Analog Interface, AD1359-1

Page 1 of 26 Created: 7/18/12 Revised: 7/24/13

Deluxe Analog Interface

AD1359-1





Table of Contents General Description ..................................................................................................................................................................................... 6

Technical Specifications ............................................................................................................................................................................... 6

Power Requirements .............................................................................................................................................................................. 6 I/O Signal Description.............................................................................................................................................................................. 6 Dimensions and Layout ........................................................................................................................................................................... 7 Compatibility with Lincoln Electric Power Sources.................................................................................................................................. 8 Features 8

User Interface Layout ................................................................................................................................................................................... 9

Installation ................................................................................................................................................................................................. 10

Non-Standard Safety Information ......................................................................................................................................................... 10 Location 10 Input and Grounding Connections ........................................................................................................................................................ 10 Recommended Cables........................................................................................................................................................................... 10 General Setup ....................................................................................................................................................................................... 10

Setup Instructions ...................................................................................................................................................................................... 10

Startup Sequence .................................................................................................................................................................................. 11 Wire Feed Speed Calibration ................................................................................................................................................................. 11 Cold Wire Feed ...................................................................................................................................................................................... 12 Voltage / Trim Calibration ..................................................................................................................................................................... 12 Teach Pendant Setup ............................................................................................................................................................................ 13 Memory Procedure Selection (For Reference) ...................................................................................................................................... 13

Procedure Selection ................................................................................................................................................................................... 14

Overview ............................................................................................................................................................................................... 14 Select by Number .................................................................................................................................................................................. 14 Search 14 Saving Procedures ................................................................................................................................................................................. 15

Welding Instructions .................................................................................................................................................................................. 16

Overview ............................................................................................................................................................................................... 16 Teach Pendant Setup ............................................................................................................................................................................ 16 Making A Weld ...................................................................................................................................................................................... 16

Advanced Menus ....................................................................................................................................................................................... 16

Overview ............................................................................................................................................................................................... 17 Explanation of Options .......................................................................................................................................................................... 17

Welding Adjustments ................................................................................................................................................................................. 19

Right Button Adjustments ..................................................................................................................................................................... 19 Left Button Adjustments ....................................................................................................................................................................... 19

Advanced References................................................................................................................................................................................. 20

Robot Controller Setup ......................................................................................................................................................................... 20 Deluxe Analog Interface Cable ............................................................................................................................................... 20

Maintenance .............................................................................................................................................................................................. 21

Non-Standard Safety Information ......................................................................................................................................................... 22 Routine Maintenance ............................................................................................................................................................................ 22 Periodic Maintenance ........................................................................................................................................................................... 22 Machine Calibration Specification ......................................................................................................................................................... 22

Troubleshooting ......................................................................................................................................................................................... 23

WAGO Interface Operation Lights ......................................................................................................................................................... 23 WAGO Interface I/O Lights .................................................................................................................................................................... 23 Miscellaneous ....................................................................................................................................................................................... 24

Replacement Parts ..................................................................................................................................................................................... 25

Bill of Materials ..................................................................................................................................................................................... 25

Wiring Schematic ....................................................................................................................................................................................... 26


GENERAL DESCRIPTION The Deluxe Analog Interface is designed to control Lincoln Power Sources with equipment not capable of ArcLink® communication. The interface is primarily intended for use with robots not supporting ArcLink® communication and will convert custom digital and analog signals to the ArcLink® protocol. Cables are available for older Fanuc and Motoman robots, but custom cables can also be made.

TECHNICAL SPECIFICATIONS

Power Requirements

Input Power (provided by Power Wave®) 24VDC 10%, <300mA

Digital Inputs 4.8k Impedance

Voff (Logic 0, Sourcing) 15 to 30 VDC

Von (Logic 1, Sourcing) -3 to 5 VDC

Digital Outputs 0.5 Amp, Short Circuit Protected

Voff (Logic 0, Sinking) 0 VDC

Von (Logic 1, Sinking) 24 VDC

Analog Inputs 0 – 10 VDC, Max: 35 VDC

Analog Outputs 0 – 10 VDC

Operating Temperature 0C to +40C

I/O Signal Description The following chart describes the connections to the 37-Pin Amphenol connector (MS, 28-21P).

