Professional Documents
Culture Documents
AD1359-1
Page 1 of 26
Created: 7/18/12
Revised: 7/24/13
Page 2 of 26
Created: 7/18/12
Revised: 7/24/13
Page 3 of 26
Created: 7/18/12
Revised: 7/24/13
Page 4 of 26
Created: 7/18/12
Revised: 7/24/13
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
Page 5 of 26
Created: 7/18/12
Revised: 7/24/13
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)
Digital Inputs
Voff (Logic 0, Sourcing)
Von (Logic 1, Sourcing)
Digital Outputs
Voff (Logic 0, Sinking)
Von (Logic 1, Sinking)
Analog Inputs
Analog Outputs
Operating Temperature
Output
24V
3.3K
Input
24V Input
Common
Arc Start
Gas Purge
Touch Sense
Cold Inch Forward
Cold Inch Reverse
Procedure Select #1 bit
Procedure Select #2 bit
Procedure Select #3 bit
Touch Sensed
Arc Detect
Gas Fault
Water Fault
Trim Input
NC
WFS Input
Analog Common (Isolated)
Voltage Feedback
NC
Current Feedback
NC
Inverter Fault
Wire Stick +
Wire Stick
I/O Description
37-Pin
Amphenol
28-21P
+24V
24V Common
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Output
Digital Output
Digital Output
Digital Output
Analog Input
--Analog Input
Analog Common
Analog Output
--Analog Output
--Digital Output
Digital Output
Wire Stick Common
r
a
R
S
T
U
V
W
X
Z
c
d
e
g
A
B
E
F
J
K
L
M
h
N
P
Page 6 of 26
Created: 7/18/12
Revised: 7/24/13
Page 7 of 26
Created: 7/18/12
Revised: 7/24/13
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.
Page 8 of 26
Created: 7/18/12
Revised: 7/24/13
Page 9 of 26
Created: 7/18/12
Revised: 7/24/13
INSTALLATION
Non-Standard Safety Information
WARNING! ELECTRIC SHOCK CAN KILL.
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
either cable
AD1144-33,-34: 6M I/O Cable for Motoman Robots Order
depending on the robot
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
Wave455 is shown below:
Robot, Robot Controller
Power Wave455
K1543-8
ArcLink Cable
AD1144-6
I/O Cable
Page 10 of 26
Created: 7/18/12
Revised: 7/24/13
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.
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.
Page 11 of 26
Created: 7/18/12
Revised: 7/24/13
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.
Page 12 of 26
Created: 7/18/12
Revised: 7/24/13
Page 13 of 26
Created: 7/18/12
Revised: 7/24/13
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
Weld Mode (NON-SYNERGIC GMAW -FCAW)
select a weld procedure by number,
Process
Weld Mode
turn the center knob (in the weld
GMAW,STANDARD CV
5
process screen). The numbers will
GMAW,POWERMODE
40
increment and a brief description will FCAW,SELF SHIELD CV
6
be displayed.
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
Steel
CO 2
93
10
20
Steel
Ar(Mix)
94
11
21
Stainless
Ar(Mix)
61
31
41
Stainless
Ar/He/CO 2
63
33
43
Wire Size
3/64
Aluminum 4043
Ar
148
71
Aluminum 5356
Ar
151
75
Wire Size
.045
MetalCor CV
ArCO 2
81
Weld Mode (GMAW-P)
Wire Size
.030
.035
.045
Steel (Crisp)
Ar (Mix)
95
12
22
Steel (Rapid Arc)
ArCO 2
13
18
Steel (Soft)
Ar (Mix)
14
19
Stainless (Pulse)
ArCO 2
62
32
42
Stainless (Pulse)
HeArCO 2
64
34
44
Wire Size
.035
3/64
Aluminum 4043
Pulse on Pulse
98
99
Aluminum 5356
Pulse on Pulse
101
102
Aluminum 4043
Ar
149
72
Aluminum 5356
Ar
152
76
Wire Size
.045
MetalCor (Pulse)
ArCO 2
82
MetalCor (Rapid
ArCO2
87
Arc)
Wire Size
.035
.045
Ni Alloy
170
175
Si Bronze
192
-
.052
24
25
1/16
73
77
.052
83
1/16
107
1/16
85
.052
26
27
28
1/16
100
103
74
78
.052
84
88
108
1/16
86
89
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.
