Lincoln Electric IM10022 User Manual

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POWER WAVE AC/DC 1000 SD

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IM10022-C

November, 2012

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,

most importantly, think before you act and be careful.

11592, 11881, 11918

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877

FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email globalservice@lincolnelectric.com

IP 23

OPERATORʼS MANUAL

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

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SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

skin or wet clothing. Wear dry, hole-free

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

ventilation and/or exhaust at the arc to keep

vapors

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a.Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

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SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. WARNING: This equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons. Follow your local and

national standards for installation and use. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement;

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

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SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Public Supply System

Welding equipment should be connected to the public supply system according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the public supply system. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

vivi

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g., ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica-

tions

_________________________

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

Page 8

Thank You

viivii

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Page 9

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Specifications .......................................................................................................................A-1

Safety Precautions. ..............................................................................................................A-2

Location and Mounting..................................................................................................A-2

Stacking ........................................................................................................................A-2

Lifting.............................................................................................................................A-2

Environmental Limitations .............................................................................................A-2

Electromagnetic Compatibility.......................................................................................A-2

Clearance Requirements ..............................................................................................A-3

Input Voltage Selection and Ground Connections ........................................................A-4

Connection Diagram .....................................................................................................A-4

System Connection .......................................................................................................A-5

Connection Diagrams and Check List ...........................................................A-6 thru A-16

Electrode and Work Connection .................................................................................A-17

Cable Inductance, Remote Sense Lead Connection.........................................A-18, A-19

Multi-Arc Circumfirential Welds ...................................................................................A-20

Control Cable Connections, Common Equipment Connections .................................A-21

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions, Definition of Welding Modes, Graphic Symbols ...........................B-1, B-2

Product Summary, Recommended Process, Process and Equipment Limitations..............B-3

Common Equipment Packages and Recommended Equipment .........................................B-3

Case Front Control Descriptions .........................................................................................,B-4

Input Power Section .............................................................................................................B-4

Case Back Components ...............................................................................................B-5, B-6

Power-Up Sequence ............................................................................................................B-7

Duty Cycle ............................................................................................................................B-7

Common Welding Procedures .............................................................................................B-7

Overview of the AC/DC Submerged Arc Process ................................................................B-7

Multiple Arc System Considerations.....................................................................................B-8

Basic Modes of Operation (CC / CV) ...................................................................................B-8

Weld Sequence, Start Options, End Options, Re-Strike Timer ............................................B-9

Weld Process Adjustment, Wave Balance, DC Offset, Frequency ....................................B-10

Phase Adjustment for Multiple Arc Systems .....................................................................B-11

________________________________________________________________________________

Accessories.....................................................................................................Section C

Kits, Options and Accessories...............................................................................C-1

Software Tools.......................................................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine and Periodic Maintenance........................................................................D-1

Calibration Specification........................................................................................D-1

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Using the Status LED to Troubleshoot System Problem.......................................E-2

Error Codes....................................................................................................E-3, E-4

Troubleshooting Guide ..........................................................................................E-5

________________________________________________________________________

Wiring Diagrams and Dimension Print..........................................................Section F

Wiring Diagram - Power Wave

Wiring Diagram - AC Switch ................................................................................F-2

Dimension Print .....................................................................................................F-3

________________________________________________________________________

Parts List.................................................................................................................P-612

AC/DC 1000®SD................................................F-1

viiiviii

Page 10

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Power Wave

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS

3 PHASE

50/60 Hz

380 400 460 500 575

OPEN

CIRCUIT

VOLTAGE

INPUT

CURRENT AMPS

82 79

69 62

AUXILIARY POWER

(CIRCUIT BREAKER

PROTECTED)

OUTPUT

CONDITIONS

1000A@44V.

100% Duty Cycle

OUTPUT

PROCESS CURRENT RANGES (AC or DC)

AC/DC 1000®SD (K2803-1)

IDLE

POWER

WATTS

225

POWER FACTOR

@ RATED OUTPUT

.95

A-1

EFFICIENCY

@ RATED OUTPUT

86%

70V

70VACpk.