Signal Description I/O Description 37-Pin Amphenol

28-21P

Fanuc Robot Signal Description (AD1144-6 Cable)

24V Input +24V r +24 VDC (Robot Power)

Common 24V Common a O VDC (Robot Common)

Arc Start Digital Input R WDO1 (Weld Cycle Start)

Gas Purge Digital Input S WDO2 (Gas Valve On)

Touch Sense Digital Input T WDO3 (Touch Sense Command)

Cold Inch Forward Digital Input U WDO4 (Feed Forward)

Cold Inch Reverse Digital Input V WDO5 (Feed Reverse)

Procedure Select #1 bit Digital Input W WDO6 (Procedure Select bit 1)

Procedure Select #2 bit Digital Input X WDO7 (Procedure Select bit 2)

Procedure Select #3 bit Digital Input Z WDO8 (Procedure Select bit 3)

Touch Sensed Digital Output c WDI1 (Touch Sense Detect)

Arc Detect Digital Output d WDI2 (Arc Detect)

Gas Fault Digital Output e WDI3 (Gas Shortage)

Water Fault Digital Output g WDI5 (Water Shortage)

Trim Input Analog Input A DACH1 (Weld Volts CMD)

NC --- B COMDA1 (Common)

WFS Input Analog Input E DACH2 (Weld WFS CMD) / Analog Out

Analog Common (Isolated) Analog Common F COMDA2 (Common) / Analog Out

Voltage Feedback Analog Output J ADCH1(Weld Voltage) / Analog In

NC --- K COMAD1 (Common) / Analog In

Current Feedback Analog Output L ADCH2 (Weld Amps) / Analog In

NC --- M COMAD2 (Common) / Analog In

Inverter Fault Digital Output h WDI6 (Pwr Supply Fail) / Input

Wire Stick + Digital Output N WDI+ (+Wire Stick Detect) / Input

Wire Stick – Wire Stick Common P WDI- (-Wire Stick Detect) / Input

Output

3.3K

24V

Input


Dimensions and Layout


Compatibility with Lincoln Electric Power Sources The Deluxe Analog Interface is compatible with many Lincoln Electric power sources including (but not limited to) Power Wave®455R, Power Wave®455M, Power Wave®455M/STT®, Power Wave® 655R, i400, S350 and R350.

Features

The Deluxe Analog Interface includes a user interface to set the weld parameters. These parameters include Weld Mode, Run-in, Arc Control, Burnback, and Cold Inch Functions.

Multiple procedures can be displayed and stored in the eight available memory positions.

All weld modes are stored and referenced through the Deluxe Analog Interface from the Lincoln Electric power source.

The Deluxe Analog Interface responds to many welding inputs and outputs except wire fault and the wire stick alarm.

All the components for Touch Sensing and TAST are internal to the Power Wave® and no additional power supply or current sensor is required.


USER INTERFACE LAYOUT This section describes the front panel user interface.

1-LEFT DISPLAY:

This display will show Amps or WFS during welding (the lights to the left will indicate the active parameter). This display will show the desired WFS while the welder is not welding.

2-LEFT KNOB: This knob will increase or decrease the desired WFS when the Digital Inputs Only option is selected.

3-MAIN DISPLAY:

The main display will indicate the weld mode and help the user navigate through different menus and settings.

4-LEFT SELECT BUTTON:

This button will change the Pinch or Wave Control attribute during Weld mode programming. It is also used to navigate through the setup menus (softkey).

5-MEMORY PUSH BUTTONS: The memory push buttons are used to store and retrieve the Welding Procedures. To preview the procedure stored in a memory location, briefly press the push button. To save a setting to a memory location, press and hold the push button for 2 seconds. During welding, the active memory location will be determined by the “Procedure Select” inputs.

6-COLD WIRE FEED FWD/REV: These buttons will command the wire feeder to move the wire forward or reverse. Rotating the Left Knob (2) will change the wire feed speed.

7-RIGHT SELECT BUTTON:

This button will change the Preflow time, Run-In WFS, Burnback time, and Postflow time. It is also used to navigate through the setup menus (softkey).

8-SETUP MODE INDICATOR This light indicates when the user is in a setup menu.

9-RIGHT DISPLAY: This display will show Volts or Trim during welding (the lights to the left will indicate the active parameter).

10-SET SWITCH SELECTOR: This knob/button is used to navigate through different options on the Deluxe Analog Interface. Briefly press the knob to activate the Weld Search Mode.


