Lincoln Electric IM877 User Manual

Operator’s Manual

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POWER WAVE ® SYSTEM INTERFACE

For use with machines having Code Numbers:

11030

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM877 | Issue D ate Jun-13

© Lincoln Global, Inc. All Rights Reserved.

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to talk to a Service Representative

Hours of Operation:

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no later than the following business day.

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THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

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.

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.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.
SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly
toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

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

Gasoline Engines

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

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.

SAFETY

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.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.

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

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.

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.

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.

3

SAFETY

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.

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

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.

between the

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 within applicable OSHA PEL and
ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

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

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. 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.f. Also see item 1.b.

4

cause

SAFETY

WELDING AND CUTTING
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. Remember that welding
sparks and hot 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 though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
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.

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

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

5

vi

TABLE OF CONTENTS

Page

Product Description......................................................................................................................1

General Information......................................................................................................................2

Specifications and Regulatory Requirements............................................................................3

Installation.......................................................................................................................Section A

Safety Precautions. ..............................................................................................................A-1

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

Internal Controls Description.........................................................................................A-1

Bank S1.........................................................................................................................A-1

Bank S2.........................................................................................................................A-1

DeviceNet Mac ID ......................................................................................................A-2

________________________________________________________________________

Case Mounting Hole Dimension and Connection Diagram.........................Section F

________________________________________________________________________

Parts List..................................................................................................................P521

________________________________________________________________________

vi

1

PRODUCT DESCRIPTION

1

PRODUCT INFORMATION FOR
POWER WAVE SYSTEM INTER­FACE

PRODUCT DESCRIPTION

The Power Wave System Interface enables a number
of Power Wave AC/DC 1000 machines to be easily
integrated into a multi-arc system. Its primary role in
the system is to provide the means to synchronize the
AC wave shapes of up to four different arcs to a com­mon carrier frequency. This frequency can range
from 10 hertz to 300 hertz, with the most practical
range being 10 to 100 hertz. The phase angle
between arcs can also be adjusted to reduce the
effects of welding related issues such as "Arc Blow".

In such a system each welding arc may be driven by
one machine or multiple machines connected in paral­lel. The actual number of power sources per arc will
vary depending on the application. When only one
machine is required for an arc group, it must be con­figured as a Master. When multiple parallel machines
are required, one is designated as the Master and the
rest as Slaves. The Master controls the AC switching
for the arc, and the Slaves respond accordingly. In a
multi-arc system, the Master for each arc relies on a
dedicated external synchronization signal from the
System Interface to determine its frequency and bal­ance. The arc to arc phase relationship is determined
by the timing of each arcʼs "sync" signal relative to the
"sync" signal of ARC 1.

RECOMMENDED PROCESSES

The Power Wave System Interface is designed to be
part of a multi-arc Power Wave AC/DC 1000 sub­merged arc welding (SAW) system. Its primary role is
to provide a means to synchronize the output wave­forms of up to 4 different arc groupings.

EQUIPMENT LIMITATIONS

The Power Wave System Interface is not to be used
in outdoor environments.

Operating Temperature Range is 0° C to + 40° C.

The Power Wave System Interface is currently limited
to the synchronization of 4 different arcs.

In a typical multi-arc system, each arc is controlled by
its own Power Feed 10A Controller. The basic charac­teristics of the individual arcs such as WFS, ampli­tude, and offset are set locally by each arcʼs dedicated
controller. The frequency, balance, and phase shift
parameters of each arc are controlled by the Power
Feed 10A Controller for ARC 1, which must be con­nected to its Master through the Power Wave System
Interface (see Connection Diagram).

An alternate method of control utilizes a PLC inter­face. The PLC is typically connected directly to the
Power Wave System Interface and each power
source group in the system through a DeviceNet con­nection. In this method, only the Master of each power
source group need be connected to the PLC.