40 VDC AT

10 AMPS

115 VAC AT

10 AMPS

RECOMMENDED INPUT WIRE AND FUSE SIZES

3 PHASE INPUT

VOLTAGE 50/60Hz

380 400 460 500 575

MODEL

K2803-1

OPERATING TEMPERATURE RANGE

CONFORMITY MARK

EN 60974-1 CSA

C/US

14°F to 104°F(-10°C to 40°C)

SAW-DC+ 100 amps @24 Volts SAW-DC- 1000 Amps @44 Volts SAW-AC (Actual range may be limited by process)

TYPE 90°C

COPPER WIRE

CONDUIT

AWG (mm

3(25) 3(25) 4(25) 4(25) 6(16)

)

}

COPPER GROUNDING

CONDUCTOR

PHYSICAL DIMENSIONS

HEIGHT

49.13 in

1248 mm

WIDTH

19.71 in 501mm

TEMPERATURE RANGES

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to 85°C)

AWG (mm

8 (10) 8 (10) 8 (10) 8 (10) 10 (6)

)

DEPTH

46.60 in

1184 mm

TIME-DELAY FUSE

OR BREAKER

AMPS

100

90 90 80 70

WEIGHT

800 lbs.

363 kg.

Insulation Class: Class F(155°C)

Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the magnitude of current increases.

Fail to use proper type of copper wire will cause fire hazards.

* An external filter will be required to meet CE and C-Tick conducted emission requirements. It will meet CE and C-Tick requirements with the

use of an optional external filter. (K2444-3 CE and C-Tick Filter Kit)

WELDING PROCESSES

Process

SAW

Electrode Diameter Range

5/64 – 7/32" (2 – 5.6 mm)

POWER WAVE®AC/DC 1000®SD

Output Range (Amperes)

100 - 1000

Wire Feed Speed Range

See Wire Drive Manual

Page 11

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF 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.

-----------------------------------------------------------------------

LOCATION AND MOUNTING

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and front. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns. See the Clearance Requirements and Figure A.1. in this section.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

-----------------------------------------------------------------------

STACKING

Power Wave®AC/DC 1000®SD machine cannot be stacked.

LIFTING

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable

when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

-----------------------------------------------------------------------

Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave accessories attached to it.

AC/DC 1000®SD with

ENVIRONMENTAL LIMITATIONS

The Power Wave®AC/DC 1000®SD can be used in an outdoor environment with an IP 23 rating. It should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

ELECTROMAGNETIC COMPATIBILITY (EMC)

The EMC classification ot the Power Wave®AC/DC

SD is Industrial, Scientific and Medical (ISM)

1000 group 2, class A. The Power Wave is for industrial use only.

Locate the Power Wave machinery.

away from radio controlled

AC/DC 1000®SD

CAUTION

The normal operation of the Power Wave

SD may adversely affect the operation of RF

1000 controlled equipment, which may result in bodily injury or damage to the equipment.

-----------------------------------------------------------------------

AC/DC

POWER WAVE®AC/DC 1000®SD

Page 12

A-3

INSTALLATION

CLEARANCE REQUIREMENTS

The maintenance requirements of the Power Wave AC/DC 1000®SD demand that enough clearance behind the machine be maintained. This is especially important where more than one machine is to be used or if the machines are going to be rack mounted.

The rear portion of the machine that contains the filter and the cooling fans slides out for easy access to clean the heat sink fins.

FIGURE A.1 - CLEARANCE REQUIREMENTS

Removing the four(4) clips and pulling back on the rear portion of the machine will provide access for cleaning the machine and checking the filter. The filter is removed from the right side of the machine.

Where machines are mounted side by side, the machine that is furthest to the right will need to have the indicated clearance to the right side for filter removal. See Figure A.1.

A-3

33.00

WIDTH NEEDED FOR FILTER MAINTENANCE ACCESS

FILTER REMOVAL FROM SIDE OF MACHINE

22.63

61.30

POWER WAVE®AC/DC 1000®SD

Page 13

A-4

INSTALLATION

A-4

INPUT AND GROUND CONNECTIONS

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol shown is located inside the reconnect / input access door for this purpose. See your local and national electrical codes for proper grounding methods.

INPUT CONNECTION

WARNING

ELECTRIC SHOCK can kill.

• Only a qualified electrician should connect the input leads to the Power Wave should be made in accordance with all local and National Electrical Codes and the connection diagram located on the inside of the reconnect / input access door of the machine. Failure to do so may result in bodily injury or death.

-----------------------------------------------------------------------

Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the case back. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram.

