Lincoln Electric IM718 User Manual

IM718

R

RETURN TO MAIN MENU

POWER WAVE AC/DC

For use with machines having Code Numbers:

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 thought­ful 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.

™

10849

June 2002

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

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 •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

POWER WAVE AC/DC

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
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.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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.

ARC RAYS can burn.

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.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
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.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.

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.

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.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

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.

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.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

POWER WAVE AC/DC

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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.

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.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• 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.

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.

FOR ELECTRICALLY
powered equipment.

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.

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

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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.

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.

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.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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 lev­age, 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.

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.

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.

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.

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 ray­onnement 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.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

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, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

POWER WAVE AC/DC

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to 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.

vv

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.

vi

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

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE AC/DC (K1860-1)

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

50/60HZ.

3 PHASE

OUTPUT

CONDITIONS

INPUT

CURRENT

AMPS

IDLE

POWER

POWER FACTOR

@ RATED OUPUT

A-1

EFFICIENCY

@ RATED OUPUT

460/500/575V

OPEN

CIRCUIT

VOLTAGE

90VDC

PROCESS CURRENT RANGES (AC or DC)

CURRENT

RANGE

DC

20-500

500A@40V.100%

PULSE

FREQUENCY

0.15 - 1000 Hz

SAW / MIG / MAG

FCAW

Pulse

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE /

FREQUENCY

50/60HZ

31/29/25

OUTPUT

PULSE

VOLTAGE

RANGE

5 - 55 VDC

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC. -

3.3 SEC.

800 Watts

Max.

CURRENT

50-500 Average Amps
40-500 Average Amps

15-725 Peak Amps

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG[IEC]

SIZES (MM2)

.95 MIN.

AUXILIARY POWER

(CIRCUIT BREAKER

PROTECTED)

40 VDC AT

10 AMPS

115 VAC AT

10 AMPS

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

84%

TYPE 75°C

460V
500V
575V

HEIGHT

38 in

965 mm

WIDTH

19 in

483 mm

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-20°C to +40°C

8 (10)
8 (10)
10 (6)

10 (6)
10 (6)
10 (6)

45
40
35

PHYSICAL DIMENSIONS

DEPTH

33 in

838 mm

STORAGE TEMPERATURE RANGE

-40°C to +40°C

WEIGHT

490 lbs.

222 kg.

POWER WAVE AC/DC

A-2

SAFETY PRECAUTIONS

INSTALLATION

LIFTING

A-2

Read this entire installation section before you
start installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel
should perform this installa­tion.

• Turn the input power OFF at

the disconnect switch or fuse
box before working on this

equipment. Turn off the input
power to any other equipment connected to the
welding system at the disconnect switch or fuse
box before working on the equipment.

• 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.

-------------------------------------------------------------

SELECT SUITABLE LOCATION

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.

Do not mount the PowerWave over combustible sur­faces. 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.

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.

STACKING

Power Wave AC/DC machine cannot be stacked.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground
terminal marked with the symbol is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.

HIGH FREQUENCY PROTECTION

Locate the Power Wave away from radio controlled
machinery.

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.

------------------------------------------------------------------------

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

A-3

XA

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

INSTALLATION

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

A-3

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 dia­gram located on the inside of the reconnect/input
access door of the machine. Failure to do so may
result in bodily injury or death.

-------------------------------------------------------------

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.

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 con­nection 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 volt­age, 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.

POWER WAVE AC/DC

A-4

INSTALLATION

WELDING WITH MULTIPLE UNSYN­CHRONIZED POWER WAVES

CAUTION

A-4

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.

Special care must be taken when more than one
Power Wave is welding unsynchronized on a sin­gle 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 addi­tional information on work voltage sense leads
see sections entitled "Voltage Sensing" and
"Multiple Unsynchronized Arc Sense Lead and
Work Lead Placement Guidelines".

------------------------------------------------------------------------

FIGURE A.2

TWO POWER WAVES

Every welding gun requires a separate shielding gas
regulator for proper flow rate and shielding gas cover­age. 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.)

Travel
Direction

Connect All Welding
Work Leads at the
Beginning of the Joint.

POWER WAVE AC/DC

Connect All Work
Sense Leads at the End
of the Joint.

A-5

INSTALLATION

A-5

MULTIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

Power

Arc #1

Current Flow

Arc #2

Work #1

Sens

Work #2

Sense #

Source

#1



Current flow from Arc #1

e

1

#

Power

2

Source

#2

affects sense lead #2



Current flow from Arc #2
affects sense lead #1



Neither sense lead picks up
the correct work voltage,

BAD

causing starting and welding
arc instability.

Power

Source

#1

Work #1
Sense #1

Arc #1

Arc #1

Current Flow

Sense #1
Sen se # 2

Current Flow

Arc #2

Arc #2

Work # 1

Work #2

Work #2

Sens e # 2

Power

Source

#1

Power

Source

#2

Power

Source

#2

BETTER



Sense #1 is only affected by weld
current from Arc #1



Sense #2 is only affected by weld
current from Arc #2



Due to voltage drops across work piece,
Arc voltage may be low, causing need
for deviation from standard procedures.

BEST



Both Sense leads are out of the current
paths.



Both Sense leads detect arc voltage
accurately.



No voltage drop between Arc and Sense
lead.



Best starts, best arcs, most reliable
results.

POWER WAVE AC/DC

A-6

INSTALLATION

ELECTRODE AND WORK CABLE
CONNECTIONS

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, espe­cially 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.

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 ter­minals. 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-6

CABLE INDUCTANCE, AND ITS EFFECTS
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 elec­trode cable length (A) + work cable length (B) + work
length (C) (See Figure A.3).