POWER WAVE®SYSTEM INTERFACE

2

GENERAL INFORMATION

2

CONNECTIONS AND INTERNAL CONTROLS

ArcLink
(OUTPUT)

DEVICENET

ETHERNET
(DIAGNOSTIC)

ArcLink
(INPUT)

S3

ETHERNET
P.C. BOARD

S4

S1

S2

RS-232
(DIAGNOSTIC)

ARC OUTPUTS
(SYNC SIGNALS)

POWER WAVE®SYSTEM INTERFACE

3

SPECIFICATIONS

TECHNICAL SPECIFICATIONS -POWER SOURCE ACCESSORY

INPUT VOLTAGE CURRENT

MODEL

INPUT VOLTAGE ± 10%

INPUT AMPERES

3

K2282-1

SAW

(Supplied by ArcLink Control Cable)

40VDC

PHYSICAL DIMENSIONS

MODEL

K2282-1

HEIGHT

9.26

(235 mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

32°F to 104°F(0°C to 40°C)

REGULATORY REQUIREMENTS

The Power Wave System Interface is a peripheral
component of the Power Wave AC/DC 1000
Submerged Arc Welding system. There are no specif­ic regulatory requirements.

WIDTH

15.94

(405 mm)

<500 mA

DEPTH

5.36 in

(136 mm)

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to 85°C)

WEIGHT

8 lbs.

(3.46 kg.)

POWER WAVE®SYSTEM INTERFACE

A-1

INSTALLATION

INSTALLATION INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• DISCONNECT INPUT POWER
BEFORE SERVICING.

• DO NOT OPERATE WITH COVERS
REMOVE.

• DO NOT TOUCH ELECTRICALLY LIVE PARTS.

• ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT.

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

1. Disconnect the input power from all components in

the system prior to installation.

2.

Refer to the Connection Diagram at the end of this
document for basic installation. Additional informa­tion can be found in the Power Wave AC/DC 1000
Instruction Manual and Training Literature.

3. The DeviceNet Module in the Power Wave System

Interface is factory configured with a Baud Rate of
125K and the Mac ID of 62. Refer to the DIP switch
setting section of this instruction sheet for special
applications and other configuration information.

4. When installation is complete, re-apply power and

verify the appropriate status lights on all system
components are solid green.

INTERNAL CONTROLS DESCRIPTION

BANK (S1)

Switch Description

1

Object Instance LSB* (see table A.1)(default ON)

2

Object Instance MSB** (see table A.1)(default OFF)
3 Equipment Group 1 Select (default OFF)
4 Equipment Group 2 Select (default OFF)
5 Equipment Group 3 Select (default OFF)
6 Equipment Group 4 Select (default OFF)
7 Reserved for future use (default OFF)
8 Reserved for future use (default OFF)

*LSB - Least Significant Bit
**MSB - Most Significant Bit

TABLE A.1

OBJECT INSTANCE

switch 2 switch 1 Instance

off off 0
off on 1(default)
on off 2
on on 3

BANK (S2)

Switch

1
2

Description
DeviceNet Baud Rate
see Table A.2

TABLE A.2

DeviceNet Baud Rate:

Switch 1 Switch 2 Baud Rate

off off 125K (default)
on off 250K
off on 500K
on on Programmable value

A-1

DIP SWITCH SETTINGS

1 2 3 4 5 6 7 8

O
N

'BANK S1 DEFAULT'

1 2 3 4 5 6 7 8

O
N

DEFINES INTERFACE OPERATION

'BANK S4'

1 2 3 4 5 6 7 8

O
N

'BANK S2 DEFAULT'

1 2 3 4 5 6 7 8

O
N

DEFINES I/O TERMINATION

'BANK S3'

POWER WAVE®SYSTEM INTERFACE

Switch

3
4
5
6
7
8

Description

DeviceNet Mac ID
Default ID=62
(see Table 3)

A-2

INSTALLATION

TABLE A.3 DEVICENET MAC ID

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

*Software Selectable (Line 0)
**Default Setting (Line 62)

62*111110 Default Setting

A-2

POWER WAVE®SYSTEM INTERFACE

F-1

TM

POWER WAV E SYSTEM INTERFACE WIRING DIAGRAM

DIAGRAMS

A

X

W
V
U
T

8

1

5

7

1

4

6

1

7

5

1

ARE NOT USED

N

O

M

C

D

E

S

N

E

I

H

H

G

W

L

O

E

M

O

C

D

4

0

V

V

S

C

N

A

C

B

ARCLINK (IN)

N

A

C

A

5

0

0

E

5

4

0

E

6

7

5

4

2

E

5

4

1

E

L3

L4

6

B

6

W

J71,J77,J 79 & J711

J712

PORT

ETHERNET

J70

N.A.

