Lincoln Electric IM839 User Manual

DEVICENET MODULE

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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.

IM839

July, 2003

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

OPERATOR’S MANUAL

Copyright © 2003 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.

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

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

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.

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.

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

PRÉCAUTIONS DE SÛRETÉ POUR

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.

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

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

vv

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

Module Installation Instructions. ...........................................................................................A-1

DeviceNet Module Setup......................................................................................................A-1

Power Wave Setup...............................................................................................................A-1

DeviceNet Dip Switches .......................................................................................................A-2

DeviceNet Mac ID...................................................................................................A-2 thru A-4

DeviceNet Mac ID – ON=1, OFF =0: (Table 3) ...................................................................A-5

DeviceNet Module Board Figure A.3....................................................................................A-6

________________________________________________________________________________

Trouble Shooting............................................................................................................Section B

How To Use Troubleshooting Guide ......................................................................B-1

Troubleshooting Guide ............................................................................B-2 Thru B-4

________________________________________________________________________

vi

A-1

FIGURE A.1

ITEMS CONTAINED IN HARDWARE BAG

Plastic LED lens (1)

Locknut (6)

Rubber Ring (1)

# 10 Hardware
(Washer, Lockwasher,Nut

(1 Each)

INSTALLATION

MODULE INSTALLATION INSTRUCTIONS

REQUIRED TOOLS

3/8 Wrench or nut Driver
Short Phillips Screw Driver

A-1

Remove the "optional" portion of the Communication
Interface Module decal on the top door assembly and
discard; apply the DeviceNet decal as shown in the
DECAL MOUNTING detail.

DISCARD

OPTIONAL TOOLS

Serial Cable (Radio Shack Cat. Num. 26-269)
Microsoft Windows compatible computer.

DEVICENET MODULE DESCRIPTION

This module adds DeviceNet communication capabili­ty to a Power Wave “M” type power source. It has a 5­pin sealed mini connector per ANSI B93.55M-1981.

THIS MANUAL COVERS:

• The setup and installation of the DeviceNet Module
in a Power Wave “M” type power source.

• The installation of the software on a PC and its con­nection to a Power Wave.

• How to connect the Power Wave to a DeviceNet net­work.

• How to get the Power Wave up and running on the
DeviceNet network.

WARNING

• ELECTRIC SHOCK CAN KILL.

DEVICENET
DECAL

DECAL MOUNTING

Remove the screws in the door assembly. Lower door
as shown in Figure A.1. Do not lean against the door
assembly during installation, hinge damage may
occur.

J16

1

D

4

A

• Do not touch electrically live part
or electrode with skin or wet cloth­ing.

• Insulate yourself from work and ground.

• Turn off input power using the disconnect switch
at the fuse box before working on the equip­ment..

___________________________________________

Locate the hardware bag and review its contests.
Some items in the HARDWARE BAG will not be
used.

C

3

F

2

Place the DeviceNet Interface Module (ITEM 1) onto
the self-clinching studs.

Fasten the module to the door assembly using three
of the supplied locknuts (ITEM 2).

Install the plastic LED lens through the open hole in
the front of the door assembly and roll the rubber ring
onto lens from the rear of the door assembly (ITEM 3).

Seat the status LED into the lens from the rear of the
door assembly.

DEVICENET MODULE

A-2

FIGURE A.2

INSTALLATION

A-2

Install the DeviceNet bulkhead connector by removing
the plastic plug covering the circular hole (ITEM 4) in
the front lower panel assembly. Install the 5-pin con­nector and mounting plate over the mounting studs as
shown in (Figure A.1). Fasten with two of the supplied
locknuts.

If a Wire Drive Interface Module is not installed
(Figure A.1), locate the 6-pin to 4-pin interconnect.
Insert the interconnect between J73 on the DeviceNet
module and J16 in the machine harness. Discard the
4-pin to 4-pin interconnect and proceed to the next
section.

If a Wire Drive Interface Module is installed (Figure
A.2), locate the 4-pin to 4-pin interconnect. Insert the
interconnect between J73 on the DeviceNet module
and J81 on the Wire Drive Interface Module. Discard
the 6-pin to 4-pin interconnect.