FIGURE A.3

POWER
WAVE

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.)

POWER
WAVE

K1796 COAXIAL CABLE

MEASURE FROM END
OF OUTER JACKET OF
CABLE

FIGURE A.4

A

C

WORK

A

C

B

SLIDING GROUND

A

WORK

B

C

FOR A DETAILED CONNECTION DIAGRAM USING

Suggested Copper Cable Sizes - 100 Duty Cycle Combined

K1796 COAXIAL CABLE, SEE PAGE F-4.

Length of Electrode and Work Cables (Table A.1)

Cable Length (ft (m) Parallel Cables Cable Size
0 (0) to 100 (30.4) 1 4/0 (120mm
100 (30.4) to 200 (60.8) 2 2/0 (70mm2)
200 (60.8) to 250 (76.2) 2 3/0 (95mm2)

When using inverter type power sources like the
Power Wave, use the largest welding (electrode and
work) cables that are practical. When pulsing, the

2

)

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.

------------------------------------------------------------------------

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

CAUTION

A-7

INSTALLATION

VOLTAGE SENSING

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 influ­ence 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 perfor­mance. Sense Lead Kits (K490-series) are available
for this purpose.

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.

A-7

Work Voltage Sensing
The Power Waves are shipped from the factory
with the work sense lead disabled.

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.

• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.

In extremely sensitive applications requiring volt­age 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 sec­tion entitled "Welding with Multiple Independent
Power Waves."

------------------------------------------------------------------------

The ELECTRODE sense lead (67) is built into the
K1795 control cable. The WORK sense lead (21) con­nects 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

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional**
GMAW-P
FCAW 67 lead required 21 lead optional**
GTAW

SAW 67 lead required 21 lead optional

* The electrode voltage 67 sense lead is part of the

control cable to the wire feeder.

** For consistent weld quality, work voltage sensing is

recommended.

67 lead required 21 lead optional**

Voltage sense at studs Voltage sense at studs

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

-----------------------------------------------------------

1. Turn off power to the power source at the discon­nect switch.

2. Remove the front cover from the power source.

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 pre­sent.

5. Replace the cover and screws. The PC board will
(read) the switch at power up, and configure the
work voltage sense lead appropriately.

Electrode Voltage Sensing

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.

123456 78

O

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POWER WAVE AC/DC

A-8

INSTALLATION

A-8

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.

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.

CAUTION

Excessive voltage drops at the work piece con­nection often result in unsatisfactory pulse weld­ing performance.

------------------------------------------------------------------------

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) connec­tor on the master connects to the top (female) connec­tor 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.

CONTROL CABLE CONNECTIONS
BETWEEN A POWER SOURCE
AND PHASE GENERATOR

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.

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.

CAUTION

The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communi­cation problems (system shutdowns), poor motor
acceleration (poor arc starting) and low wire dri­ving force (wire feeding problems). Use the short­est length of control cable possible. Do not coil
excess cable as this can cause communication
problems (system shutdowns).

------------------------------------------------------------------------

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.

ETHERNET CONNECTIONS

The PowerWave is equipped with an Ethernet con­nector, which is located under the spring loaded out­put cover. All Ethernet cables external to either a con­duit 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 con­nection 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.

FIGURE A.4a

POWER WAVE ETHERNET LAYOUT SETUP

- MAX TOTAL CABLE LENGTH I S 70 METERS
(FROM POWER WAVE TO PATCH PANEL)

- SHIELDED CABLE SHOULD BE GROUNDED
AT JUNCTION BOX

- REFER TO ISO / IEC 11801 FOR SPECIFICATIONS

CAT 5 CABLE
SOLID, SHIELDED,
WITH A DRAIN
(MAX LENGTH =
3 METERS)

PHASE
GENERATOR

POWER WAVEPOWER WAVEPOWER WAVE

JUNCTION BOX

ENVIRONMENTAL
ENCLOSURE

ETHERNET SWITCH

PATCH PANEL

POWER WAVE POWER WAVE

CONDUIT WITH CAT 5 UTP CABLE

POWER WAVE AC/DC

A-9

INSTALLATION

A-9

EXTERNAL I/O CONNECTOR

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.

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)

FIGURE A.5

HIGH SPEED GEAR BOX

Changing the ratio requires a gear change and a PC
board DIP switch change. As shipped from the facto­ry, 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:

WARNING

ELECTRIC SHOCK can kill.

• 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.

-----------------------------------------------------------

WARNING

1. Turn off power to the power source at the dis­connect switch.

Trigger Input

+15 VDC for Trigger Group

1

2

A

B

4 Step Input

Dual Procedure Input

4

3

Cold Inch Forward

+15 VDC for Cold Inch Group

78

6

5

D

E

C

Gas Purge Input

Cold Inch Reverse

+15 for shutdown group

910

G

F

Shutdown1 input

Shutdown2 input (Water Fault)

11

12

H

I

2. Remove the front cover from the power source.

Reserved for future use

3. The wire feed head board is on the right side of the

4. Using a pencil or other small object, slide

5. Replace the cover and screws. The PC

power source. Locate the 8-position DIP
switch and look for position 8 of the DIP
switch.

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.

board will "read" the switch at power up, automati­cally adjusting all control parameters for the speed
range selected

123456 78

O

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POWER WAVE AC/DC

A-10

INSTALLATION

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:

WARNING

• 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.

• 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.