INSTALLATION

Non-Standard Safety Information

Location Do not use Deluxe Analog Interface in outdoor environments. It should not be subjected to falling water, nor any parts be submerged in water. Doing so may cause improper operation as well as a safety hazard. The best practice is to keep the machine in a dry, sheltered area. Degree of Environmental Protection: IP21S

Input and Grounding Connections

The Deluxe Analog Interface should be properly grounded. Consult local and national electric codes for proper grounding methods. Recommended Cables The Deluxe Analog Interface (AD1359-1) does not come with cables. To easily connect the product, several cables are recommended:

K1543-8: 8’ ArcLink® Cable (other lengths are also available)

AD1144-6: 7M I/O Cable for Fanuc Robots

AD1144-33,-34: 6M I/O Cable for Motoman Robots prior to the to the DX-100 Series

General Setup Connect the Deluxe Analog Interface to the Lincoln Electric power source using an ArcLink® Cable and to the controller using an I/O cable. An example of a Deluxe Analog Interface setup using a Fanuc Robot and Power Wave®455 is shown below:

WARNING! ELECTRIC SHOCK CAN KILL.

ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION.

TURN OFF INPUT POWER TO THE POWER SOURCE AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS EQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHER EQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE EQUIPMENT.

DO NOT TOUCH ELECTRICALLY HOT PARTS. ALWAYS CONNECT THE POWER WAVE® GROUNDING LUG (LOCATED INSIDE

THE RECONNECT INPUT ACCESS DOOR) TO A PROPER SAFETY (EARTH) GROUND.

ALWAYS CONNECT THE DELUXE ANALOG INTERFACE ENCLOSURE TO A PROPER SAFETY (EARTH) GROUND. WHEN MOUNTED TO THE POWER WAVE®, BOND THE DELUXE ANALOG INTERFACE ENCLOSURE TO THE CASE OF THE POWER WAVE®.

Order either cable depending on the robot

Deluxe Analog Interface Power Wave®455 Robot, Robot Controller

K1543-8 ArcLink® Cable

AD1144-6 I/O Cable

*Note: Many newer non-Fanuc robots (ex. ABB, DX-100 Motoman), already support ArcLink® communication. In this case the Deluxe Analog Interface is not necessary.


SETUP INSTRUCTIONS

Startup Sequence To startup the system, make all necessary connections and power ON the robot and power source. The Deluxe Analog Interface will turn ON with the power source. When power is applied, the display will read AI Initializing and continue to startup for approximately 30 seconds. After the startup is complete, the active memory location (determined by the robot through the I/O cable) will have a blinking light next to it. The main display will indicate the weld mode. Wire Feed Speed Calibration The Deluxe Analog Interface requires a voltage-to-WFS (in/min) ratio setup. A voltage generated by the robot will be converted to Wire Feed Speed through the Deluxe Analog Interface but first must be accurately set. To setup the parameters, follow the example below:

1. Press and hold both page buttons until screen reads P.0.

2. Turn center knob until screen reads P.36. Press the right page button.

3. Turn the center knob to select the ratio. An explanation of the options is available in the “Advanced Menus” section under P.36. In this example, select Fixed (50-800). Press the button for OK and wait five seconds.

4. Press both page buttons to return to the weld process screen.

5. On the Fanuc teach pendant, press the MENUS button, select I/O and make sure I/O Weld Out is displayed.

6. Cursor down to Wire Feed, press the button for NEXT then press the button for CONFIG. Cursor down to row 4 and key in 50 for the first number and 800 for the second number. The screen should appear as follows.


Cold Wire Feed To feed the wire through the system or adjust the wire length, use the cold wire feed buttons. The speed is set to 80 in/min.

Voltage / Trim Calibration The Voltage / Trim calibration is a similar setup to the Wire Feed Calibration. The limits are set from 50-150 as shown below.

On the teach pendant, the Trim value can be varied from 50-150. This value will determine either the Trim or Welding Voltage during operation.

In synergic welding this value represents a percentage of the pre-programmed voltage. The pre-programmed voltage is determined by the power source based on the wire feed speed. In non-synergic welding this value represents a direct voltage. The voltage is not determined by the power source based on the wire feed speed. Use the chart below as an example of how to determine the Trim Number for the Desired Voltage. This graph may vary depending on the weld mode.


Teach Pendant Setup The Teach Pendant I/O should be set similar to the following:

Memory Procedure Selection (For Reference) A memory is selected from three I/O inputs in the Deluxe Analog Interface. The inputs are connected on pins W, X and Z on the I/O cable. These inputs then produce a binary pattern to select the desired memory. The below table shows the relationships of what memory will be selected from the different I/O states from these pins.

