Connections Between Multiple Power Sources Run in Parallel (K1795 - Control Cable). To increase the output capacity for a given arc, the output studs of multiple Power Wave AC/DC 1000 machines can be connected in parallel. The parallel machines utilize a master/slave control scheme to distribute the load and coordinate AC switching. The 22 pin parallel control cable contains all of the necessary signals to keep the machine outputs synchronized, including polarity, ready, kill, and arc voltage feedback signals. The cable connects between the Master/Slave I/O connec- tors (S12 & S13) located on the rear of the Power Wave AC/DC 1000. The input connector (S12) is located on the lower left side of the case back (as viewed from the rear), and the output connector (S13) is located on the lower right side. The output connec- tor (S13) on the master connects to the input connec- tor (S12) on the slave. If needed the output connector on the slave machine can be used to connect to the input connector of another slave machine in a daisy chain fashion. This connection scheme can be repeat- ed as required until the desired output capacity is achieved. The system is currently limited to a maxi- mum of 5 slaves per master, or a total of 6 machines per arc.
NOTE: In addition to the parallel control cable, parallel connected machines also require an Ethernet connection to share critical weld parameter information. For more information refer to the "Connections Between a Power Source and Ethernet Network" section of this document.
Connection Between Power Source and Ethernet Network. Ethernet connections are required for sys- tems with parallel connected power sources (more than one power source per arc), or to utilize the tools provided in the Power Wave Submerged Arc Utilities software package. To facilitate this, the Power Wave AC/DC 1000 is equipped with an RJ-45 Ethernet con- nector, which is located under the spring loaded out- put cover. External Ethernet equipment (cables, switches, etc.) must be supplied by the customer. It is critical that all Ethernet cables external to either a con- duit or an enclosure are solid conductor, shielded cat 5 cable, with a drain. The drain should be grounded at the source. The use of cat 5+, cat 5E, cat 6 or stranded cable is not recommended. For best results, route Ethernet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field. For additional guidelines refer to ISO/IEC 11801. Failure to follow these recommendations can result in an Ethernet connection failure during welding.
NOTE: See Ethernet Configuration section for addi- tional information.
Connections Between a Power Source and System Interface (K1795 - Control Cable). When multiple arcs need to be synchronized, a Power Wave System Interface (K2282-1) is required. The system interface provides a dedicated synchronization signal for frequency and balance to each of the four ARC (a.k.a. PHASE) receptacles. The synchronization sig- nals for ARC1 through ARC4 can be phase shifted with respect to one another to reduce the effects of "arc blow" and other welding related issues. The indi- vidual synchronization signals are relayed to the mas- ter machine of their corresponding arc via a 22 pin control cable. The control cable(s) connect between the individual ARC receptacles on the system inter- face, and the Master/Slave input connector on the master of each corresponding arc group. The Master/Slave input connector (S12) is located on the lower left side of the case back (as viewed from the rear) of the Power Wave AC/DC 1000.
NOTE: In addition to the 22-pin arc synchronization cables, the system interface also requires a connection to the system controller either via ArcLink for Power Feed 10A controlled sys- tems (see "Connection Between Power Source and Power Feed 10A Controller" ), or via DeviceNet for PLC controlled systems (see "Connection Between a Power Source and Optional DeviceNet PLC Controller").
Connections Between a Power Source and Local PC (RS-232 – Null Modem Cable). For diagnostic and set up purposes it is sometimes necessary to connect the power source directly to a PC (personal computer). The Power Wave AC/DC 1000 is equipped with an RS-232DB-25 style serial connector for this purpose. It is located under the spring loaded output cover on the case front. RS-232 cables must be sup- plied by the user (Radio Shack part # 26-269; Note: USB port adapter - part #26-183 - is also required for PC’s equipped with USB instead of a serial port). For best results, route the RS-232 cable away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field.