FEED HEAD BOARD DIP SWITCH:

Switch Description Comments
1 Object Instance LSB (see table A.3)
2 Object Instance MSB (see table A.3)
3 Equipment Group 1 Select
4 Equipment Group 2 Select
5 Equipment Group 3 Select
6 Equipment Group 4 Select

off Electrode polarity positive (default)

7

on Electrode polarity negative

off Low speed gear (default)

8

on High speed gear

Used for ArcLink Configuration

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)

ETHERNET BOARD DIP SWITCH:
Bank S1

Switch Description Comments
1 Object Instance LSB (see table A.3)
2 Object Instance MSB (see table A.3)
3 Equipment Group 1 Select
4 Equipment Group 2 Select
5 Equipment Group 3 Select
6 Equipment Group 4 Select
7 Reserved for future use
8 Reserved for future use

Used for ArcLink Configuration

A-10

CONTROL BOARD DIP SWITCH

Switch Description Comments
1 Object Instance LSB (see table A.3)
2 Object Instance MSB (see table A.3)
3 Equipment Group 1 Select
4 Equipment Group 2 Select Used for ArcLink
5 Equipment Group 3 Select configuration
6 Equipment Group 4 Select
7 Reserved for future use

off work sense lead not connected

8

on work sense lead connected

Used for configuring
work sense lead

(See Work Volktage

Sensing in Section A)

OBJECT INSTANCE
switch 2 switch 1 Instance

off off 0
off on 1
on off 2
on on 3

(default)

T ABLE A.3

Bank S2:

Switch Description Comments
1 DeviceNet Baud Rate
2 (See Table A.4)
3
4
5 DeviceNet Mac ID
6 (See Table A.5)
7
8

Used for DeviceNet

Configuration

DeviceNet Baud Rate:
switch 1 switch 2 Baud rate

off off 125K
on off 250K
off on 500K
on on Programmable value

T ABLE A.4

POWER WAVE AC/DC

A-11

INSTALLATION

DEVICENET MAC ID

TABLE A.5

Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3

0 0 0 0 0 0 0 Software Selectable
1000001
2000010
3000011
4000100
5000101
6000110
7000111
8001000
9001001
10001010
11001011
12001100
13001101
14001110
15001111
16010000
17010001
18010010
19010011
20010100
21010101
22010110
23010111
24011000
25011001
26011010
27011011
28011100
29011101
30011110
31011111
32100000
33100001
34100010
35100011
36100100
37100101
38100110
39100111
40101000
41101001
42101010
43101011
44101100
45101101
46101110
47101111
48110000
49110001
50110010
51110011
52110100
53110101
54110110
55110111
56111000
57111001
58111010
59111011
60111100
61111101
62111110 Default Setting

A-11

POWER WAVE AC/DC

A-12
Bank S3 and S4

INSTALLATION

A-12

POWER WAVE AC/DC

A-13

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 proper­ly 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

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 con­nected to the ethernet hub).

INSTALLATION

A-13

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 mul­tiple machines.

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 frequen­cy or it can use an external signal as a reference. An
external Phase Generator provides the means to syn­chronize 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 exter­nal 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 practi­cal range being from 50 to 100 hertz. It may be desir­able that sync signals 2, 3, or 4 are some multiple of
the first signal. The frequency and phase shift are
controlled by software.

ARC

#1

ARC

#2

PC

Ethernet Hub

PULSE

GENERATOR

ARC

#3

ARC

#4

POWER WAVE AC/DC

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 elec­trically 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.

B-1

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dan­gerous.

• 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 begin­ning of this manual.

POWER WAVE AC/DC

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

B-2

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

U

U

U

SMAW

GMAW

FCAW

GTAW

OPEN CIRCUIT

0

1

2

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

I

1

I

2

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING

POWER WAVE AC/DC

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 cor­rect voltage and amperage based on the wire feed
speed (WFS) set by the operator.

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

B-3

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

B-4

OPERATION

B-4

GENERAL DESCRIPTION

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 fre­quency of different machines can be synchronized.

The Power Wave AC/DC is a high performance, digi­tally controlled inverter welding power source capable
of complex, high-speed waveform control. The Power
Wave AC/DC is capable of producing a variable fre­quency and amplitude AC output, a DC positive out­put, or a DC negative output. The Power Wave
AC/DC can support constant current, constant voltage
and pulse welding modes.

The Power Wave AC/DC is designed to communicate
with other Arc-Link equipment. Additionally it can com­municate 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.

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED EQUIPMENT
/INTERFACE

Robotic Operation

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.

Hard Automation

Operating the Power Wave AC/DC in a hard automa­tion 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.

SemiAutomatic Operation

Operating the Power Wave AC/DC in the semi-auto­matic mode requires an Arc-Link compatible wire
feeder and user interface.

RECOMMENDED PROCESSES

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 prepro­grammed 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 Wave AC/DC can be configured for robot­ic, hard-automation or semi-automatic use.

PROCESS LIMITATIONS

The Power Wave AC/DC is suitable only for the
processes listed.

EQUIPMENT LIMITATIONS

• 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.

REQUIRED EQUIPMENT

• 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

• 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

B-5

OPERATION

CASE FRONT CONTROLS

All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)

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.

B-5

6. LEAD CONNECTOR S2 (SENSE LEAD)

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)

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.

TABLE B1

Light

Condition

Steady Green

Blinking
Green

Alternating
Green and
Red

Steady Red
Blinking Red

System OK. Power source communicating normal­ly with wire feeder and its components.

Occurs during a reset, and indicates the PW­AC/DC 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 operation.

Non-recoverable system fault. If the PS
Status light is flashing any combination of
red and green, errors are present in the PW­AC/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 sepa­rated by a green light.