Selected Memory

I/O on 37 pin connector

Pin W Pin X Pin Z

1 OFF OFF OFF

2 ON OFF OFF

3 OFF ON OFF

4 ON ON OFF

5 OFF OFF ON

6 ON OFF ON

7 OFF ON ON

8 ON ON ON


PROCEDURE SELECTION

Overview The power source will communicate all stored welding procedures to the Deluxe Analog Interface, available for use. These procedures can be selected either by number or through a search. Once a procedure is selected it can be stored in memory locations 1-8. During operation (welding), a memory location can be selected by the robot activating the stored procedure. These procedures can be switched immediately without halting robot operation. To navigate through the menus and different screens, use the knob and push buttons on the Deluxe Analog Interface.

Select by Number All weld procedures are referenced by a number. The follow chart explains the weld procedure numbers. To select a weld procedure by number, turn the center knob (in the weld process screen). The numbers will increment and a brief description will be displayed.

Weld Mode (NON-SYNERGIC GMAW -FCAW)

Process Weld Mode

GMAW,STANDARD CV 5

GMAW,POWERMODE 40

FCAW,SELF SHIELD CV 6

FCAW,GAS SHIELD CV 7

FCAW, FLUX CORE C0 2 90

FCAW, FLUC CORE ArCO 2 91

Weld Mode (GMAW (MIG SYNERGIC WELDING)

ELECTRODE AND GAS WIRE SIZE

Wire Size .030 .035 .045 .052 1/16

Steel CO 2 93 10 20 24 -

Steel Ar(Mix) 94 11 21 25 107

Stainless Ar(Mix) 61 31 41 - -

Stainless Ar/He/CO 2 63 33 43 - -

Wire Size - 3/64 1/16 -

Aluminum 4043 Ar - 148 71 73 -

Aluminum 5356 Ar - 151 75 77 -

Wire Size .045 .052 1/16

MetalCor CV ArCO 2 81 83 85

Weld Mode (GMAW-P)

Wire Size .030 .035 .045 .052

Steel (Crisp) Ar (Mix) 95 12 22 26 108

Steel (Rapid Arc) ArCO 2 - 13 18 27 -

Steel (Soft) Ar (Mix) 14 19 28 -

Stainless (Pulse) ArCO 2 62 32 42 - -

Stainless (Pulse) HeArCO 2 64 34 44 - -

Wire Size .035 3/64 1/16 -

Aluminum 4043 Pulse on Pulse - 98 99 100 -

Aluminum 5356 Pulse on Pulse - 101 102 103 -

Aluminum 4043 Ar - 149 72 74 -

Aluminum 5356 Ar - 152 76 78 -

Wire Size .045 .052 1/16

MetalCor (Pulse) ArCO 2 - - 82 84 86

MetalCor (Rapid Arc)

ArCO2 - - 87 88 89

Wire Size .035 .045

Ni Alloy - 170 175 - -

Si Bronze - 192 - - -

Note 1: This chart is a basic example of some of the weld modes. To find exact weld modes for a specific machine, visit http://www.powerwavesoftware.com Note 2: Mode “0” is a development mode and will not appear unless the power source has been specially programmed. When Mode “0” is available, the Deluxe Analog Interface will automatically make it the active mode.

http://www.powerwavesoftware.com/


Search If the weld procedure number is not known, the Deluxe Analog Interface allows the user to search for the procedure by selecting different parameters. The following example shows the procedure to search and select weld mode 18.

Saving Procedures A procedure must be saved to a memory location for use during operation. To save a displayed procedure, press and hold the desired memory location button for four seconds (similar to a car radio). Upon release, the screen will display a saved message. To review the procedure stored in a memory location, tap the button. The example below shows saving procedure 18 in memory location 1.

1. To begin the search, press the center knob, then the button for Begin.

2. Rotate the center knob until screen reads Pulse GMAW-P and press the right page button.

3. Rotate the center knob until screen reads Steel and press the right page button.

4. Rotate the center knob until screen reads .045” and press the right page button.

5. Verify screen reads Rapid Arc ArCO2 and press the right page button.

6. Verify screen reads 18.


WELDING INSTRUCTIONS

Overview To weld with the Deluxe Analog Interface, all installation and setup items in the previous sections must be completed. The robot will request a weld procedure and communicate the procedure to the Deluxe Analog Interface. The interface will translate that procedure and requested wire feed speed to the power source. Teach Pendant Setup On the teach pendant, ensure the welding schedules are setup correctly. The weld procedures are stored on the Deluxe Analog Interface, however the Wire Feed Speed is controlled through the robot. The example below shows how to setup the first weld procedure (memory location 1) to weld at 300 in/min.

Making A Weld Create a robot welding program, using the weld schedules corresponding to the different memory locations to determine the desired welding process. Running the program, the desired weld procedures will be activated upon command. The Deluxe Analog Interface will also display information about the weld in real-time and freeze on the last value once welding is complete.

