5
6
7
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
Software Selectable
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Default Setting
POWER WAVE AC/DC
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A-12
A-12
INSTALLATION
Bank S3 and S4
POWER WAVE AC/DC
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A-13
A-13
INSTALLATION
The PC will function as the control center for the
AC/DC system as well as the user interface. The
Ethernet hub splits the Ethernet port from the PC to all
the power sources and the phase generator. The PC
will act to coordinate the welding sequence of the mul-
tiple machines.
MULTI-ARC SYSTEM DESCRIPTION
The following is a general description of how the
PowerWave AC/DC can be configured in a multi-arc
set-up.
Each welding arc may be driven by one machine or up
to four machines connected in parallel. The hardware
for the power source has been designed so that the
power source can either operate as a master or a
slave. A few DIP switches must be configured proper-
ly to set the machine’s identity. Each power source
has a rating of 500 amps average current, with a peak
current of 725 amps. So, four machines are capable
of driving 2000 amps of output current with up to 2900
amps of peak current available. Each arc must have
one power source designated as the master. If only
one machine is required for an arc, then it must be set
up as the master. The master power source controls
the AC switching for the arc. The slaves respond to
what the master wants
One machine will be designated the master, with the
rest of the machines connected in parallel considered
slaves. The master can generate it's own AC frequen-
cy or it can use an external signal as a reference. An
external Phase Generator provides the means to syn-
chronize the AC wave shape between multiple arcs.
The phase angle between arcs can be adjusted to
reduce "Arc Blow" and other welding related issues.
An external phase control signal is required to keep
the separate wave shapes synchronized with each
other
An Ethernet-Gateway board can be used as the exter-
nal Phase Generator. An Ethernet-Gateway PC board
that can be configured to generate four phase signals
onto four differential I/O lines. The phase signals can
then be used to synchronize the four different arcs to
a common carrier frequency. The frequency can
range 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 of
the first signal. The frequency and phase shift are
controlled by software.
Due to the flexibility of the platform the configuration
may vary. A typical subarc system will consist of four
welding arcs, which require ten power sources and
one synchronous generator. Arc # 1 & #2 will be three
machines in parallel. Arc #3 & #4 will be two machines
connected in parallel (each individual machine is con-
nected to the ethernet hub).
PC
Ethernet Hub
ARC
#1
ARC
#4
ARC
#2
ARC
#3
PULSE
GENERATOR
POWER WAVE AC/DC
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B-1
B-1
OPERATION
SAFETY PRECUATIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, when
feeding with gun trigger, the electrode
and drive mechanism are always elec-
trically energized and could remain
energized several seconds after the
welding ceases.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dan-
gerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the begin-
ning of this manual.
POWER WAVE AC/DC
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B-2
B-2
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SMAW
INPUT POWER
ON
GMAW
FCAW
GTAW
OFF
HIGH TEMPERATURE
MACHINE STATUS
CIRCUIT BREAKER
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
THREE PHASE
DIRECT CURRENT
OPEN CIRCUIT
VOLTAGE
U
U
U
I
0
1
2
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
1
I
2
PROTECTIVE
GROUND
WARNING
POWER WAVE AC/DC
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B-3
B-3
OPERATION
DEFINITION OF WELDING TERMS
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding
process variables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity of
single knob control. The machine will select the cor-
rect voltage and amperage based on the wire feed
speed (WFS) set by the operator.
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
POWER WAVE AC/DC
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B-4
B-4
OPERATION
GENERAL DESCRIPTION
RECOMMENDED EQUIPMENT
/INTERFACE
Robotic Operation
The Power Wave AC/DC power source is designed to
be a part of a modular welding system. Each welding
arc may be driven by a single machine or by a number
of machines in parallel. Additionally with the use of an
external Phase Generator the phase angle and fre-
quency of different machines can be synchronized.