To clear the error, turn power source off, and
back on to reset. See Troubleshooting
Section.

Not applicable.
Not applicable.

Meaning

3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper­ature situation occurs. Output is disabled until the
machine cools down. When cool, the light goes out
and output is enabled.

4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:
Protects 40 volt DC wire feeder power supply.

AUXILIARY POWER CIRCUIT BREAKER:

5.

Protects
case front receptacle auxiliary supply. (10 amp on
non-CE models, 5 amp on CE models.)

FIGURE B.1

WELDER OPERATION

Making a Weld

The serviceability of a product or structure utilizing the
welding programs is and must be the sole responsibili­ty of the builder/user. Many variables beyond the con­trol 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 suit­able for all applications, and the build/user is and must
be solely responsible for welding program selection.

The steps for operating the Power Wave will vary
depending upon the user interface of the welding sys­tem. The flexibility of the Power Wave lets the user
customize operation for the best performance.

First, consider the desired welding process and the
part to be welded. Choose an electrode material,
diameter, shielding gas and process (GMAW, GMAW­P, SAW, etc.)

POWER WAVE AC/DC

B-6

OPERATION

B-6

Second, find the program in the welding software that
best matches the desired welding process. The stan­dard software shipped with the Power Waves encom­passes a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales repre­sentative.

To make a weld, the Power Wave needs to know the
desired welding parameters. ArcLink allows full cus­tomization for exacting performance. The Power
Wave can be programmed with specific values for
Strike, Run-in, Crater and other parameters as need­ed.

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 inter­face which can vary. Because of the different configu­ration options your system may not have all of the fol­lowing adjustments. Regardless of availability, all con­trols are described below.

3. WELDING MODE:

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 out­put 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.

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, out­put current) according to pre-programmed settings
contained in the Power Wave. In non-synergic
modes, the WFS control behaves more like a con­ventional 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

B-7

OPERATION

CV WELDING

Synergic CV:

For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft­ware at the factory. The nominal preprogrammed volt­age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. With syner­gic programs, when the wire feed speed changes the
Power Wave will automatically adjust the voltage cor­respondingly to maintain similar arc characteristics
throughout the WFS range.

Non Synergic CV:

This type of CV mode behaves more like a conven­tional CV power source. Voltage and WFS are inde­pendent 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)

B-7

Current

FIGURE B.2

Wave Control +10.0

ave Control 0.00

ave Control -10.0

Time

POWER WAVE AC/DC

B-8

OPERATION

B-8

PULSE WELDING

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 impracti­cal, and instead the arc length is set by adjusting
"trim".

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.

The Power Wave utilizes "adaptive control" to com­pensate for changes in electrical stick-out while weld­ing. (Electrical stick-out is the distance from the con­tact 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.

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 con­trol 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)

Current

FIGURE B.3

Wave Control -10.0

Wave Control 0.0

Wave Control +10.0

Time

POWER WAVE AC/DC

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

C-1

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

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 cool­ing channels in the machine.

D-1

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 sat­isfactory 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 per­formance 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 mea­suring equipment you use. Detailed instructions
are available with the utility.

POWER WAVE AC/DC

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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.

If you do not understand or are unable to perform the
Recommended Course of Action safely, 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, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE AC/DC

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS
(SYMPTOMS)

Major physical or electrical damage
is evident when the sheet metal
covers are removed.

Input fuses keep blowing, or input
breaker keeps tripping.

Machine will not power up (no
lights, no fan, etc.)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local authorized
Lincoln Electric Field Service
facility for technical assistance.

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.

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 volt­age selection, below.

3. Input voltage selection made

improperly. Power down,
check input voltage reconnect
according to diagram on
reconnect cover.

RECOMMENDED
COURSE OF ACTION

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, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE AC/DC

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS
(SYMPTOMS)

Thermal LED is lit.

Machine won’t weld, can’t get any
output. (CR1 will not pull in.)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

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 when­ever the machine is on. The
other fan is located in the upper
portion of the machine and only
runs when the machine is trig­gered. Check for material block­ing intake or exhaust louvers, or
for excessive dirt clogging coo­ing 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.

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 out­put 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.

RECOMMENDED
COURSE OF ACTION

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, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE AC/DC

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS
(SYMPTOMS)

Machine often “noodle welds” (out­put is limited to approximately 100
amps) when running a particular
procedure

Auxiliary receptacle is “dead”— no
auxiliary voltage .

The Power Wave is triggered to
weld, but there is no output.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Secondary current limit has

been exceeded, and the
machine has phased back to
protect itself. Adjust procedure
or reduce load to lower cur­rent draw from the machine.

1. Circuit breaker CB2 (on case

front) may have opened.
Reset.

2. Circuit breaker CB4 (in recon-

nect area) may have opened.
Reset.

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.

RECOMMENDED
COURSE OF ACTION

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, con­tact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE AC/DC

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

General degradation of the weld
performance.

The Power Wave is triggered to
weld, but there is no output.

The feeder will not cold inch wire

Excessively long and erratic arc.

Arc loss fault on robot

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

OUTPUT PROBLEMS

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.

1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow / water cooler
turned off.

1. Check for proper configuration
and implementation of voltage
sensing circuits.

1. Possibly caused by wire feeding
problem.

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.

E-5

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of
misadjustments have been checked
and the problem persists, contact

your local Lincoln Authorized
Field Service Facility.

• 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

E-6

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

E-6

Troubleshooting the Power Wave Using the Status
LED

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

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.

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 opera­tion

Alternating Green and Red

Steady Red
Blinking 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 sepa­rated by a green light.

