Control Cable Connections; Common Equipment Connections - Lincoln Electric POWER WAVE I400 Operator's Manual

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CONTROL CABLE CONNECTIONS

General Guidelines
Genuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
are specifically designed for the communication and
power needs of the POWER WAVE
tems. Most are designed to be connected end to end for
ease of extension. Generally, it is recommended that the
total length not exceed 100 ft. (30.5 m). The use of non-
standard cables, especially in lengths greater than 25 ft.
(7.6 m), can lead to communication problems (system
shutdowns), poor motor acceleration (poor arc starting),
and low wire driving force (wire feeding problems).
Always use the shortest length of control cable possible,
and DO NOT coil excess cable.
CAUTION
Regarding cable placement, best results will be
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility
of interference between the high currents flowing
through the weld cables, and the low level signals in
the control cables. These recommendations apply to
all communication cables including ArcLink
Ethernet connections.
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COMMON EQUIPMENT CONNECTIONS

Connection Between Power Source and Wire Feeder
(K1785 or K2709 Control Cable)
The 14 pin wire feeder control cable connects the power
source to the wire drive. It contains all of the necessary
signals to drive the motor and monitor the arc, including
the motor power, tachometer, and arc voltage feedback
signals. The wire feeder connection on the POWER
WAVE i400 is located on the recessed control panel
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above the output studs. Fanuc robot arms are equipped
with internal cabling and provide a standard 14 pin MS-
style connection at the base of the robot, and near the
wire feeder mount at the top of the arm. The K2709
series external dress cable is recommended for severe
duty applications such as hard automation or for robot
arms not equipped with an internal control cable. Best
results will be obtained when control cables are routed
separate from the weld cables, especially in long dis-
tance applications. Maximum cable length should not
exceed 100ft(30.5m).
INSTALLATION
Connection Between Power Source and ArcLink
Compatible Controllers or Ethernet Networks. Newer
model controllers, such as the Fanuc R30iA / R30iB, com-
municate via ArcLink
tion. To facilitate this, the Power Wave i400 is equipped with
an IP67 rated ODVA compliant RJ-45 Ethernet connector,
which is located on the recessed control panel above the
/ Power Feed sys-
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output studs. A special access chute is provided above the
Ethernet connection on the Power Wave i400 to accommo-
date seamless integration with the Fanuc R30iA / R30iB
controller. The K2677-2 Integration Kit includes a specially
designed industrial rated Ethernet cable for this purpose.
It is highly recommended that all external Ethernet equip-
ment (cables, switches, etc.), as defined by the connection
diagrams, be obtained through the Lincoln Electric
Automation Division. It is critical that all Ethernet cables
external to either a conduit or an enclosure are solid con-
ductor, shielded cat 5e cable, with a drain. The drain should
be grounded at the source of transmission, such as a net-
work switch or the Fanuc R30iA / R30iB ground strip.
Ethernet cables will achieve optimal performance levels at
distances up to 25 feet. Special attention to layout may be
required to support distances greater than 25 feet, including
specialized network equipment. For best results, always
route Ethernet cables away from weld cables, wire drive
and
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control cables, or any other current carrying device that can
create a fluctuating magnetic field. For additional guidelines
refer to industry standard documents for industrial Ethernet
networks. Failure to follow these recommendations can
result in an Ethernet connection failure during welding.
The ethernet port of the Power Wave i400 is factory config-
ured with a dynamic IP address. This is required for seam-
less operation with the Fanuc R30iA / R30iB controller.
Connection Between Power Source and ArcLink
Compatible Controllers (K1543 or K2683 ArcLink
Control Cable)
Earlier model Fanuc controllers communicate via traditional
ArcLink
these systems, the 5 pin ArcLink control cable connects the
power source to the controller.
The control cable consists of two power leads, one twisted
pair for digital communication, and one lead for voltage
sensing. The sense leads and power leads are typically
unused in this application. The 5 pin ArcLink connection on
the POWER WAVE
panel above the output studs. The control cable is keyed
and polarized to prevent improper connection. Best results
will be obtained when control cables are routed separate
from the weld cables, especially in long distance applica-
tions. The recommended combined length of the ArcLink
control cable network should not exceed 200ft(61.0m).
POWER WAVE
XT over an industrial Ethernet connec-
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over a standard 2 wire CAN based network. In
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i400 is located on the recessed control
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i400
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XT
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