All welding programs and procedures are configured
through software for the robotic Power Waves. With
the proper configuration, Fanuc robots equipped with
RJ-3 or RJ-3iB controllers may communicate directly
to the Power Wave via ArcLink or DeviceNet. Proper
configuration and options allow other equipment such
as PLC’s or computers to interface with a Power
Wave through a serial, DeviceNet, ArcLink, or
Ethernet interfaces. All wire welding processes require
a robotic Power Feed wire feeder.
The Power Wave AC/DC is a high performance, digi-
tally controlled inverter welding power source capable
of complex, high-speed waveform control. The Power
Wave 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 Wave
AC/DC can support constant current, constant voltage
and pulse welding modes.
Hard Automation
Operating the Power Wave AC/DC in a hard automa-
tion application requires a PC or PLC for the user
interface. The power source communicates with the
PC via Ethernet. A wire feeder can be controlled
through Arc-link, DeviceNET or Ethernet.
The Power Wave AC/DC is designed to communicate
with other Arc-Link equipment. Additionally it can com-
municate with other industrial machines via
DeviceNET. Also the Power Wave AC/DC machines
are capable of communicating by Ethernet. The result
is a highly integrated and flexible welding cell.
SemiAutomatic Operation
Operating the Power Wave AC/DC in the semi-auto-
matic mode requires an Arc-Link compatible wire
feeder and user interface.
RECOMMENDED PROCESSES AND
EQUIPMENT
RECOMMENDED PROCESSES
EQUIPMENT LIMITATIONS
The Power Wave AC/DC can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory prepro-
grammed with multiple welding procedures, typically
including SAW, GMAW, GMAW-P, FCAW, GTAW for
a variety of materials, including mild steel, stainless
steel, cored wires, and aluminum. It carries an output
rating of 500 amps, 44 volts (at 100% duty cycle).
• The Power Waves are not to be used in outdoor
environments.
• Only Arc-Link Power Feed wire feeders may be
used with standard interfaces. Other Lincoln wire
feeders or non-Lincoln wire feeders can only be
used 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% Duty
Cycle.
The Power Wave AC/DC can be configured for robot-
ic, hard-automation or semi-automatic use.
REQUIRED EQUIPMENT
PROCESS LIMITATIONS
• 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
The Power Wave AC/DC is suitable only for the
processes listed.
• 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 PERIOD
The Power Wave AC/DC is capable of welding at a
100% duty cycle (continuous welding).
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B-5
B-5
OPERATION
6. LEAD CONNECTOR S2 (SENSE LEAD)
CASE FRONT CONTROLS
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
7. 5-PIN ARC LINK S1
8. 5-PIN DEVICENET CONNECTOR S5
9. I / O CONNECTOR
10. NEGATIVE STUD
11. INTERFACE CONNECTOR S6
12. POSITIVE STUD
13. AUXILUARY OUTPUT
14. ETHERNET CONTROLS (NOT SHOWN)
1. POWER SWITCH: Controls input power to the
Power Wave.
2. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated per table B1.
NOTE: The robotic PowerWaves’ status light will flash
green, for up to 15 seconds when the machine is first
turned on. This is a normal situation as the machine
goes through a self test at power up.
FIGURE B.1
TABLE B1
Light
Meaning
Condition
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components.
Blinking
Green
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 system
configuration is changed during operation.
Alternating Non-recoverable system fault. If the PS
Green and Status light is flashing any combination of
Red
red and green, errors are present in the PW-
AC/DC. Read the error code before the
machine is turned off.
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with
a long pause between digits. If more than
one code is present, the codes will be sepa-
rated by a green light.
WELDER OPERATION
Making a Weld
The serviceability of a product or structure utilizing the
welding 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 results
obtained in applying these programs. These variables
include, but are not limited to, welding procedure,
plate chemistry and temperature, weldment design,
fabrication methods and service requirements. The
available range of a welding program may not be suit-
able for all applications, and the build/user is and must
be solely responsible for welding program selection.
To clear the error, turn power source off, and
back on to reset. See Troubleshooting
Section.
Steady Red Not applicable.
Blinking Red Not applicable.
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper-
ature situation occurs. Output is disabled until the
machine cools down. When cool, the light goes out
and output is enabled.
