CONTROL CABLE CONNECTIONS
General Guidelines
Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed sys- tems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 100ft. (30.5m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication prob- lems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems). Always use the shortest length of control cable possible, and DO NOT coil excess cable.
Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables. These recommendations apply to all communication cables including ArcLink® and Ethernet connections.
Product specific Installation Instructions
Connection Between Power Source and ArcLink®
Compatible Wirefeeders (K1543-xx, K2683-xx –
ArcLink Control Cable)
The 5-pin ArcLink control cable connects the power source to the wire feeder. The control cable consists of two power leads, one twisted pair for digital com- munication, and one lead for voltage sensing. The 5- pin ArcLink connection on the POWER WAVE R350 is located on the rear panel above the power cord. The control cable is keyed and polarized to prevent improper connection. Best results will be obtained when control cables are routed separate from the weld cables, especially in long distance applications. The recommended combined length of the ArcLink control cable network should not exceed 200ft. (61.0m).
Connection Between Power Source and Wire Feeder (K1785 or K2709 Control Cable)
The 14-pin wire feeder control cable connects the power source to the wire drive. It contains all of the necessary signals to drive the motor and monitor the arc, including the motor power, tachometer, and arc voltage feedback signals. The wire feeder connection on the POWER WAVE R350 is located in the upper- right corner of the case back. The K2709 series exter- nal dress cable is recommended for severe duty appli- cations such as hard automation or for robot arms not equipped with an internal control cable. Best results will be obtained when control cables are routed sepa- rate from the weld cables, especially in long distance applications. Maximum cable length should not exceed 25ft (7.6m).
Connection Between Power Source and Ethernet Networks
The POWER WAVE R350 is equipped with an IP67 rated ODVA compliant RJ-45 Ethernet connector, which is located on the rear panel. All external Ethernet equipment (cables, switches, etc.), as defined by the connection diagrams, must be supplied by the customer. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid conductor, shielded cat 5e cable, with a drain. The drain should be grounded at the source of transmis- sion. For best results, route Ethernet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctu- ating magnetic field. For additional guidelines refer to ISO/IEC 11801. Failure to follow these recommenda- tions can result in an Ethernet connection failure dur- ing welding.
Selecting a Wire Drive and Setting the Wire Drive Gear Ratio.
The POWER WAVE R350 can accommodate a num- ber of standard wire drives including the AutoDrive 4R100 (default), AutoDrive 4R220, and PF-10R. The feeder control system must be configured for both the wire drive type and gear ratio (high or low speed range). This can be accomplished with the Weld Manager Utility (included on the Power Wave Utilities and Service Navigator CDʼs or available at www.powerwavesoftware.com).
Additional information is also available in the “How To” section at www.powerwavesoftware.com.