To clear the error, turn power source off, and back on
to reset.

Not applicable.
Not applicable.

POWER WAVE AC/DC

E-7

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").

TROUBLESHOOTING

E-7

Error Code #

31 Primary overcurrent error.

32 Capacitor "A" under voltage

(Left side facing machine)

33 Capacitor "B" under voltage
(Right side facing machine)

34 Capacitor "A" over voltage
(Left side facing machine)

35 Capacitor "B" over voltage
(Right side facing machine)

36 Thermal error

37 Softstart error

41 Secondary overcurrent error

Indication

Excessive Primary current present. May be related to a switch board or
output rectifier failure.

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.

Excess voltage on the main capacitors. May be caused by improper
input configuration, , excessive line voltage, or improper capacitor bal­ance (see Error 43)

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle limit
of the machine.

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 result­ing in a condition refered to as "noodle welding"
NOTE: For the PowerWave AC/DC the secondary limit is 500

The maximum voltage difference between the main capacitors has

43 Capacitor delta error

49 Single phase error

Other

been exceeded. May be accompanied by errors 32-35. May be caused
by an open or short in the primary or secondary circuit(s).

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.

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

F-1

ENHANCED DIAGRAM

TM

DIAGRAMS

8

4

3

2

CB3

BREAKER

10A CIRCUIT

H1A

612A

612B

TO SW1

TO J61

TO AUX #2

TO CB4

FAN

CB4

6A CIRCUIT

BREAKER

X5

444

TO AUX#1

H1

612A

612

CB3

TO SOLID STATE RELAY

TO AUX #1

TO SW1

RECONNECT PANEL

1

350

33A

352

550-575V

500V

440-460V

N.C.

'A'

TO AUX #2

H6

H5

H4

TO AUX #1

THIS AREA VIEWED FROM REAR OF MACHINE

TO

J5

TO

J7

J8

216A GREEN

212A BLACK (WHITE)

281B RED

211A WHITE

282B BLACK (RED)

285B YELLOW

286B BLACK (YELLOW)

282A BLACK (BROWN)

286A BLACK (BLUE)

281A BROWN

285A BLUE

CB4

TO

AUX #2

RECONNECT PANEL

H3A

H2A

H5AH5H6A

H4A

H4

H6

H2

H3

H1

TO FAN

H2 (220-230)

H1

H4 (440-460)

H5 (500)

H3 (380-415)

H6 (550-575)

U

W

(51V)

AUXILIARY TRANSFORMER #1

X3WX3

X1

X2

X3A

TO SOLID STATE RELAY

R

N

(24V)

(115V)

X4

X5

J60

CR1

TO

THIS AREA VIEWED FROM LEFT SIDE OF MACHINE

TO AC SWITCH

TO J6

TO J1AD

405

404

403

406

1

652

4

3

SWITCH BOARD #1 (LEF T)

J40

16

16

LEFT SIDE OF MACHINE

(TOP

PRIMARY

LEFT SIDE

MAIN TRANSFORMER

(TOP

TO POWER BD. RECTIFIER

X3A

1

4-

TO3WJ7

3

3R

+

SOLID

STATE

RELAY

225

1

SUPPLY BOARD

DIGITAL POWER

TO

743

741

2

1

BOARD

J81

FEED HEAD

5

4

3

1

2

CONTROL BOARD

1

8

7

5

9

4

6

3

2

J70

ETHERNET

BOARD

J47

TO

CB1

C1

.05/600V

202

TO J9

-

202A

N.D.

FROM AC SWITCH

TO AUX#1

TP4

2

444

TO FAN

J4

R5

J4

TO

J1AD

223

221

222

227

5

2

4

3

J42

J72

153

800

840

4

3

1

7

8

9

6

J1

10

12

11

L2

L5

TP1

-

WORK

TO

J11

TO

J47

475

477

476

478

1

2

6

3

4

J41

TO

J11

J47

154

500

540

539

4

3

2

1

J82

13

10

14

12

11

1

13

15

14

16

TO

J2VS

54E53

B

A

2733228

274

226

262

267

266

268A

1

8

765

4

2

9

12

10

11

J43

S6

D6

TO

S6

TO

846

845

844

843

842

841

880

886

522

521

541

3

2

J83

1

15

16

2

3

J73

J47

67A

C

S1

WIRE

847

4

8

7

6

5

6

5

4

3

2

1

J84

S3

J77

TO

TO

251

253

254

771

773

775

777

772

1

2

5

8

7

3

6

234

4

J2

J3

TO

J81

53

800

840

743

741

1

2

5

9

8

1

7

3

6

4

CB1

FEEDER

4

10

J71

J72

J9

TO

L4

52

21A

1

2513

4

D

S2

SENSE

VOLTAGE

RECEPTACLE

RECEPTACLE

SECONDARY

S4

.022

800V

D4A

OUTPUT RECT

2.7

10W

TO

C3

51

500

NEG

NEG

POS

POS

1

1

2

2

3

4

BOARD

DC BUS

J46

S7

TO

J1VS

856

855

854

853

852

851

860

859

858

857

6

5

4

8

7

3

2

1

9

10

J85

R5

J1AD

J42

J43

TO

228

226

221

267

266

268

227

779

1

9

3

2

4

5

8

7

6

9

10

J4

S1

S9

TO

S5

TO

734

733

54

892

893

891

894

733A

734A

1

2

2

3

5

4

3

1

2

4

J74

J75

J73

J2

TO

251

254

253

2

5

3

7

1

4

6

20

S3

RS232

3 CONDUCTOR

TWISTED/SHIELDED

SHIELD GROUND TO CASE

CONNECTOR

J73

J712

213A BLACK (GREEN)

712 BLACK (BLUE)

733 YELLOW

734 BLACK (YELLOW)

711 BLUE

240

714 BLACK (GREEN)

713 GREEN

224A

717 WHITE

718 BLACK (WHITE)

716 BLACK (RED)

715 RED

TO AC SWITCH

14

+

POS

C5

C

12

13

+

POS

C4

C

11

18

LEFT)

N.G.