The steps for operating the Power Wave will vary
depending upon the user interface of the welding sys-
tem. The flexibility of the Power Wave lets the user
customize operation for the best performance.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.
First, consider the desired welding process and the
part to be welded. Choose an electrode material,
diameter, shielding gas and process (GMAW, GMAW-
P, SAW, etc.)
5. AUXILIARY POWER CIRCUIT BREAKER: Protects
case front receptacle auxiliary supply. (10 amp on
non-CE models, 5 amp on CE models.)
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B-6
B-6
OPERATION
3. WELDING MODE:
Second, find the program in the welding software that
best matches the desired welding process. The stan-
dard software shipped with the Power Waves encom-
passes a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales repre-
sentative.
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 power
source
4. ARC CONTROL:
Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
"harsh" in all weld modes. It is adjustable from -10.0
to +10.0, with a nominal setting of 0.0.
To make a weld, the Power Wave needs to know the
desired welding parameters. ArcLink allows full cus-
tomization for exacting performance. The Power
Wave can be programmed with specific values for
Strike, Run-in, Crater and other parameters as need-
ed.
The Power Wave supports advanced features, like
touch 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, pulse
GMAW) WFS (wire feed speed) is the dominant
control parameter, controlling all other variables.
The user adjusts WFS according to factors such as
weld size, penetration requirements, heat input, etc.
The Power Wave then uses the WFS setting to
adjust its output characteristics (output voltage, out-
put current) according to pre-programmed settings
contained in the Power Wave. In non-synergic
modes, the WFS control behaves more like a con-
ventional CV power source where WFS and voltage
are independent adjustments. Therefore to maintain
the arc characteristics, the operator must adjust the
voltage to compensate for any changes made to the
WFS.
2. VOLTS / TRIM:
In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW
only) the user can change the Trim setting to adjust
the arc length. It is adjustable from 0.500 to 1.500.
A Trim setting of 1.000 is a good starting point for
most conditions.
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B-7
B-7
OPERATION
CV WELDING
Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The nominal preprogrammed volt-
age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. With syner-
gic programs, when the wire feed speed changes the
Power Wave will automatically adjust the voltage cor-
respondingly to maintain similar arc characteristics
throughout 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 arc
characteristics, the operator must adjust the voltage to
compensate for any changes made to the WFS.
All CV Modes:
Wave control adjusts the inductance of the wave
shape. (This adjustment is often referred to as "pinch".
Inductance is inversely proportional pinch.)
Increasing wave control greater than 0.0 results in a
crispier, colder arc while decreasing the wave control
to less than 0.0 provides a softer, hotter arc.
(See Figure B.2 for CURRENT WAVE FORM (CV)
FIGURE B.2
Wave Control +10.0
Wave Control 0.00
Wave Control -10.0
Current
Time
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B-8
B-8
OPERATION
PULSE WELDING
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 stickouts
from 0.50" (13mm) to 1.25" (32mm). At very low or
high wire feed speeds, the adaptive range may be
less due to reaching physical limitations of the welding
process.
Pulse welding procedures are set by controlling an
overall "arc length" variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impracti-
cal, and instead the arc length is set by adjusting
"trim".
Wave control in pulse programs usually adjusts the
focus or shape of the arc. Wave control values greater
than 0 increase the pulse frequency while decreasing
the background current, resulting in a tight, stiff arc
best for high speed sheet metal welding. Wave con-
trol values less than 0 decrease the pulse frequency
while increasing the background current, for a soft arc
good for out-of-position welding. (See Figure B.3)
Trim adjusts the arc length and ranges from 0.50 to
1.50, with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length.
Most pulse welding programs are syngeric. As the
wire feed speed is adjusted, the Power Wave will
automatically recalculate the waveform parameters to
maintain similar arc properties.
FIGURE B.3
Wave Control -10.0
Current
Wave Control 0.0
Wave Control +10.0
Time
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C-1
C-1
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
There are no factory installed options available for the
Power Wave.