. Connections

NPUT FUSE AND SUPPLY WIRE

CONSIDERATIONS

Refer to Specifications page for recommended fuse and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers). Choose input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

Welders are shipped connected for the highest input voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door, or the diagram shown below (Figure A.2). If the Auxiliary lead (indicated as ʻAʼ) is placed in the wrong position, there are two possible results.

a. If the lead is placed in a position higher than the applied

line voltage, the welder may not come on at all.

b. If the Auxiliary lead is placed in a position lower than the

applied line voltage, the welder may not come on, and fuse in the reconnect area may open. If this occurs, turn off the input voltage, properly conne lead, replace the fuse, and try again.

ct the auxiliary

FIGURE A.2 - INPUT SUPPLY CONNECTION FOR K2803-1 POWER WAVE®AC/DC 1000®SD

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC

SHOCK

CAN KILL

VOLTAGE=380-415V

380-415V 380-415V 380-415V 380-415V

440-460V

500V

550-575V

Do not operate with covers removed

Disconnect input power before servicing

Do not touch electrically live parts

Only qualified persons should install, use or service this equipment

VOLTAGE=440-460V

'A'

440-460V

500V

550-575V

'A'

VOLTAGE=500V

440-460V

500V

550-575V

W / L3

V / L2

U / L1

CR1

VOLTAGE=550-575V

440-460V

'A'

500V

550-575V

'A'

S26047

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

POWER WAVE®AC/DC 1000®SD

Page 14

A-5

SYSTEM CONNECTION

System Overview

INSTALLATION

A-5

The Power Wave designed to be a part of a modular welding system typically controlled by a MAXsa™ 10 Controller or a customer supplied Programmable Logic Controller (PLC). Each welding arc may be driven by a single power source or by a number of power sources connected in parallel. The actual number of power sources per arc will vary depending on the application. When only one power source is required for an arc group, it must be configured as a Master. When parallel machines are required, one is designated as the Master and the rest as Slaves. The synchronizing connectors for paralleled machines are on the back of the power source. The Master controls the AC switching for the arc group, and the Slaves respond accordingly. See Figure A.3.

AC/DC 1000®SD power source is

FIGURE A.3 - SYNCHRONIZING CONNECTORS

When employed in a multi-arc AC system the arcs must be synchronized to each other. The Master for each arc can be configured to follow a dedicated external synchronization signal to determine its frequency and balance. The Synchronizing Connectors on the back of the Power Wave

SD provide the means to synchronize the AC

1000 wave shapes of up to six different arcs to a common carrier frequency. (See Figure A.3). This frequency can range from 20 hertz to 100 hertz. It can also control the phase angle between arcs to reduce the effects of welding related issues such as "Arc Blow".

AC/DC

Multi-arc

Paralleling

Input

Output

Input

Output

LINCOLN

ELECTRIC

POWER WAVE®AC/DC 1000®SD

Page 15

A-6

INSTALLATION

A-6

The arc to arc phase relationship is determined by the timing of each arcʼs "sync" signal relative to the "sync" signal of ARC 1. DIP Switches on the in each machine must be set to identify it as a Master Lead, Master Trail or Slave. See Figure A.4

In a typical multi-arc system, each arc is controlled by its own MAXsa™ 10 Controller. The basic characteristics of the individual arcs such as WFS, amplitude, and offset are set locally by each arcʼs dedicated controller. The frequency, balance, and phase shift parameters of each arc are controlled by the MAXsa™ 10 Controller for ARC 1 (Master Lead).

NOTE: The K2803-1 Power Wave

AC/DC 1000®SD

is backwards compatible with the K2344-2

Power Wave

AC/DC 1000 in tandem or multiarc systems. The K2803-1 and K2344-2 machines cannot be connected in parallel. Paralleled machines must be of the same type. A K1805-1 (14 to 22 pin adapter cable) is required to interface to the K2282-1 Systems Interface in these setups

FIGURE A.4 - DIP SWITCH SETTINGS

A PLC interface is an alternate method of control for larger systems. The PLC is typically connected via DeviceNet directly to the Master power source of each arc group in the system. MAXsa™ 19 Controller is still required to power the Wire Drive. Contact your Local Lincoln Electric Representative for more information.

The connection diagrams describe the layout of several typical systems including Multi-Arc and Paralleled machine set-ups. Each system also has a step by step “Installation Checklist”.

POWER WAVE®AC/DC 1000®SD

Page 16

A-7

AC/DC 1000

Power Wave

K2803-1

INSTALLATION

FIGURE A.5 - CRUISER CONNECTION DIAGRAM

A-7

K2683-XX

Arclink Cable

K2607-1

Cruiser

Electrode

Work

Weld Cable

K1811-XX

Sense Lead

Work

POWER WAVE®AC/DC 1000®SD

Page 17

A-8

INSTALLATION

CRUISER™ SYSTEM CHECKLIST (See Figure A.5)

Place the Power Wave

AC/DC 1000®SD in a suitable operating location.