1. Obtain the Fanuc teach pendant.

2. Press the DATA button to setup Weld Schedule 1 for 300.0 IPM.


The value for WFS = X (X – Low Limit)/(Hi Limit – Low Limit)=% X(100)

ADVANCED MENUS

Overview The section explains how to explore more advanced features of the Deluxe Analog Interface. To enter the setup menus, press and hold both page buttons until screen reads P.0. Use the knob to scroll through the different screens and press both page buttons to exit at any time.

Explanation of Options Each Advanced Menu option is numbered P.1 - P.210. The explanation of these options is shown in the following table:

Parameter Definition

P.0 Exit Setup Menu This setup menu parameter can be used to exit the setup menu. When P.0. is displayed, press the left Mode Select button to exit the setup menu.

P.1 Wire Feed Speed Units P.1 selects which units wire feed speed will be displayed in. English = in/min wire feed speed units (default). Metric = Meters/min wire feed speed units.

P.2 Arc Display Mode P.2 selects what value will be shown on the upper left display while welding. Amps = the left display show Amperage while welding (default). WFS = the left display shows WFS while welding.

P.3 Display Energy P.3 selects whether or not energy is displayed while welding. The total energy from the previous weld will persist on the display until another weld is started, or a user interface control is changed. P.3 will only show up in the list if the power source is capable of calculating energy ( a power source software update may be necessary). When P.3 = No, energy will not be displayed (default). When P.3 = Yes, energy is displayed.

P.14 Reset Wire P.14 option resets the current weight of the consumable package to its initial value. This option is only used to reset the consumable weight for Production Monitoring.

P.31 Mode selection P.31 option has three different modes to operate.

1. Standard Analog Interface: This is the basic mode for most applications. It used the analog signals plus the digital signals. 2. DNet F2 Configuration: Do not use. Option will be used in future Deluxe Analog Interface development.

3. Digital Only: Same as the 1st option except it ignores the analog inputs. Use will have to input the Workpoint and Trim values by using the display. Used for “simple” interfaces that can only provide digital I/O and not Analog inputs

P.32 Display Analog Inputs P.32 if this option is TRUE, the analog inputs for the WFS and TRIM (S-VOLTS) are displayed real time during the idle state. The default settings hold the last valid set points from the weld (required for applications where analog outputs are only active during the weld).

P.33 Hysteresis of the Analog Inputs P.33 option sets all three hysteresis values at once (attributes 610,611 and 612). This function is used to filter out small fluctuations on the analog inputs (i.e. the analog inputs value must change by this amount before it is converted and accepted as a new value).

P.34 Event Meter Frequency P.34 option sets the Event Meter Frequency rate.

P.35 Metering Time Constant P.35 option sets the Metering Time Constant (attribute 30758 in the weld controller).

P.36 WFS Scaling This controls how the Analog Input for the Wire Feed Speed is scaled. This has three settings:

1. Fixed (0-1200). The analog input signal will be interrupted from a range of 0 to 1200 IPM. On the robot, the user should set the WFS range from 0 to 1200 as well. The main advantage of this option is that for standard Lincoln wire drives and weld modes, this should allow for the full range of WFS to be used. The main disadvantage is that the user can select WFS that is out of limit on the robot. The actual WFS limits depend on the welding mode that is selected.

2. Fixed (50-800). The analog input signal will be interrupted from a range of 50 to 800 IPM. On the robot, the user should set the WFS range from 50 to 800 as well. This option is similar to the above option except the resolution of the analog input signal will be greater. The main disadvantage is that the user can select a WFS that is out of limit on the robot and might not be able to select the upper end of wire feed speeds for certain weld modes. The actual WFS limits depend on the welding mode that is selected.

3. Percent. The Deluxe Analog Interface will rescale the analog input signal for each selected weld mode. When this option is used, the user should use a “percent” on the robot (0.0 to 100.0). The main advantage of this setting is that the analog input will never be out of limits and offers the best resolution. The main disadvantage is that the WFS cannot be entered in IPM on the robot. Note: If only one weld mode is used, then the actual WFS limits can be used and entered as such on the robot. Then the user can enter the WFS in IPM on the robot.

PARAMETER DEFINITION P.1 through P.99

P.101 through P.210 Unsecured Parameter (always adjustable) Diagnostic Parameters (always read only)


P.80 Sense From Studs Use this option for diagnostic purposes only. When power is cycled, this option is automatically resets to False.