11

14

12

12

LEFT)

PRIMARY

(BOTTOM

N.B.

LEFT)

S4

D4B

TO

CB1

J41

J82

S1

50

540

475

476

477

478

76543

8

J47

511

512

862

861

13

151216

14

11

224

225A

222A

223

240

1

2

10

12

11

830

2

6

1

3

4

J76

TO

L2

J47

50

52

CB1

BREAKER

10A CIRCUIT

LEFT)

(BOTTOM

SECONDARY

S4

S4

S3

S3

S3

.022

800V

D3A

D3B

2.7

10W

224

224B

220

292A

268

220

DC BUS

6

5

487

3

2

1

THERM

J86

224A

220

231

232

776

4

3

3

4

2

1

J5

J3J6J7

TO

771

772

773

774

775

776

777

1

7

2

654

3

J77

TO

WORK

N.E. CONNECTION

TP3

268A

292A

R5

262

THERM

5

487

3

2

9

1

10

J60

TO

J40

J50

J1AD

J77

238

774

604

504

302

5054301

405

8

7

5

9

6

13

10

15

14

12

11

J6

778

779

1

9

8

7

2

654

3

10

J79

S4

115V

RECEPTACLE

FRONT OF MACHINE

S8

418

414

CURRENT

TRANSFORMER

S3

TOJ4J43

6

404

123

16

9

8

32

31

115/230V

AC SWITCH

RECEPTACLE

TO SWITCH

BD #1

TO SWITCH

BD #2

INPUT BOARD

12

WHITE

RED

#1

N.G.

9

10

1112131415

J87

1W

1B

281

282

4

1

2

10

TO

CB2

AUX 2

32A

N.J.

REAR OF MACHINE

POSNEG

L6

FILTER

HARMONIC

TO

CR1

J6

AUX #1

231

238

X3

601

232

604

1

857

4

6

2

3

J60

SWITCH BOARD #2 (RIGHT)

THIS AREA VIEWED FROM RIGHT SIDE OF MACHI NE

TO

J10A

15

518

WHITE

16

514

RED

N.B.

CURRENT

TRANSFORMER

#2

SECONDARY

S2

.022

800V

D2A

2.7

10W

C3TOAUX 1

X2

POS

AC

AC

POWER BD

RECTIFIER

16

TO

S9

LED

2B

2W

285

286

778

7

8

5

9

6

11

13

10

12

J7

711

712

713

1

2

3

7

8

5

6

4

3

J710

AUX FAN

S5

1

DEVICENET

CONNECTOR

G

5

AC1

POS

POS

AC2

INPUT

RECTIFIER

NEG

AC3

NEG

CR1

TO

SW1

CB4

T1

T2

T3

612

H1D

1

5

6

2

3

7

9

8

4

10

J61

TO J6

TO J1AD

505

506

504

503

1

2

6

5

4

3

J50

292A

224B

SW. BD.

THERM.

11

17

RIGHT)

N.G.

PRIMARY

(BOTTOM

RIGHT)

(BOTTOM

S2

NEG

281A

282A

282B

281B

2

1

4

3

3R3R

3W

211A

1

14

15

16

S9

TO

714

715

716

717

7

6

4

5

J712

TO

J75

892

891

893

894

5

4

2

3

CAN_L

CAN_H

+24V

+24V GND

S1

S2

S2

.022

800V

D2B

D1A

2.7

10W

X1

POS

POS

POS

NEG

NEG

NEG

TO

C3

+

285A

285B

286A

286B

P7A

8

5

6

7

S2

WORK

TO J1 VOLTAGE SENSE

202

206

213A

212A

216A

1

7

8

3

2

5

6

4

2

3

J9

J8

TOJ4J6

J40

J42

718

8

506

225A

222

503

222A

302

225

1

234

5

7

6

AUX. DRIVER BOARD

J1AD

31

CB2

BREAKER

10A CIRCUIT

841

S6

ROBOTIC/

A

WIREDRIVE

INTERFACE

RECEPTACLE

TO J61

67

J50

403

TO

J46

8

844

B

T1

T2

T3

(TOP

PRIMARY

(TOP

SECONDARY

S1

POWER BD RECT

21A

6

5

406

301

9

10

S4

AUX 2

33

842

C

601

TO J60

+

+

RIGHT)

RIGHT)

D1B

TO CT #1

TO CT #2

514 R

414 R

418 W

2

1

1

2

J10A

J10B

VOLTAGE SENSE

843

845

846

E

F

D

L1

L1A

TO SW1

L2

L3

L3A

TO SW1

CR1

X4

TO AUX #1

17

C

C7

NEG

15

18

C

C6

NEG

16

13

N.G.

S1

S1

N.F.

FAN

AUX.

32A

TO

J43

J82

273

274

154

518 W

1

2

3

4

J11

TO

J9

J85

511

67B

512

1

2

5

4

3

J1

SELECT BOARD

TO

J83

886

880

D6

DIODE

+40VDC

AC

AC

TO

J84

J2VS

J83

847

539

541

521

67B

I

JKL

NPRSTUV

H

G

M

NATIONAL ELECTRICAL CODE.