FIELD INSTALLED OPTIONS / ACCESSORIES
Required Accessories
For Paralleling machines
• Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100
In Robotic Applications
• Control Cables (for use on FANUC robot arm, 22 pin to
14 pin, 10 ft), K1804-1
• Control Cables (for use on FANUC robot arm, 14 pin to
22 pin, 18 in), K1805-1
• Control Cables (for use on FANUC robot arm, 22 pin to
14 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
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
•
Do not touch electrically hot parts.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically
blowing out the machine, using a low pressure
airstream, to remove accumulated dust and dirt
from the intake and outlet louvers, and the cool-
ing channels in the machine.
PERIODIC MAINTENANCE
Calibration of the Power Wave AC/DC is critical to
its operation. Generally speaking the calibration
will not need adjustment. However, neglected or
improperly calibrated machines may not yield sat-
isfactory weld performance. To ensure optimal
performance, the calibration of output Voltage
and Current should be checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the
factory. Generally speaking the machine calibration
will not need adjustment. However, if the weld per-
formance changes, or the yearly calibration check
reveals a problem, contact the Lincoln Electric
Company for the calibration software utility.
The calibration procedure itself requires the use
of a grid, and certified actual meters for voltage
and current. The accuracy of the calibration will
be directly affected by the accuracy of the mea-
suring equipment you use. Detailed instructions
are available with the utility.
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE AC/DC
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal
covers are removed.
Lincoln Electric Field Service
facility for technical assistance.
Input fuses keep blowing, or input
breaker keeps tripping.
1. Make certain that fuses or
breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.
2. Welding procedure is drawing
too much output current, or
duty cycle is too high.
Reduce output current, duty
cycle, or both.
3. There is internal damage to
the power source. Contact an
authorized Lincoln Electric
Service facility.
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.
Machine will not power up (no
lights, no fan, etc.)
1. Make certain that the Power
Switch (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 made
improperly. Power down,
check input voltage reconnect
according to diagram on
reconnect cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Thermal LED is lit.
1. Machine’s thermostat has
opened. Check for proper fan
operation. There are two main
fans in the PowerWave AC/DC.
One machine is located in the
lower portion of the machine
which should be running when-
ever the machine is on. The
other fan is located in the upper
portion of the machine and only
runs when the machine is trig-
gered. Check for material block-
ing intake or exhaust louvers, or
for excessive dirt clogging coo-
ing channels in machine.
2. DC Bus PC board thermostat
has opened check for excessive
load on 40VDC supply.
3. Be sure process does not
exceed duty cycle limit of the
machine.
1. Input voltage is too low or too
high. Make certain that input
voltage is proper, according to
the Rating Plate located on the
rear of the machine.
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Machine won’t weld, can’t get any
output. (CR1 will not pull in.)
Authorized Field Service Facility.
2. If the Thermal LED is also lit,
see “Yellow Thermal LED is Lit”
section.
3.Primary current limit has been
exceeded. Possible short in out-
put circuit. Turn machine off.
Remove all loads from the output
of the machine. Turn back on. If
condition persists, turn power off,
and contact an authorized
Lincoln Electric Field Service
facility.
4. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes
by the status light. See
"Troubleshooting the Power
Wave / Power Feed System
Using the Status LED" section
of this text.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine often “noodle welds” (out- 1. Secondary current limit has
put is limited to approximately 100
amps) when running a particular
procedure
been exceeded, and the
machine has phased back to
protect itself. Adjust procedure
or reduce load to lower cur-
rent draw from the machine.
Auxiliary receptacle is “dead” — no 1. Circuit breaker CB2 (on case
auxiliary voltage .
front) may have opened.
Reset.
2. Circuit breaker CB4 (in recon-
nect area) may have opened.
Reset.
The Power Wave is triggered to
weld, but there is no output.
1. Check for fault signals from
the I/O connector. Possible
faults are lack of water flow
2. Circuit breaker CB4 (in recon-
nect area) may have opened.
Reset.
If all recommended possible areas
of misadjustments have been
checked and the problem persists,
contact your local Lincoln
Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
General degradation of the weld
performance.