N

O

M

M

O

C

C

E

D

4

0

V

E

S

N

E

I

H

H

G

W

L

O

D

V

S

C

N

A

C

B

N

A

C

A

ARCLINK (OUT)

5

0

0

D

5

4

0

D

6

7

5

4

2

D

5

4

1

D

L1

L2

J76

J75

6

W

2

1

6

B

4

5

4

0

E

3

5

0

0

E

2

5

4

2

E

5

4

1

E

1
4

5

4

0

D

3

5

0

0

D

2

5

4

2

D

5

4

1

D

1

6

4

1

9

3

1

8

2

1

3

1

1

2

J

7

1

0

1

6

1

5

2

5

1

1

4

1

3

1

2

1

1

10
9
8
7
6
5
4

3

2

2

5

4

1

2

5

3

4

3

8

3

0

2
1

6

8

9

4

5

8

9

1

4
3

8

9

3

2

8

9

2

1

J74

J73

J72

2

5
4

01/26/2005

1

V

D

V

N

G

N

I

H

H

G

N

W

L

O

3

+

2

4

4

A

C

DEVICENET

A

C

5

2

+

2

4

8

9

4

A

8

9

2

8

9

1

RS232

CONNECTOR

251

254

253

1

2

3

5

7

4

6

20

ETHERNET

RJ 45 TYPE

CONNECTOR

L5

7
6

9

1

8

S
R

P
N

M
L
K
J

ARC 1

I

H
G
F
E
D

13

C

1

B
A

X

W
V
U
T
S
R

P
N

M
L
K
J

I

H
G
F
E
D

1
1

C
B
A

X

W
V
U
T
S
R

P
N

M
L
K
J

I

H
G
F
E
D

1
1

C
B
A

X

W

V
U
T
S
R

P
N

M
L
K
J
I
H
G
F
E
D

1

C
B
A

(formerly PHASE 0)

ARC 2

(formerly PHASE 1)

ARC 3

(formerly PHASE 2)

ARC 4

(formerly PHASE 3)

F-1

M20572

6

LATCH

B=BLACK

W=WHITE

U=BLUE

R=RED

N=BROWN

G=GREEN

LEAD COLOR CODING

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS

NOTES:

ELECTRICAL SYMBOLS PER E1537

ALIGNS WITH WHITE LEAD OF LED SOCKET.

RESISTORS=OHMS/WATTS

CAPACITORS=MFD/VOLTS

COMPONENT VALUES:

2

712

1

EX. 12 PIN CONNECTOR

CONNE CT O R PI N N UMBERS:

VIEW OF CONNECTOR ON PC BOARD

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®SYSTEM INTERFACE

F-2

CONNECTION DIAGRAM

F-2

DEVICENET
(OPTIONAL PLC
CONTROLLER)

ARC 1

PF-10A

K1543-X ArcLink

(5 PIN STANDARD)

K2282-1

ARC 4 ARC 3 ARC 2 ARC 1

ARC 2

PF-10A

CABLE

TYPICAL TWO ARC SYSTEM WITH
POWER FEED 10A CONTROLLERS

(WIRE FEEDERS NOT SHOWN)

ETHERNET
(DIAGNOSTIC)

RS-232
(DIAGNOSTIC)

K1795-X CABLE
(22 PIN STANDARD)

BACK VIEW OF
POWER WAVE AC/DC 1000
MACHINES

K1795-X CABLE
(22 PIN STANDARD)

OPTIONAL PARALLEL MACHINES
FOR ADDITIONAL CAPACITY.

ETHERNET CONNECTIVITY IS
REQUIRED.

(UP TO 6 MACHINES TOTAL PER ARC)

R

E

T

S

A

M

R

E

T

S

A

M

E

V

LA

S

E

V

A

L

S

E

V

A

L

S

E

V

A

L

S

POWER WAVE®SYSTEM INTERFACE

F-3

14.9

6

7.0

9

7.

8

8

15.7

5

CASE MM

OUNTITINGNG HHOLE

DIMENSIONS

DIMENSIONS

F-3

CA

OUN

DI

14

15

POWER WAVE®SYSTEM INTERFACE

NOTES

POWER WAVE®SYSTEM INTERFACE

NOTES

POWER WAVE®SYSTEM INTERFACE

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 vêtements

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 electro-

dos 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 alimentación

de poder de la máquina antes de ini­ciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten abschal-

ten! (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.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information
or advice create, expand or alter any warranty with respect to the sale
of our products.

Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.

Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.