Page 14 of 26
Created: 7/18/12
Revised: 7/24/13
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.
1. To begin the search, press the center knob, then the
button for Begin.
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.
3. Rotate the center knob until screen reads Steel and press
the right page button.
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.
Page 15 of 26
Created: 7/18/12
Revised: 7/24/13
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.
1. Obtain the Fanuc teach pendant.
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.
Page 16 of 26
Created: 7/18/12
Revised: 7/24/13
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
P.0
PARAMETER
DEFINITION
Definition
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
P.2
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
P.33
P.34
P.35
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
The value for WFS = X
limits can be used and entered as such on the robot. Then the user can enter
(X Low Limit)/(Hi Limit Low Limit)=% X(100)
the WFS in IPM on the robot.
Page 17 of 26
Created: 7/18/12
Revised: 7/24/13
P.80
False = Voltage sensing is determined by the DIP switch configuration and the selected weld mode (default).
P.99
True = Voltage sensing is forced to studs regardless of the DIP switch configuration and selected weld mode
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
P.102
P.103
P.104
P.105
P.106
P.107
P.200
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
P.206
P.207
WorkPoint Analog In
Displays value from Workpoint Analog input.
P.208
Trim Analog In
Displays value from Trim Analog input.
P.209
P.210
Page 18 of 26
Created: 7/18/12
Revised: 7/24/13
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.
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.
Page 19 of 26
Created: 7/18/12
Revised: 7/24/13
ADVANCED REFERENCES
Robot Controller Setup
MONITORING FUNCTIONS
1 Arc loss
2 Gas shortage
3 Wire shortage
4 Wire stick
5 Power supply failure
6 Coolant shortage
WELD RESTART FUNCTION
7 Return to path
8 Overlap distance
9 Return to path speed
ENABLED
DISABLED
DISABLED
ENABLED
ENABLED
ENABLED
DISABLED
0mm
200mm/s
TIMING (cont.)
18 Gas detect time
19 Gas purge time
20 Gas preflow time
21 Gas postflow time
0.05s
1.00s
0.50s
0.00s
DISABLED
1
50.0V
0.00s
0.60V
9.60V
50.0V
150.0V
DISABLED
5mm
12mm/s
ON-THE-FLY FUNCTION
13 On-The-Fly
14 Voltage increment
15 Wire feed increment
16 Current increment
ENABLED
1.0V
5.0IPM
5.0A
0.00V
10.00
0.0A
400.0A
OTHER FUNCTIONS
17 Weld from teach pendant
18 Run in
19 Wire burnback/retract
ENABLED
DISABLED
DISABLED
0.60V
9.60V
50(75)IPM
800(1200)IPM
MIG
DI 0
FD
AO
80IPM
IPM
0.60V
9.60V
0.0V
80.0V
0.60V
9.60V
0.0A
750A
WELD RUN IN
7 Voltage
8 Current
9 Wire feed
10 Time
50.0V
250.0A
200IPM
0.00s
SYSTEM VARIABLES
$AWEUPR $WSTK_ENA_DLY 0.10s
WIRE BURNBACK/RETRACT
11 Voltage
12 Current
13 Wire feed
14 Time
50.0V
250.0A
0IPM
0.00s
TIMING
15 Arc start error time
16 Arc detect time
17 Arc loss error time
2.00s
0.10s
0.30s
Page 20 of 26
Created: 7/18/12