ONLY FOR MACHINES WITH A DEVICENET MODULE

AND A WIRE DRIVE INTERFACE MODULE

4-pin to 4-pin interconnect

switch 3 = Equipment Group 1 Select (Default = Off)
switch 4 = Equipment Group 2 Select (Default = Off)
switch 5 = Reserved for future use
switch 6 = Reserved for future use
switch 7 = Reserved for future use
switch 8 = Reserved for future use

Bank S2

switch 1 = DeviceNet Baud Rate (Default = OFF)
(See Table 2)
switch 2 = DeviceNet Baud Rate (Default = OFF)
(See Table 2)

DeviceNet Baud Rate (Table 2)

Switch 1 Switch 2 Baud Rate

Off Off 125K
On Off 250K
On On 500K
On On Programmable Value

switch 3 = DeviceNet Mac ID (Default = Off)
(See Table 3)

Wire Drive Module

DeviceNet Baud rate: The default Baud rate is 125K.
If another Baud rate is desired, see table 2 in this sec­tion and set switches 1 and 2 of bank S2. Every
device on a DeviceNet network must have the same
Baud Rate.

DeviceNet Module DIP Switches:

Bank S1

switch 1 = Object Instance LSB (Default = OFF)
(See Table 1)
switch 2 = Object Instance MSB (Default = OFF)
(See Table 1)

Object Instance (Table 1)

Switch 2 Switch 1 Instance

Off Off 0
Off On 1
On Off 2
On On 3

switch 4 = DeviceNet Mac ID (Default = On)
(See Table 3)

switch 5 = DeviceNet Mac ID (Default = On)
(See Table 3)

switch 6 = DeviceNet Mac ID (Default = On)
(See Table 3)

switch 7 = DeviceNet Mac ID (Default = On)
(See Table 3)

switch 8 = DeviceNet Mac ID (Default = On)
(See Table 3)

DeviceNet MAC ID:

The default Mac ID is 62. Every device on the
DeviceNet network should have a unique ID. If anoth­er MAC ID is desired, refer to Table 3.

• Complete Board Installation

Close door assembly insuring not to cut or
pinch any wires.

Reinstall the screws in door assembly.
Re-apply power and verify the appropriate

status lights on the Power Wave are green.
Discard any remaining hardware.

DEVICENET MODULE

A-3

INSTALLATION

A-3

• Software Installation

Insert the supplied CD into the PC. The PC
should automatically start the software install
of the programs.

If the PC does not automatically start the soft­ware installation then you will have to manual­ly start the software installation.

Open Windows Explorer
From the software CD run "setup.exe"
The installation program will guide you

through the rest of the software setup
process.

• DeviceNet Network Installation

For wiring the DeviceNet network to the
Power Wave, see the document "DeviceNet
Cabling Planning and Installation manual",
Allen Bradley Publication DN-6.7.2. This doc­ument can be downloaded from the Allen
Bradley web site. Connect the Power Wave to
the trunk or drop using a female ‘sealed-mini’
style connector. Avoid routing the DeviceNet
control cables in close proximity to the weld­ing output leads. The Power Wave has no
internal DeviceNet bus termination.

Some DeviceNet scanners require an EDS
file be install before they can connect to the
device. If your DeviceNet scanner does not
require an EDS files to be installed, this step
can be skipped. The EDS files for the Power
Wave are located on the CD that was shipped
with the DeviceNet Module.

Power Wave Product Code EDS File to USE

1 Undefined - Contact

Lincoln Electric
2 PW455
5 PW655
8 PW AC/DC
9 F355i

Configure the DeviceNet scanner to talk to the
Power Wave.

Verify that the DeviceNet scanner can see the
Power Wave.

• Connect PC to Power Wave

With a standard 9 pin to 25 pin RS232 serial
cable (Radio Shack cat no. 26-269), make a
connection with the Power Wave and a PC.

Turn on the Power Wave
Verify that no other application is using the

serial port. This includes any Hot Sync
Application.

• DeviceNet Software Settings

With the PC connected to the Power Wave,
double click on the Power Wave Utilities on
the Desktop to run the Power Wave PC appli­cation Launching program.

From the Applications tab select DeviceNet
Observer. This will run Power Wave
Observer.

Select the appropriate communication port
and click OK.

To find the correct EDS file to install, go to the
DeviceNet Configuration screen in Observer
(complete Installation Software). The bottom
left of this lists the Product Code and Vendor
Revision. Based on these settings, pick the
appropriate EDS file, see the table below for
more information on which EDS file to use.
Note that the product code that the DeviceNet
reports back is based on software that is
loaded into the control board.