False = Voltage sensing is determined by the DIP switch configuration and the selected weld mode (default).

True = Voltage sensing is forced to “studs” regardless of the DIP switch configuration and selected weld mode P.99 Show Test Modes

Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to “Yes”. When the power source is turned off and back on again, the test modes will no longer appear in the mode list. Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding.

P.100 View Diagnostics Diagnostics are only used for servicing or troubleshooting the Power Wave® system. Select “Yes” to access the diagnostic options in the menu. Additional parameters will now appear in the setup menu (P.101, P.102, etc).

P.101 View Events Logs Used for viewing all the system event logs. Press the right MSP Button to enter the option. Rotate Set knob to select the desired system log to read. Press the right button again to enter the selected log. Rotating the Set knob will scroll through the event log, displaying the log index number, event code and some other data. Press the left button to back out to select another log. Press the left button again to exit this option.

P.102 View Fatal Logs Used for viewing all the system fatal logs. Press the right MSP button to enter this option. Rotate Set knob to select the desired log to read. Press the right button again to enter that log. Rotating the Set knob will scroll through the log, displaying the log index number and fatal code. Press the left button to back out to select another log. Press the left button again to exit this option.

P.103 View Software Version Information Used for viewing the firmware versions for each board in the system. Press the right MSP button to enter the option. Rotate Set knob to select the desired board to read. Press the right button again to read the firmware version. Press the left button to back out to select another board. Rotate the SET knob to select another board, or press the left button to exit this option.

P.104 View Hardware Version Information Used for viewing the hardware version for each board in the system. Press the right MSP button to enter this option. Rotate Set knob to select the desired board to read. Press the right button again to read the hardware version. Press the left button to back out to select another board. Press the left button again to exit this option.

P.105 View Welding Software Information Used for viewing the Weld Set in the Power Source. Press the right MSP button to read the Weld Set version. Press the left button to back out and exit this option.

P.106 View Ethernet IP Address Used for viewing the Ethernet Network IP address if there is an Ethernet board present in the system. Press the right MSP button to read the IP address. Press the left button to back out and exit this option. The IP address cannot be changed using this option.

P.107 View Power Source Protocol Used for viewing the type of power source the feeder is connected to. Press the right MSP button to identify the power source as either LincNet or ArcLink®. Press the left button to back out and exit this option.

P.200 Digital Inputs View Displays a hexadecimal value representing the states of the Digital Inputs. The value is decode as follows:

0x01 = Arc Start 0x10 = Cold Inch Reverse

0x02 = Gas 0x20 = Procedure Input 0

0x04 = Touch Sense 0x40 = Procedure Input 1

0x08 = Cold Inch Forward 0x80 = Procedure Input 2

P.201 Touch Sense Used to turn off and on Digital Output “Touch Sense Detect”.

P.202 Arc Detect Used to turn off and on Digital Output “Arc Detect”.

P.203 Gas Fault Used to turn off and on Digital Output “Gas Fault”.

P.204 Water Fault Used to turn off and on Digital Output “Water Fault”.

P.205 Power Source Fault Used to turn off and on Digital Output “Power Source Fault”.

P.206 Wire Stick Detect Used to turn off and on Digital Output “Wire Stick Detect”.

P.207 WorkPoint Analog In Displays value from Workpoint Analog input.

P.208 Trim Analog In Displays value from Trim Analog input.

P.209 Voltage Analog Output Used to send out a voltage on Analog Output 1.

P.210 Current Analog Output Used to send out current on Analog Output 2.


WELDING ADJUSTMENTS

Right Button Adjustments

Preflow Time: Adjusts the time the shielding gas flows prior to welding.

Run-In WFS: Sets the wire feed speed from the time the welding is commanded until an arc is established

Burnback: Adjusts the time the weld output continues after the wire stops feeding. This prevents the wire from sticking and prepares the end of the wire for the next arc start.

Postflow Time: Adjusts the time the shielding gas flows after welding. Left Button Adjustments

Pitch/Wave Control: Adjusts the output characteristics of the welding current. In general, increasing wave control results in a harsher, colder arc while decreasing the wave control provides a softer, hotter arc. Examples of the effect on the waveform are shown below.