TO A SYSTEM GROUND PER

1

J1AD ,J3

J61,J77,

U

V

W

J79,J86

4

J8,

J47,J60

J84,J712

TO SUPPLY LINES

TO

1

3

J1VS,J9,

1

J14,J40,J42,

J50,J75,J83,J711

2

J82

1

J2,J5,J11,

J41,J46,J72

J73,J76,J81

1

J10A, J10B,

J2VS, J7

AUX #1

TO

CB3

H4A

H2A

H5A

H6A

H3A

2

3

4

6

5

P50

H2 (220-230)

H4 (440-460)

H5 (500)

H3 (380-415)

H6 (550-575)

R

W

(115V)

(230V)

1

4

2

352

350

33A

S8

TO

J10B

6

4

1

TO S4,

33

32

352A

RIGHT SIDE

352A

TO

AUX2

S4

TO

SIDE OF CT TO THE SWITCH BOARD. THE ARROW ON THE CT SHOULD POI NT FROM THE SWITCH BOARD TO THE TRANSFORMER.

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE) ALI GNS WITH BLACK LEAD OF LED SOCKET.

N.B. CTs MUST BE ORIENTED IN THE PROPER DIRECTION. TRANSFORMER LEADS SHOULD GO FROM TRANSFORMER THROUGH THE DOTTED

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575 V OPERATION.

N.D. CONNECT TO 202C OUTPUT RESISTOR ON AC SWITCH

NOTES:

TO

S6

S1

67

67A

206

216

TO J9

J2

N.E.

N.A.

TO J7

N.K.

THERMAL LED (Y)

STATUS LED (R/G)

1B

2W

2B

1W

852

851

522

GND-A

853

S7

12 PIN

3

2

1

CONNECTOR

215

3

X

W

16

E

J87

J1,J6,J7

J10,J70,J85

10

9

1

8

6

8

J710

5

1

7

6

14

4

J4,J13,

J43,J71

8

1

4

3

2

H1A

1

H1

(VIEWED FROM COMPONENT SIDE OF BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

6

12

7

1

RESISTORS=OHMS/WATTS

COMPONENT VALUES:

CAPACITORS=MFD/VOLTS

AUXILIARY TRANSFORMER #2

B=BLACK

G=GREEN

W=WHITE

U=BLUE

R=RED

N=BROWN

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537

CB2,

AUX. FAN

RIGHT SIDE OF MACHINE

N.J. CONNECT TO POWER RECEPTACLE ON AC SWITCH

N.E. CONNECT TO 206B OUTPUT STUD ON AC SWITCH

N.F. CONNECT TO DC POSITIVE CHOPPER BOARD ON AC SWITCH

N.G. CONNECT TO RECTIFIER ON AC SWITCH (FOUR PLACES)

N.K. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) ALIGNS WI TH BLACK LEAD OF LED SOCKET.

TO TP3

AC SWITCH

CONNECTIONS

L1A

L3A

A.01

TO CONTACTOR

(TOP)

LOAD LINE

612B

H1D

TO J61

TO CB3

A

TO J7

TO RECONNECT PANEL

SW1

POWER

TO

J85

861

855

856

857

858

859

860

854

862

GND-A

GND-B

7

4

5

6

8

9

11

10

12

8

7

4

6

9

101112

F-1

G4048

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

POWER WAVE AC/DC

F-2

DIAGRAMS

F-2

REAR OF MACHINE

RECEPTACLE

S8 POWER

N.E.

1

4

3

2

33B

350A

352B

350B

34

B3, B6

CHOPPER B

BOTTOM

344

B3, B6

40

CHOPPER D

FAN

350B

352B

4

3

1

2

S14

352C

350C

36

345

311

B1, B4

+

-

314

B2, B5

2

8

D

1

B

8

8

2

2

D

B

7

320

Thermostat

321

TOP

J15

38

B1, B4

-

315

+

318

B2, B5

2

8

6

D

B

8

2

5

8

D

B

7

321

Thermostat

322

TO CONTROL BOARD

TO CONTROL BOARD

DRAIN

DRAIN

240

282A

286A

281B

285B

285A

282B

281A

281A

282B

285A

285B

281B

282A

5

4

2

7

3

1

S11

282D

281C

285C

285D

281D

282C

230 VAC

( violet)

11

1

S23

331

330

345

311
312
313
314

722

721

286B

212A

211A

216A

213A

224A

721

286B

286A

6

9

8

286D

286C

350C

352C
1

6

S22

blue

230

VAC

brown

18 VAC

( white)

230 VAC

(orange)

6

2

1

16

332

333

50W

347

346

341

342

330

331

1

2

202C

J1

SNUBBER # 1

1
2

J2

3
4

TO ETHERNET BOARD

CIRCUIT

BREAKER

ABC

D

F

E

734B

734C

714

715

714

713

716

733

711

712

734

717

718

240

211A

213A

216A

212A

224A

5

4

6

7

3

1

2

S10

211

324

213

212

216

320

18 VAC

( red)

18 VAC

( yellow)

18 VAC

(green)

4

3

7

5

6

8

AUXILIARY TRANSFORMER

50W

344

343

348

332

333

1

2

J1

SNUBBER # 2

1
2

J2

3
4

714A

712

711

713

734

9

8

315
316
317
318

N.D.