1. Check for feeding problems, bad
connections, excessive loops in
cabling, etc..
2. Verify weld mode is correct for
processes.
3. The power source may require
calibration.
• Check the current calibration
• Check the voltage calibration
• Check the WFS calibration
1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow / water flow
turned off.
The Power Wave is triggered to
weld, but there is no output.
The feeder will not cold inch wire
1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow / water cooler
turned off.
Excessively long and erratic arc.
Arc loss fault on robot
1. Check for proper configuration
and implementation of voltage
sensing circuits.
1. Possibly caused by wire feeding
problem.
If all recommended possible areas of
misadjustments have been checked
and the problem persists, contact
your local Lincoln Authorized
Field Service Facility.
2. Possible causes/solutions are:
• Problem - Conduit leading to the
wire feeder has bends or twists,
which can reduce the wire feed
speed.
• Solution - Remove bends and
twists from conduit.
• Problem – Conduit leading up to
the wire feeder from the wire reel
is too long.
• Solution – Use a shorter length of
conduit
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE AC/DC
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E-6
E-6
TROUBLESHOOTING
Troubleshooting the Power Wave Using the Status
LED
USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.
The Power Wave is equipped with a status light if a
problem occurs it is important to note the condition of
the status light.Therefore, prior to cycling power to the
system, check the power source status light for error
sequences as noted below.
Included in this section is information about the power
source Status LED, and some basic troubleshooting
charts for both machine and weld performance.
Steady Green
Blinking Green
System OK. Power source communicating normally
with wire feeder and its components.
Occurs during a reset, and indicates the Power Wave
is 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
Alternating Green and Red
Non-recoverable system fault. If the PS Status light is
flashing any combination of red and green, errors are
present in the Power Wave. Read the error code
before the machine is turned off.
Error Code interpretation through the Status light is
detailed in the Service Manual. Individual code digits
are flashed in red with a long pause between digits. If
more 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 on
to reset.
Steady Red
Blinking Red
Not applicable.
Not applicable.
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E-7
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWERWAVE
The following is a list of possible error codes that the Power Wave AC/DC can output via the status light (see
"Troubleshooting the Power Wave / Power Feed System Using the Status LED").
Error Code #
Indication
31 Primary overcurrent error.
Excessive Primary current present. May be related to a switch board or
output rectifier failure.
32 Capacitor "A" under voltage
(Left side facing machine)
Low voltage on the main capacitors. May be caused by improper input
configuration, or an open/short circuit in the primary side of the
machine.
33 Capacitor "B" under voltage
(Right side facing machine)
34 Capacitor "A" over voltage
(Left side facing machine)
Excess voltage on the main capacitors. May be caused by improper
input configuration, , excessive line voltage, or improper capacitor bal-
ance (see Error 43)
35 Capacitor "B" over voltage
(Right side facing machine)
Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle limit
of the machine.
36 Thermal error
37 Softstart error
Capacitor precharge failed. Usually accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this
occurs the machine output will phase back to 100 amps, typically result-
ing in a condition refered to as "noodle welding"
41 Secondary overcurrent error
NOTE: For the PowerWave AC/DC the secondary limit is 500
The maximum voltage difference between the main capacitors has
been exceeded. May be accompanied by errors 32-35. May be caused
by an open or short in the primary or secondary circuit(s).
43 Capacitor delta error
49 Single phase error
Indicates machine is running on single phase input power. Usually
caused 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 Source
Control Board. If cycling the input power on the machine does not clear
the error, contact the Service Department.