Revised: 7/24/13
WI
1
WO
3
P82-e
P82-f
(see comments)
WFS command
Arc Detect
Gas Fault
No Connection
Water Fault
No Connection
INPUT(Analog)
INPUT(Analog)
INPUT(Analog)
OUTPUT (Digital)
OUTPUT (Digital)
OUTPUT (Digital)
------
OUTPUT (Digital)
OUTPUT (Digital)
------
No Connection
No Connection
No Connection
No Connection
INPUT (Digital)
INPUT (Digital)
INPUT (Digital)
INPUT (Digital)
INPUT (Digital)
OUTPUT
(see comments)
OUTPUT
(see comments)
ROBOT POWER
ROBOT POWER
------
------
------
------
INPUT (Digital)
No Connection
------
INPUT (Digital)
No Connection
------
INPUT (Digital)
No Connection
------
------
------
------
------
No Connection
------
Robot GND
Current Feedback
OUTPUT (Analog)
------
No Connection
------
ROBOT GND
------
Voltage Feedback
OUTPUT (Analog)
Page 21 of 26
Created: 7/18/12
Revised: 7/24/13
P82-D
P82-B
P82-s
P82-H
P82-r
P82-r
P82-P
P82-N
P82-Z
P82-X
P82-W
P82-V
P82-U
P82-T
P82-S
P82-R (Fanuc)
{P82-C (Motoman)}
P82-n
P82-m
P82-b
P82-a
P82-M
P82-L
P82-K
P82-J
No Connection
------
P82-k
P82-j
P82-h
P82-g
P82-d
P82-c
P82-F
P82-E
P82-F
P82-A
INPUT(Analog)
37 Pin Amphenol
(MS Style 28-21P)
Deluxe Analog
Interface
Input / Output
------
------
------
------
WDO8
WDO7
WDO6
WDO5 (Wire-)
WDO4 (Wire+)
0V
0V
0V
0V (Robot GND)
No Connection
No Connection
COMAD2
COMAD1
WDI8
WDI7
WDI4
COMDA1
------
------
------
------
CRW1-34
CRW1-33
CRW1-32
CRW1-31
CRW1-30
CRW1-29
CRW1-28
CRW1-27
CRW1-26
CRW1-25
CRW1-24
CRW1-23
CRW1-22
CRW1-21
CRW1-20
CRW1-19
CRW1-18
CRW1-17
CRW1-16
CRW1-15
CRW1-14
CRW1-13
CRW1-12
CRW1-11
CRW1-10
CRW1-9
CRW1-8
CRW1-7
CRW1-6
CRW1-5
CRW1-4
CRW1-3
CRW1-2
CRW1-1
Fanuc
Robot Controller
(34 Pin Honda)
Additional Notes
Short Detect (+) & (-) combine to provide a High/Low Impedance Short Detect (-) is tied to the Robotic GND on the Power Wave
Output for Robot Wire Stick Detect Circuitry.
450 Interface Board
Note Scaling
Note Scaling
Note Scaling
Note Scaling
Comments
MAINTENANCE
Non-Standard Safety Information
WARNING! ELECTRIC SHOCK CAN KILL.
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.
Page 22 of 26
Created: 7/18/12
Revised: 7/24/13
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
I/O ERR (RED)
I/O RUN (GRN)
OFF
ON
BLINKING
BLINKING
BLINKING
OFF
LED CONDITION
I/O RUN (GRN)
I/O ERR (RED)
OFF
OFF
ON
OFF
BLINKING
OFF
OFF
OFF
BLINKING
ON
BLINKING
BLINKING
LED CONDITION
I/O RUN (GRN)
I/O ERR (RED)
OFF
OFF
DEVICE STATUS
Normal
Startup
Field Bus Fault
DESCRIPTION
Normal Operating Condition. I/O Run on - Field
Bus OK
Normal Startup Sequence, both should stop blink
after a couple of seconds
A field bus fault has been detected
DEVICE STATUS
DESCRIPTION
No Power
Normal
Device in Standby
Minor Fault
Unrecoverable
Fault
Self Testing
DEVICE STATUS
No Power, Not
On-Line
ON
OFF
Normal
BLINKING
OFF
OFF
BLINKING
OFF
ON
Online, Not
Connected
Connection TimeOut
Critical Link
Failure
Page 23 of 26
Created: 7/18/12
Revised: 7/24/13
DESCRIPTION
The device might not be powered or the device
might not have completed the Dup Mac Id test
yet & is not on-line.
