Deluxe Analog Interface

AD1359-1

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Revised: 7/24/13

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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

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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

24VDC 10%, <300mA

4.8k Impedance
15 to 30 VDC
-3 to 5 VDC
0.5 Amp, Short Circuit Protected
0 VDC
24 VDC
0 10 VDC, Max: 35 VDC
0 10 VDC
0C to +40C

Output

24V
3.3K
Input

I/O Signal Description

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

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

Fanuc Robot Signal Description

(AD1144-6 Cable)
+24 VDC (Robot Power)
O VDC (Robot Common)
WDO1 (Weld Cycle Start)
WDO2 (Gas Valve On)
WDO3 (Touch Sense Command)
WDO4 (Feed Forward)
WDO5 (Feed Reverse)
WDO6 (Procedure Select bit 1)
WDO7 (Procedure Select bit 2)
WDO8 (Procedure Select bit 3)
WDI1 (Touch Sense Detect)
WDI2 (Arc Detect)
WDI3 (Gas Shortage)
WDI5 (Water Shortage)
DACH1 (Weld Volts CMD)
COMDA1 (Common)
DACH2 (Weld WFS CMD) / Analog Out
COMDA2 (Common) / Analog Out
ADCH1(Weld Voltage) / Analog In
COMAD1 (Common) / Analog In
ADCH2 (Weld Amps) / Analog In
COMAD2 (Common) / Analog In
WDI6 (Pwr Supply Fail) / Input
WDI+ (+Wire Stick Detect) / Input
WDI- (-Wire Stick Detect) / Input

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Revised: 7/24/13

Dimensions and Layout

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Created: 7/18/12
Revised: 7/24/13

Compatibility with Lincoln Electric Power Sources

The Deluxe Analog Interface is compatible with many Lincoln Electric power sources including (but not limited
to) Power Wave455R, Power Wave455M, Power Wave455M/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.

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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.

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Created: 7/18/12
Revised: 7/24/13

INSTALLATION
Non-Standard Safety Information
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.

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

*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.

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

Deluxe Analog Interface

Power Wave455
K1543-8
ArcLink Cable

AD1144-6
I/O Cable

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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.

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

screen.

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

5. On the Fanuc teach pendant, press the MENUS button,

select I/O and make sure I/O Weld Out is displayed.

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.

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.

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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.

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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
1
2
3
4
5
6
7
8

I/O on 37 pin connector

Pin W
Pin X
Pin Z
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
ON
ON
ON
ON

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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.

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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.

2. Rotate the center knob until screen reads Pulse GMAW-P

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.

6. Verify screen reads 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.

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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.

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

IPM.

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.

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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

P.1 through P.99

P.101 through P.210

Unsecured Parameter (always adjustable)

Diagnostic Parameters (always read only)

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

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
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.

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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).

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

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.

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.

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 +10.0

Wave Control 0.00

Wave Control -10.0

Wave Control -10.0

Wave Control 0.0
Wave Control +10.0

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

WIRE STICK FUNCTION

22 Reset
23 Reset tries
24 Voltage
25 Time

DISABLED
1
50.0V
0.00s

0.60V
9.60V
50.0V
150.0V

SCRATCH START FUNCTION

10 Scratch start
11 Distance
12 Return to start speed

DISABLED
5mm
12mm/s

VOLTAGE OUTPUT SCALING

26 Minimum reference
27 Maximum reference
28 Minimum output
29 Maximum output

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

CURRENT OUTPUT SCALING

30 Minimum reference
31 Maximum reference
32 Minimum output
33 Maximum output

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

WIRE FEED SPEED OUTPUT SCALING

34 Minimum reference
35 Maximum reference
36 Minimum output
37 Maximum output

0.60V
9.60V
50(75)IPM
800(1200)IPM

WELD EQUIPMENT SETUP

1 Weld process
2 Remote arc enable
3 Weld power control Wire
4 Wire feed control
5 Wire+ Wire- speed
6 Wire feed speed units

MIG
DI 0
FD
AO
80IPM
IPM

VOLTAGE INPUT SCALING

38 Minimum reference
39 Maximum reference
40 Minimum output
41 Maximum output

0.60V
9.60V
0.0V
80.0V

CURRENT INPUT SCALING

42 Minimum reference
43 Maximum reference
44 Minimum output
45 Maximum output

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

TOUCH SENSING SETUP

Sensor port type
Sensor port number
Circuit port type
Circuit port number

Page 20 of 26
Created: 7/18/12
Revised: 7/24/13

WI
1
WO
3

P82-e
P82-f

(see comments)

WFS command

WFS command GND

Touch Sense Detect

Arc Detect

Gas Fault

No Connection

Water Fault

Abnormal Operation / Power Fault

No Connection

INPUT(Analog)

INPUT(Analog)

INPUT(Analog)

OUTPUT (Digital)

OUTPUT (Digital)

OUTPUT (Digital)

------

OUTPUT (Digital)

OUTPUT (Digital)

------

Gas Flow Command

Cold Inch FWD

Cold Inch REV

Procedure #1 binary bit

Procedure #2 binary bit

Procedure #3 binary bit

Short Detect Signal (+)

Short Detect Signal (-)

+24V Robot PWR

+24V Robot PWR

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

------

------

------

------

Arc Start Command (Trigger)

INPUT (Digital)

