Lincoln Electric Soldering Gun IM718 User Manual
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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  
POWER WAVE AC/DC  
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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  
[email protected]%  
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).  
POWER WAVE AC/DC  
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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.)  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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  
POWER WAVE AC/DC  
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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  
POWER WAVE AC/DC  
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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  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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.  
POWER WAVE AC/DC  
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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  
POWER WAVE AC/DC  
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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  
POWER WAVE AC/DC  
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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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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
welding applications, speeds and costs. Practice materials,  
exercises, questions and answers are suggested for each  
lesson.  
With over 500,000 copies of previous editions published  
since 1933, the Procedure Handbook is considered by many to  
be the “Bible” of the arc welding industry.  
This printing will go fast so don’t delay. Place your  
order now using the coupon below.  
528 pages, well illustrated, 6” x 9” size, bound in simulated,  
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The hardbound book contains over 750 pages of welding  
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$5.00 postage paid U.S.A. Mainland  
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The book contains the latest information and application  
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and ask for bulletin ED-80 or call 216-383-2259 and ask for the  
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187 pages with more than 100 illustrations. Size 8-1/2” x 11”  
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Lincoln Welding School  
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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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