Online and allocated to a Master, Normal
Condition
Device is online, but not connected to master
One or more I/O connections are in the TimedOut state
Detected communication error - Duplicate Mac
Id or Bus-off
Input, Slot 2
Output, Slot 3
Output, Slot 6
Arc Start
Cold Inch
Reverse
Touch Sense
Detect
Power Source
Fault
Gas Purge
Procedure
Select 1
Arc Detect
Wire Stick
Detect
Touch Sense
Command
Procedure
Select 2
Gas Fault
Cold Feed
Forward
Procedure
Select 3
Water Fault
1 2 3 4 5 6 7 8
Input, Slot 1
+24VDC
DNET (WHITE WIRE)
+24VDC
0 VDC
750-346
750-408 750-408 750-516 750-467 750-550 750-509 750-600
Miscellaneous
The chart below shows miscellaneous problems and possible solutions.
Problem
Display shows Power
WSource is not Connected
No Display
Mode display shows:
"Err dn"
No LED's are lit on the I/O
block
False or dimly lit I/O Block
indicators
Corrective Action
The user interface is not finding the Control board. Try resetting the system. If this does not fix the
problem, contact Lincoln Service.
Check the ArcLink cable connection between the Deluxe Analog Interface box and the Power Source.
Check the 24V power coming in from the Robot/PLC.
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.
Make sure the 37-pin communication cable shield from the Robot is properly terminated (connected to
case ground at the Deluxe Analog Interface).
Page 24 of 26
Created: 7/18/12
Revised: 7/24/13
REPLACEMENT PARTS
Bill of Materials
The table below indicates the Bill of Material. This list may be used to order parts if necessary.
Item #:
LECO #:
Description:
Qty.:
1
2*
3*
4*
5*
6
7
8*
9
10
11*
12
13*
14
15*
16
17
18*
L15927
L15927-1
L15027-2
L15927-3
L15927-4
L10373-7
S29406-1
CF000057
T13639-3
T14034-4
S27401
S23055-1
E1906.187
S23394-57
S8025-96
9SM17803
S23395-11
T11577-52
1
1
1
1
1
1
1
4
3
3
1
12
10 ft
1
8
1
1
1
Layout
Page 25 of 26
Created: 7/18/12
Revised: 7/24/13
524
525
550
519
521
0 VDC IN
ARC START
GAS PURGE
PROCEDURE SELECT 1
PROCEDURE SELECT 2
PROCEDURE SELECT 3
0 VDC
ARC DETECT
GAS FAULT
WATER FAULT
+24VDC
SHIELD
WD1+
WD1-
WDO1
WDO2
WDO3
WDO4
WDO5
WDO6
WDO7
WDO8
0 VDC
0 VDC
WDI1
WDI2
WDI3
WDI4
WDI5
WDI6
WDI7
WDI8
N/A
N/A
N/A
24 VDC
SHIELD
534
517
528
533
535
546
523
529
520
518
527
526
ADCH2
516
515
COMAD2
CURRENT FEEDBACK
VOLTAGE FEEDBACK
535
750-408
524
0VDC ON 750-408
750-467
531
ANALOG COMMON
536
WFS COMMAND
*KEY AT 12 O'CLOCK
TRIM COMMAND
530
529
0 VDC
523
750-408
546
PROCEDURE SELECT 3
VOLTAGE FEEDBACK
515
750-550
102
CURRENT FEEDBACK
516
PROCEDURE SELECT 2
101
750-516
102
WATER FAULT
528
101
517
750-509
0 VDC IN
527
526
GAS FAULT
521
COMADI
27
24VDC ON 750-408
ADCHI
COMDA4
534
+24VDC
519
ARC DETECT
DACH4
536
ANALOG COMMON
533
TOUCH SENSE DETECT
550
PROCEDURE SELECT 1
COMDA2
531
WFS COMMAND
525
COLD INCH REV
520
GAS PURGE
DACH2
COMDA3
518
C
ARC START
+2 4 VDC
0 VDC
0 VDC
+24VDC
750-346
WHITE DN ET
SHIELD
BLUE DNET
+24VDC
BLU-A
WHT-B
S23394-57
DACH3
530
COMDA1
TRIM COMMAND
DACH1
CRW1
8
6 7
5
3 4
Page 26 of 26
Created: 7/18/12
Revised: 7/24/13
1 2
T11577-52
.0047 CAPACITOR
0 VDC
27
750-346
WHITE DNET
SHIELD
BLUE DNET
+24VDC
BLU-A
MOLEX, PC BOARD
0 VDC
1 2 3 4 5 6 7 8
WHT-B
WIRING SCHEMATIC