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A-21
CONTROL CABLE CONNECTIONS
GENERAL GUIDELINES
These guidelines apply to all communication
cables including optional DeviceNet and Ethernet
connections.
• Genuine Lincoln control cables should be used
at all times (except as noted otherwise). Lincoln
cables are specifically designed forthe communica-
tion and power needs of the Power Wave
MAXsa™ systems. Most are designed to be con-
nected end to endfor ease of operation.
• Always use the shortest cable lengths possi-
ble. DO NOT coil excess cable. It is recommend-
ed that the total length of control cable does not
exceed 100ʼ (30.5M). The use of non-standard
cables in excess of 25ʼ (7.5M) can lead to commu-
nication problems (system shutdowns), poor motor
acceleration (poor arc starting), and low wire dri-
ving force (wire feeding problems).
• Best results will be obtained when the control
cables are routed separate from the weld
cables. This minimizes the possibility of interfer-
ence between the high currents flowing through
the weld cables and the low level signals in the
control cables.
COMMON EQUIPMENT CONNECTIONS
Connection Between MAXsa™ Controller and
MAXsa™ series Wire Drive (K1785-xx)
The 14 pin Wire Drive Control Cable (K1785-xx) con-
nects the Controller (MAXsa™ 10 or MAXsa™ 19) to
the Wire Drive (MAXsa™ 22 or MAXsa™ 29). This
cable should be kept as short as possible.
Connection Between Power Source and the
MAXsa™ Controller (K2683-xx - ArcLink Control
Cable).
Single and tandem arc systems are typically con-
trolled by a MAXsa™ 10 Controller. In a tandem, or
multi-arc system, each arc requires its own dedicated
controller.
The 5-pin ArcLink control cable connects the power
source to the MAXsa™ 10. If there is more than one
power source per arc, it connects from the MAXsa™
10 to the power source designated as the Master for
that arc. The control cable consists of two power
leads, one twisted pair for digital communication, and
one lead for voltage sensing (67).
INSTALLATION
NOTE
Connections Between Power Source and Optional
DeviceNet Programmable Logic Controller(PLC).
It is sometimes more practical and cost effective to
use a custom PLC interface to control a multi-arc sys-
tem (refer to the "DeviceNet Configuration" section for
interface information). The Power Wave
1000
style receptacle for this purpose. The receptacle is
located on the rear panel of the machine See Figure
®
/
B.3 The DeviceNet cable is keyed and polarized to
prevent improper connection.
NOTE: DeviceNet cables should not be routed
In a typical system, a DeviceNet connection is made
between the master power source of each arc, and
the PLC interface. DeviceNet cables must be sourced
locally by the customer. For additional guidelines refer
to the "DeviceNet Cable Planning and Installation
Manual" (Allen Bradley publication DN-6.7.2).
Connections Between Parallel Power Sources
(K1785-xx - Control Cable).
To increase the output capacity for a given arc, the
output studs of multiple Power Wave
SD machines can be connected in parallel. The paral-
lel machines utilize a master/slave control scheme to
distribute the load evenly and to coordinate AC
switching. K1785-xx cables connect the paralleled
machines via the synchronizing connectors on the
back of the machine. The system is currently limited to
a maximum of 2 slaves per master, or a total of 3
machines per arc.
Connections Between Power Sources in Multi-Arc
Applications (K1785-xx - Control Cable).
Synchronizing Connectors are available on the rear
panel of the machine for Multi-Arc applications using
the K1875-xx control cables. The system is currently
limited to six(6) arcs, or a "Lead" and five "Trail" arcs.
POWER WAVE
®
AC/DC 1000
SD is equipped with a 5-pin DeviceNet mini
®
with weld cables, wire drive control cables,
or any other current carrying device that
can create a fluctuating magnetic field.
®
SD
A-21
®
AC/DC
AC/DC 1000
®
®
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