NPR

G

HIJKL

M

733

734C

GND

717A

718A

718

717

713A

282C

B

7

281C

B

8

35

324

Thermostat

323

TOP

285C

B

7

286C

B

8

323

Thermostat

322

MASTER / SLAVE INPUT S12

ABCDEFG

V

U

S

T

X

W

722

716

715

715A

716A

722A

312

B1, B4

+

-

33

B3, B6

313

B2, B5

CHOPPER A

BOTTOM

37

B3, B6

B1, B4

316

+

-

317

39

B2, B5

CHOPPER C

NPRSTUV

HIJKL

M

714A

717A

718A

713A

MASTER / SLAVE OUTPUT S13

X

W

722A

716A

715A

C

G4076-2

RIGHT SIDE OF MACHINE

TM

LEFT SIDE OF MACHINE

37

38

.022

800V

RECTIFIER

2.7

10W

.022

800V

2.7

10W

N.A.

40

.022

800V

2.7

10W

N.A.

4

216

3

211
213

2

212

1

C

K

H

O

E

N

T

E

R

T

A

P

39

.022

800V

2.7

10W

N.A.

CURRENT

TRANSDUCER

C

E

36

35

N.A.

34

33

N.B.

NOTES:

N.C. CONNECT TO 206A IN POWER SOURCE (VOLTAGE FEEDBACK)

N.B. CONNECT TO OUTPUT RECTIFIER HEATSINK IN POWER SOURCE

N.A. CONNECT TO TRANSFORMER LEADS FROM POWER SOURCE

N.D. CONNECT TO OUTPUT STUD IN POWER SOURCE (CENTERTAP CONNECTION)

N.E. CONNECT TO POWER RESEPTACLE IN POWER SOURCE

206B

C1

TP1

N.C.

FRONT OF MACHINE

OUTPUT STUDS

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

POWER WAVE AC/DC

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 +15vdc Tach voltage Reserved for future use Reserved for future use
B Tach common Reserved for future use Reserved for future use
C Tach 1A differential signal Sync In Reserved for future use
D Tach 1B differential signal Sync In Reserved for future use
E Tach 2A differential signal Ready In Ready In
F Tach 2B differential signal Ready In Ready In
G Single Tach Input Polarity Out Polarity Out
H Reserved for future use Polarity Out Polarity Out
I Voltage sense lead Ground
J Motor "+" Reserved for future use Reserved for future use
K Motor "-" Reserved for future use Reserved for future use
L Reserved for future use +40v (COM) Reserved for future use
M Reserved for future use +40v ("+") Reserved for future use
N +40vdc for solenoid Reserved for future use Reserved for future use
P solenoid input Reserved for future use Reserved for future use
R Reserved for future use Reserved for future use Reserved for future use
S Reserved for future use Reserved for future use Reserved for future use
T Shield ground to case Drain (ethernet) Drain (ethernet)
U Reserved for future use Kill Out Kill Out
V Reserved for future use Kill Out Kill Out
W Reserved for future use Reserved for future use Reserved for future use
X Reserved for future use Reserved for future use Reserved for future use

F-3

TABLE F.2 WIRE FEEDER RECEPTACLE S1

Pin Lead # Function

A 53 Arclink L

B 54 Arclink H
C 67A Electrode Voltage Sense
D 52 Ground(0v)
E 51 +40vdc

TABLE F.3 VOLTAGE SENSE RECEPTACLE S2

Pin Lead # Function

3 21A Work Voltage Sense

TABLE F.4 RS232 CONNECTOR S3

Pin Lead # Function

2 253 RS232 Receive
3 254 RS232 Transmit
4 # S3 Pin5
5 # S3 Pin4
6 ## S3 Pin20
20 ## S3 Pin6
7 251 RS232 Common

TABLE F.5 DEVICENET CONNECTOR S5

Pin Lead # Function

2 894 +24vdc Devicenet
3 893 Commom Devicenet+
4 892 Devicenet H
5 891 Devicenet L

TABLE F.6 EXTERNAL I/O S7

Pin Lead # Function

1 851 +15vdc for Trigger group
2 852 Trigger input
3 853 Dual procedure input
4 854 4 Step input
5 855 +15vdc for cold inch group
6 856 cold inch forward
7 857 cold inch reverse
8 858 gas purge input
9 859 +15vdc for shutdown group
10 860 shutdown1 input
11 861 shutdown2 input
12 862 input B

POWER WAVE AC/DC

F-4

K1796 COAXIAL WELD CABLE

User supplied
work lead

User supplied
electrode lead

-

+

POWERWAVE

CONTROL CABLE K1805-1

WORK SENSE LEAD K940

DEVICENET CABLE

K1804-1 CONTROL CABLE OR
K1804-2 AND ANY K1795 CONTROL CABLE

User supplied
work lead

User s uppl ied
elect rod e lea d

CONTROL CABLE K1805-1

CONNECTION DIAGRAM

Robotic Set Up, Electrode Positive, CV/Pulse
Configuration

F-4

POWER WAVE AC/DC

F-5

DIMENSION PRINT

.65

.96

F-5

XA

L11656

14.62

33.08

37.46

34.96

9.45

19.16

19.83

18.80

POWER WAVE AC/DC

NOTES

POWER WAVE AC/DC

NOTES

POWER WAVE AC/DC

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BOOKS OR FREE INFORMATIVE CATALOGS Telephone: [phone] or, for fastest service, FAX this completed form to: 216-361-5901.

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Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

Exp Date

Name: _______________________________________________
Address: _______________________________________________

_______________________________________________

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Month Year

Signature as it appears on Charge Card:

______________________

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

Educational Video Information Incentive Management $5.00 IM

(ED-93)

James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

New Lessons in Arc Welding $5.00 L

How to Read Shop Drawings $4.50 H

A New Approach to Industrial Economics $5.00 NA

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● 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

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com