| INSTALLATION |
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 100 ft. (30.5 m). The use of non- standard cables, especially in lengths greater than 25 ft. (7.6 m), can lead to communication problems (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
CAUTION
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.
COMMON EQUIPMENT CONNECTIONS
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® i400 is located on the recessed control panel above the output studs. Fanuc robot arms are equipped with internal cabling and provide a standard 14 pin MS- style connection at the base of the robot, and near the wire feeder mount at the top of the arm. The K2709 series external dress cable is recommended for severe duty applications 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 separate from the weld cables, especially in long dis- tance applications. Maximum cable length should not exceed 100ft(30.5m).
Connection Between Power Source and ArcLink®XT Compatible Controllers or Ethernet Networks. Newer model controllers, such as the Fanuc R30iA, communicate via ArcLink®XT over an industrial Ethernet connection. To facilitate this, the Power Wave i400 is equipped with an IP67 rated ODVA compliant
It is highly recommended that all external Ethernet equip- ment (cables, switches, etc.), as defined by the connection diagrams, be obtained through the Lincoln Electric Automation Division. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid con- ductor, shielded cat 5e cable, with a drain. The drain should be grounded at the source of transmission, such as a net- work switch or the Fanuc R30iA ground strip. Ethernet cables will achieve optimal performance levels at distances up to 25 feet. Special attention to layout may be required to support distances greater than 25 feet, including specialized network equipment. For best results, always route Ethernet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuat- ing magnetic field. For additional guidelines refer to industry standard documents for industrial Ethernet networks. Failure to follow these recommendations can result in an Ethernet connection failure during welding.
The ethernet port of the Power Wave i400 is factory config- ured with a dynamic IP address. This is required for seam- less operation with the Fanuc R30iA controller.
Connection Between Power Source and ArcLink® Compatible Controllers (K1543 or K2683 ArcLink Control Cable)
Earlier model Fanuc controllers communicate via traditional ArcLink® over a standard 2 wire CAN based network. In these systems, the 5 pin ArcLink control cable connects the power source to the controller.
The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The sense leads and power leads are typically unused in this application. The 5 pin ArcLink connection on the POWER WAVE® i400 is located on the recessed control panel above the output studs. 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 applica- tions. The recommended combined length of the ArcLink control cable network should not exceed 200ft(61.0m).
POWER WAVE® i400