DEVICENET MODULE

Note 1: MAC ID

Using bank S2, and switches 3 to 8, set the
DeviceNet MAC ID on the gateway board.
Note that every device on a DeviceNet net­work must have a unique MAC ID. Use table
3 in this section of the report to set the correct
MAC ID. Changes to the DeviceNet MAC ID
or Baud Rate require a cycle of power in order
for them to take effect.

A-4

• Configuration Verification

From the file menu select Device Net and then
Configuration. The configuration window will open up
and allow you to verify that the set MAC ID and baud
rate are correct.

If the DeviceNet scanner will not be commanding the
Power Wave then refer under the DeviceNet
Configuration section of the Power Wave Observer
Manual for proper setup. If the DeviceNet scanner
does not support explicit messages, then refer to all of
the following sections in the Power Wave Observer
User Manual: Additional Weld Schedule Variables and
DeviceNet Configuration Section to properly setup the
Power Wave.

From the file menu select Device Net and then
Monitor. The DeviceNet Monitor (shown below) will
display the status of the connection and its data. If
everything is operating correctly, the "Polled IO Cnx
State" will display "Established" and the IO Scans/Sec
will have a non-zero value.

INSTALLATION

A-4

DEVICENET MODULE

A-5

INSTALLATION

DeviceNet Mac ID – ON=1, OFF =0: (Table 3)

Mac ID Switch 8 Switch 7 Switch 6 Switch 5 Switch 4 Switch 3

000000 0
100000 1
200001 0
300001 1
400010 0
500010 1
600011 0
700011 1
800100 0

900100 1
1000101 0
1100101 1
1200110 0
1300110 1
1400111 0
1500011 1
1601000 0
1701000 1
1801001 0
1901001 1
2001010 0
2101010 1
2201011 0
2301011 1
2401100 0
2501100 1
2601101 0
2701101 1
2801110 0
2901110 1
3001111 0
3101111 1
3210000 0
3310000 1
3410001 0
3510001 1
3610010 0
3710010 1
3810011 0
3910011 1
4010100 0
4110100 1
4210101 0
4310101 1
4410110 0
4510110 1
4610111 0
4710111 1
4811000 0
4911000 1
5011001 0
5111001 1
5211010 0
5311010 1
5411011 0
5511011 1
5611100 0
5711100 1
5811101 0
5911101 1
6011110 0
6111110 1
6211111 0

A-5

DEVICENET MODULE

A-6

INSTALLATION

FIGURE A.3

A-6

DEVICENET MODULE

B-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.

__________________________________________________________________________

B-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.

DEVICENET MODULE

B-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

B-2

Device does not go on line.

1. 24v bus power

2. Baud rate

3. MAC address

4. Termination

5. Wiring

1. Verify that LED 2 on the Power
Wave’s DeviceNet Module is on
when the DeviceNet network is
powered. This should be done
with the power on the Power
Wave turned off.

2. Verify the Baud rate setting on the

Power Wave and on the
DeviceNet Master are the same.
The Configuration section of
Observer displays the Power
Wave’s baud rate.

3. Verify the Device Net MAC

address is correct. The
Configuration section of Observer
displays the Power Wave’s MAC
address.

4. Verify that the Device Net bus is

terminated correctly.

5. Verify the wiring of all multi-port

taps and field attachable ends.

6. EDS files

6. Verify that the correct EDS files

are being used if they are needed.
The Configuration section of the
Observer application displays the
current Product Code and Vendor
Revision of the Power Wave.

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.

DEVICENET MODULE

B-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

B-3

1. Current Interference

2. Termination

3. Shield

Device goes off line during welding

4. Power Supply

5. Expected Packet Rate

For more trouble shooting of a DeviceNet network the following references should be used.

1. Verify that cables are not run

along current carrying conductors.
This would include the welding
cables.

2. Verify that the DeviceNet bus is

terminated correctly.

3. Verify that the cable shielding is

correctly grounded at the bus
power supply. The shield should
be tied into the bus ground at only
one point.

4. Verify that the power supply can

supply more than enough current
for the devices in the network.

5. Verify that 1000/(Expected Packet

Rate) ≤ (scans per seconds). The
Monitor section of the Observer
application displays these values.

Allen-Bradley Cat. Num. DN-6.7.2
Rockwell Automation Document 8842
ODVA web site (www.odva.org)

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.

DEVICENET MODULE

NOTES

DEVICENET MODULE

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’entretien.

● 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 •

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