Wave Control 0.00

Wave Control +10.0

Wave Control -10.0

Wave Control 0.0

Wave Control +10.0

Wave Control -10.0


ADVANCED REFERENCES

Robot Controller Setup

MONITORING FUNCTIONS 1 Arc loss ENABLED 2 Gas shortage DISABLED 3 Wire shortage DISABLED 4 Wire stick ENABLED 5 Power supply failure ENABLED 6 Coolant shortage ENABLED WELD RESTART FUNCTION 7 Return to path DISABLED 8 Overlap distance 0mm 9 Return to path speed 200mm/s SCRATCH START FUNCTION 10 Scratch start DISABLED 11 Distance 5mm 12 Return to start speed 12mm/s ON-THE-FLY FUNCTION 13 On-The-Fly ENABLED 14 Voltage increment 1.0V 15 Wire feed increment 5.0IPM 16 Current increment 5.0A OTHER FUNCTIONS 17 Weld from teach pendant ENABLED 18 Run in DISABLED 19 Wire burnback/retract DISABLED WELD EQUIPMENT SETUP 1 Weld process MIG 2 Remote arc enable DI 0 3 Weld power control Wire FD 4 Wire feed control AO 5 Wire+ Wire- speed 80IPM 6 Wire feed speed units IPM WELD RUN IN 7 Voltage 50.0V 8 Current 250.0A 9 Wire feed 200IPM 10 Time 0.00s WIRE BURNBACK/RETRACT 11 Voltage 50.0V 12 Current 250.0A 13 Wire feed 0IPM 14 Time 0.00s TIMING 15 Arc start error time 2.00s 16 Arc detect time 0.10s 17 Arc loss error time 0.30s

TIMING (cont.) 18 Gas detect time 0.05s 19 Gas purge time 1.00s 20 Gas preflow time 0.50s 21 Gas postflow time 0.00s WIRE STICK FUNCTION 22 Reset DISABLED 23 Reset tries 1 24 Voltage 50.0V 25 Time 0.00s VOLTAGE OUTPUT SCALING 26 Minimum reference 0.60V 27 Maximum reference 9.60V 28 Minimum output 50.0V 29 Maximum output 150.0V CURRENT OUTPUT SCALING 30 Minimum reference 0.00V 31 Maximum reference 10.00 32 Minimum output 0.0A 33 Maximum output 400.0A WIRE FEED SPEED OUTPUT SCALING 34 Minimum reference 0.60V 35 Maximum reference 9.60V 36 Minimum output 50(75)IPM 37 Maximum output 800(1200)IPM VOLTAGE INPUT SCALING 38 Minimum reference 0.60V 39 Maximum reference 9.60V 40 Minimum output 0.0V 41 Maximum output 80.0V CURRENT INPUT SCALING 42 Minimum reference 0.60V 43 Maximum reference 9.60V 44 Minimum output 0.0A 45 Maximum output 750A SYSTEM VARIABLES $AWEUPR $WSTK_ENA_DLY 0.10s TOUCH SENSING SETUP Sensor port type WI Sensor port number 1 Circuit port type WO Circuit port number 3


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MAINTENANCE

Non-Standard Safety Information

Routine Maintenance Routine maintenance consists of periodically inspecting the interface and cabling for loose or broken connections, worn switches, and signs of improper cable strain relief. Light cleaning is also recommended, using a low-pressure airstream, to remove accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in the machine.

Periodic Maintenance Calibration of the Lincoln Electric Power Source is critical to its operation and can adversely affect the performance of the system. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and Current should be checked yearly.

Machine Calibration Specification The Lincoln Electric Power Source output Voltage, Current, and WFS are calibrated at the factory. Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. Detailed instructions are available with the utility. Once the calibration has been verified, the analog feedback calibration between the Robot to the Deluxe Analog Interface should also be checked and adjusted as required. All analog adjustments must be made at the Robot.

WARNING! ELECTRIC SHOCK CAN KILL.

ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION.

TURN OFF INPUT POWER TO THE POWER SOURCE AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS EQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHER EQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE EQUIPMENT.

DO NOT TOUCH ELECTRICALLY HOT PARTS. ALWAYS CONNECT THE POWER WAVE® GROUNDING LUG (LOCATED INSIDE

THE RECONNECT INPUT ACCESS DOOR) TO A PROPER SAFETY (EARTH) GROUND.

ALWAYS CONNECT THE DELUXE ANALOG INTERFACE ENCLOSURE TO A PROPER SAFETY (EARTH) GROUND. WHEN MOUNTED TO THE POWER WAVE®, BOND THE DELUXE ANALOG INTERFACE ENCLOSURE TO THE CASE OF THE POWER WAVE®.


TROUBLESHOOTING WAGO Interface Operation Lights Inside the Deluxe Analog Interface is a WAGO interface block capable of converting the analog and digital signals from the 37-pin I/O cable into ArcLink® communication. The operation lights on the WAGO interface can be used to troubleshoot the Deluxe Analog Interface as described below.