Other
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE AC/DC
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ENHANCED DIAGRAM
F-1
F-1
DIAGRAMS
REAR OF MACHINE
H C I T W S C A O T
H C T
A O C T S W I
+
E N I H C A
O R N F T O F M
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F-2
F-2
DIAGRAMS
I N E C H
O F A M R A R E
2
S 1 P U N T A V E S I L E R S / A T M
3
S 1 U P T
A V E S O L U E T R / M A S T
E L C A E P T R E C
R E P O S W 8
D
A R B T O E N H E R E O T T
D R A O L O B R T N O C T O
D R A O L O B N T R T O C O
C
2 8 2
B7
B8
2 8 1 C
281D
282D
320
B8
B7
3 2 4
3 2 3
321
315
316
317
1
2
3
311
312
313
1
2
3
4
2 8 5 C
B7
B8
8 6 2 C
318
4
314
286D
285D
B8
B7
3 2 3
321
3 2 2
322
2 1 6
2 1 1
2 1 3
2 1 2
4
3
2
1
E K O H C
P A T R E T N E C
E N I H C A
O N F T R O F M
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F-3
F-3
PIN, LEAD CONNECTOR SETUPS
Table F.1 INTERFACE CONNECTOR WIRING
Pin
Robotic Interface Connector (S6)
Master / Slave Input(S12)
Master / Slave Output(S13)
A
B
C
D
E
F
G
H
I
+15vdc Tach voltage
Tach common
Reserved for future use
Reserved for future use
Sync In
Sync In
Ready In
Ready In
Polarity Out
Polarity Out
Ground
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Ready In
Ready In
Polarity Out
Polarity Out
Tach 1A differential signal
Tach 1B differential signal
Tach 2A differential signal
Tach 2B differential signal
Single Tach Input
Reserved for future use
Voltage sense lead
Motor "+"
J
K
L
Reserved for future use
Reserved for future use
+40v (COM)
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Drain (ethernet)
Kill Out
Kill Out
Reserved for future use
Reserved for future use
Motor "-"
Reserved for future use
Reserved for future use
+40vdc for solenoid
solenoid input
Reserved for future use
Reserved for future use
Shield ground to case
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
M
N
P
R
S
T
U
V
W
X
+40v ("+")
Reserved for future use
Reserved for future use
Reserved for future use
Reserved for future use
Drain (ethernet)
Kill Out
Kill Out
Reserved for future use
Reserved for future use
TABLE F.5 DEVICENET CONNECTOR S5
TABLE F.2 WIRE FEEDER RECEPTACLE S1
Pin
2
3
4
5
Lead #
894
893
892
891
Function
+24vdc Devicenet
Commom Devicenet+
Devicenet H
Pin
A
B
C
D
Lead #
53
54
67A
52
Function
Arclink L
Arclink H
Electrode Voltage Sense
Ground(0v)
Devicenet L
E
51
+40vdc
TABLE F.6 EXTERNAL I/O S7
TABLE F.3 VOLTAGE SENSE RECEPTACLE S2
Pin
1
2
3
4
5
6
7
8
Lead #
851
852
853
854
855
856
857
858
859
860
861
862
Function
+15vdc for Trigger group
Trigger input
Dual procedure input
4 Step input
+15vdc for cold inch group
cold inch forward
cold inch reverse
gas purge input
+15vdc for shutdown group
shutdown1 input
shutdown2 input
input B
Pin
3
Lead #
21A
Function
Work Voltage Sense
TABLE F.4 RS232 CONNECTOR S3
Pin
2
3
4
5
6
20
7
Lead #
253
254
#
#
##
Function
RS232 Receive
RS232 Transmit
S3 Pin5
9
10
11
12
S3 Pin4
S3 Pin20
S3 Pin6
RS232 Common
##
251
POWER WAVE AC/DC
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F-4
F-4
CONNECTION DIAGRAM
Robotic Set Up, Electrode Positive, CV/Pulse
Configuration
CONTROL CABLE K1805-1
K1804-1 CONTROL CABLE OR
K1804-2 AND ANY K1795 CONTROL CABLE
User supplied
electrode lead
DEVICENET CABLE
User supplied
work lead
K1796 COAXIAL WELD CABLE
WORK SENSE LEAD K940
POWER WAVE AC/DC
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F-5
F-5
DIMENSION PRINT
POWER WAVE AC/DC
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NOTES
POWER WAVE AC/DC
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NOTES
POWER WAVE AC/DC
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New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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