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A-13
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 100ft. (30.5m). The
use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication prob-
lems (system shutdowns), poor motor acceleration
(poor arc starting), and low wire driving force (wire
feeding problems). Always use the shortest length of
control cable possible, and DO NOT coil excess
cable.
Regarding cable placement, best results will be
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.
Product specific Installation Instructions
Connection Between Power Source and ArcLink
Compatible Wirefeeders (K1543, K2683 – ArcLink
Control Cable)
The 5-pin ArcLink control cable connects the power
source to the wire feeder. The control cable consists
of two power leads, one twisted pair for digital com-
munication, and one lead for voltage sensing. The 5-
pin ArcLink connection on the POWER WAVE
S500CE is located on the rear panel (See Case Back
Controls in the Operation Section). The control cable
is keyed and polarized to prevent improper connec-
tion. Best results will be obtained when control cables
are routed separate from the weld cables, especially
in long distance applications. The recommended com-
bined length of the ArcLink control cable network
should not exceed 200ft. (61.0m).
INSTALLATION
/ Power Feed
sys-
®
™
®
and
®
®
POWER WAVE
Connection Between Power Source and Ethernet
Networks
The POWER WAVE
S500CE is equipped with an
®
IP67 rated ODVA compliant RJ-45 Ethernet connec-
tor, which is located on the rear panel. All external
Ethernet equipment (cables, switches, etc.), as
defined by the connection diagrams, must be supplied
by the customer. It is critical that all Ethernet cables
external to either a conduit or an enclosure are solid
conductor, shielded cat 5e cable, with a drain. The
drain should be grounded at the source of transmis-
sion. For best results, route Ethernet cables away
from weld cables, wire drive control cables, or any
other current carrying device that can create a fluctu-
ating magnetic field. For additional guidelines refer to
ISO/IEC 11801. Failure to follow these recommenda-
tions can result in an Ethernet connection failure dur-
ing welding.
S500CE
®
A-13
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