LED CONDITION DEVICE STATUS DESCRIPTION

I/O ERR (RED) I/O RUN (GRN)

OFF ON Normal Normal Operating Condition. I/O Run on - Field Bus OK

BLINKING BLINKING Startup Normal Startup Sequence, both should stop blink after a couple of seconds

BLINKING OFF Field Bus Fault A field bus fault has been detected


I/O RUN (GRN) I/O ERR (RED)

OFF OFF No Power There is no power applied to the device

ON OFF Normal The device is operating in a Normal Condition

BLINKING OFF Device in Standby The device needs commissioning due to the configuration is missing, incomplete, or incorrect

OFF BLINKING Minor Fault Recoverable Fault

OFF ON Unrecoverable Fault

The device has an unrecoverable fault; may need replacing

BLINKING BLINKING Self Testing The Device is in Self Test


I/O RUN (GRN) I/O ERR (RED)

OFF OFF No Power, Not On-Line

The device might not be powered or the device might not have completed the Dup Mac Id test yet & is not on-line.

ON OFF Normal Online and allocated to a Master, Normal Condition

BLINKING OFF Online, Not Connected

Device is online, but not connected to master

OFF BLINKING Connection Time-Out

One or more I/O connections are in the Timed-Out state

OFF ON Critical Link Failure

Detected communication error - Duplicate Mac Id or Bus-off


WAGO Interface I/O Lights The I/O lights on the WAGO interface can be used to troubleshoot the Deluxe Analog Interface as described below. For digital I/O, the lights will switch on/off depending on the status. The picture below shows a summary of the lights and the setup of the WAGO connectors.

750-408 750-516 750-467 750-550 750-509 750-600750-408

750-346

87

65

43

21

+24VDC

DNET (WHITE WIRE)

DNET (BLUE WIRE)

0 VDC

+24VDC 0 VDC

Arc Start

Gas Purge

Touch Sense

Command

Cold FeedForward

Cold InchReverse

ProcedureSelect 1

ProcedureSelect 2

ProcedureSelect 3

Touch SenseDetect

Arc Detect

Gas Fault

Water Fault

Power SourceFault

Wire StickDetect

Input, Slot 1 Input, Slot 2 Output, Slot 3 Output, Slot 6

SET DIP SWITCHESAS SHOWN

WIRE FROM S23394-57CONNECTOR

Miscellaneous The chart below shows miscellaneous problems and possible solutions.

Problem Corrective Action

Display shows “Power WSource is not Connected”

The user interface is not finding the Control board. Try resetting the system. If this does not fix the problem, contact Lincoln Service.

No Display Check the ArcLink® cable connection between the Deluxe Analog Interface box and the Power Source.

Mode display shows: "Err dn"

Check the 24V power coming in from the Robot/PLC.

No LED's are lit on the I/O block

Check the 24V power coming in from the Robot/PLC. This also powers the DeviceNet® communications and should light up Led 2 on the Gateway board if there is 24 volts present.

False or dimly lit I/O Block indicators

Make sure the 37-pin communication cable shield from the Robot is properly terminated (connected to case ground at the Deluxe Analog Interface).


REPLACEMENT PARTS Bill of Materials

The table below indicates the Bill of Material. This list may be used to order parts if necessary.

*Indicates not shown in the Layout

Layout

Item #: LECO #: Description: Qty.:

1 L15927 Enclosure, Wall Mount 1

2* L15927-1 Sheetmetal enclosure (Reference) 1

3* L15027-2 Interface plate (Reference) 1

4* L15927-3 Mounting plate (Reference) 1

5* L15927-4 Cover plate brkt (Reference) 1

6 L10373-7 Overlay Deluxe Analog Interface Enclosure 1

7 S29406-1 PC BD ASBLY 1

8* CF000057 #6 32x.25RHS-FULL-GR2-3445 4

9 T13639-3 Knob 3

10 T14034-4 Shaft Seal 3

11* S27401 Potentiometer Insulation 1

12 S23055-1 Button Cover 12

13* E1906.187 Heat Shrink Tubing 3/16” 10 ft

14 S23394-57 Cable, Deluxe Analog Interface,DN 1

15* S8025-96 Self Tapping Screw 8

16 9SM17803 Plug & Lead Asbly 37 pin 1

17 S23395-11 Wago Analog Int, Dnet Eco-coupler 1

18* T11577-52 .0047 Capacitor 1


WIRING SCHEMATIC

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Documents

Analog Interface, AD1359-1