Touch Sense Command

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

TRIM (Voltage) Command

INPUT(Analog)

37 Pin Amphenol
(MS Style 28-21P)

POWER WAVE 455

Signal Description

Deluxe Analog
Interface
Input / Output

+24V (Robot PWR)

+24V (Robot PWR)

------

------

------

------

WDI- (Wire stick detect)

WDI+ (Wire stick detect)

WDO8

WDO7

WDO6

WDO5 (Wire-)

WDO4 (Wire+)

WDO3 (Touch sense command)

WDO2 (Gas start)

WDO1 (Weld start)

0V

0V

0V

0V (Robot GND)

No Connection

No Connection

COMAD2

ADCH2 (Current feedback)

COMAD1

ADCH1 (Voltage feedback)

WDI8

WDI7

WDI6 (Power fault)

WDI5 (Water fault)

WDI4

WDI3 (Gas fault)

WDI2 (Arc detect)

WDI1 (Touch sense signal)

COMDA2 (WFS command GND)

DACH2 (WFS command)

COMDA1

DACH1 (Voltage/Trim command)

Fanuc Signal Name

------

------

------

------

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)

Read description for WD06

The 3 binary selection bits will decide memory locations used

for welding. Memory location:
1 = 0,0,0 2 = 0,0,1
3 = 0,1,0 4 = 0,1,1
5 = 1,0,0 6 = 1,0,1
7 = 1,1,0 8 = 1,1,1.
Read description for WD06

COMAD1 common to COMDA1 and COMDA2

COMAD1 common to COMDA1 and COMDA2

COMDA1 common to COMDA2 at Robot. Isolated from Robot

GND. Common tied to digital out #3 and #6 Wago cards.

COMDA1 common to COMDA2 at Robot or in Cable?

Additional Notes

Tied together in Robot.

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

80 IPM Fixed Speed

80 IPM Fixed Speed

Motoman version of Power Wave 450 had alternate trigger

location.

Note Scaling

Note Scaling

Generated via external Gas Fault input (P84 in Power Wave

450)

Note Scaling

Note Scaling

Comments

Deluxe Analog Interface Cable

MAINTENANCE
Non-Standard Safety Information
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.

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

There is no power applied to the device

The device is operating in a Normal Condition
The device needs commissioning due to the
configuration is missing, incomplete, or incorrect
Recoverable Fault
The device has an unrecoverable fault; may need
replacing
The Device is in Self Test

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

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.

SET DIP SWITCHES

AS SHOWN

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

WIRE FROM S23394-57

CONNECTOR

+24VDC
DNET (WHITE WIRE)

DNET (BLUE WIRE)

0 VDC

+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

Enclosure, Wall Mount

Sheetmetal enclosure (Reference)
Interface plate (Reference)
Mounting plate (Reference)
Cover plate brkt (Reference)
Overlay Deluxe Analog Interface Enclosure
PC BD ASBLY
#6 32x.25RHS-FULL-GR2-3445
Knob
Shaft Seal
Potentiometer Insulation
Button Cover
Heat Shrink Tubing 3/16
Cable, Deluxe Analog Interface,DN
Self Tapping Screw
Plug & Lead Asbly 37 pin
Wago Analog Int, Dnet Eco-coupler
.0047 Capacitor

1
1
1
1
1
1
1
4
3
3
1
12
10 ft
1
8
1
1
1

*Indicates not shown in the Layout

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

TOUCH SENSE CMD

COLD INCH FWD

COLD INCH REV

PROCEDURE SELECT 1

PROCEDURE SELECT 2

PROCEDURE SELECT 3

0 VDC

TOUCH SENSE DETECT

ARC DETECT

GAS FAULT

WATER FAULT

POWER SOURCE 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

WIRE STICK DETECT

ADCH2

516

515

COMAD2

CURRENT FEEDBACK

VOLTAGE FEEDBACK

535

750-408

COLD INCH FWD

524

0VDC ON 750-408

750-467

531

ANALOG COMMON

536

WFS COMMAND

*KEY AT 12 O'CLOCK

TRIM COMMAND

530

ANALOG INPUT, CARD #4

TOUCH SENSE CMD

529

0 VDC

523

750-408

546
PROCEDURE SELECT 3

VOLTAGE FEEDBACK

515

750-550

ANALOG COM JUMPER #2

102

CURRENT FEEDBACK

516

ANALOG OUTPUT, CARD #5

PROCEDURE SELECT 2

101

750-516

102

WATER FAULT

528

ANALOG COM JUMPER #2

ANALOG COM JUMPER #1

101

POWER SOURCE FAULT

517

750-509

0 VDC IN

527

WIRE STICK DETECT

526

DIGITAL OUTPUT, CARD #6

GAS FAULT

521

ANALOG COM JUMPER #1

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

DIGITAL OUTPUT, CARD #3

DACH1

CRW1

DIGITAL INPUT, CARD #2

8
6 7
5
3 4

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

1 2

DIGITAL INPUT, CARD #1

T11577-52
.0047 CAPACITOR

0 VDC

27

750-346

WHITE DNET

SHIELD

BLUE DNET

+24VDC

BLU-A

MOLEX, PC BOARD

750-408 750-408 750-516 750-467 750-550 750-509 750-600

0 VDC

1 2 3 4 5 6 7 8

WHT-B

WIRING SCHEMATIC