Place the Cruiser™ Tractor in itʼs operating location.

A-8

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave

AC/DC 1000®SD and

the Cruiser™ Tractor

Install Work Voltage Sense Lead (21) from the Power Wave

AC/DC 1000®SD per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave

AC/DC 1000®SD front panel and check the DIP switch settings per the decal on the

panel. Factory Setting is “Master-Lead”. (See Figure A.4).

Connect input power to Power Wave

AC/DC 1000®SD per recommended guidelines.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Turn on Power Wave

AC/DC 1000®SD, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

POWER WAVE®AC/DC 1000®SD

Page 18

A-9

AC/DC 1000

K2803-1

Power Wave

INSTALLATION

FIGURE A.6 - SINGLE ARC CONNECTION DIAGRAM

Electrode

Weld Cable

A-9

Work

Weld Cable

K2683-XX

Arclink Cable

™

K2370-2

MAXsa

™

K2814-1

MAXsa

K1785-XX

14-Pin Cable

POWER WAVE®AC/DC 1000®SD

K231-XX

67 Lead

Contact Nozzle

K1811-XX

Sense Lead

Work

Page 19

A-10

INSTALLATION

SINGLE ARC SYSTEM CHECKLIST (See Figure A.6)

Place the Power Wave

AC/DC 1000®SD in a suitable operating location.

Mount MAXsa™ 10 Controller.

Install MAXsa™ 22 Wire Drive and other accessories in their operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave and MAXsa™ 10.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 and the MAXsa™ 22.

Install Electrode Sense Lead (67) at the feeder and the Work Sense Lead (21) from the Power Wave

1000

SD per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave

AC/DC 1000®SD front panels and check the DIP switch settings per the decal on the

panel. Factory Setting is “Master-Lead”. (See Figure A.4).

Connect input power to Power Wave

AC/DC 1000®SD per recommended guidelines.

A-10

AC/DC

Turn on Power Wave

AC/DC 1000®SD, and verify all system Status Lights are solid green.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Select a Welding process and configure starting and ending options.

POWER WAVE®AC/DC 1000®SD

Page 20

A-11

INSTALLATION

FIGURE A.7 - TANDEM ARC CONNECTION DIAGRAM

A-11

K2803-1

Power Wave

AC/DC 1000

K2803-1

K1785-XX 14-Pin Cable

Power Wave

AC/DC 1000

Electrode Weld Cable

K2683-XX

Arclink Cable

K1811-XX

Sense Lead

™

K2814-1

MAXsa

™

K2814-1

MAXsa

K2683-XX

Arclink Cable

Electrode

Weld Cable

Work Weld Cable

67 Leads

K1785-XX

14-Pin Cable

™

K2370-2

MAXsa

K1785-XX

14-Pin Cable

K231-XX

Contact Nozzle

™

K2370-2

MAXsa

Work

POWER WAVE®AC/DC 1000®SD

Page 21

A-12

INSTALLATION

TANDEM ARC (2-ARC) SYSTEM CHECKLIST (See Figure A-7)

Place the Power Wave

AC/DC 1000®SD units in a suitable operating location.

Mount MAXsa™ 10 Controllers.

Install MAXsa™ 22 Wire Drives and other accessories in their operating location.

Connect a K1785-xx Wire Feeder Control Cable (14 pin) between the two power sources (top connectors).

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave units and MAXsa™ 10 controllers.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 controllers and the MAXsa™ 22 feeders.

A-12

Install Electrode Sense Lead (67) at each feeder and the Work Sense Lead (21) from the Lead Power Wave AC/DC 1000®SD Master per guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave

AC/DC 1000®SD front panels and configure DIP switch settings per the decal on the

panel. (See Figure A.4).

Connect input power to Power Wave

Turn on Power Wave

AC/DC 1000®SD and verify all system Status Lights are solid green.

AC/DC 1000®SD units per recommended guidelines.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Run the subarc cell configurator from PC Tools (See Section C of this manual or go to www.powerwavesoftware.com).

Select a Welding process and configure starting and ending options.

POWER WAVE®AC/DC 1000®SD

Page 22

A-13

INSTALLATION

A-13

FIGURE A.8 - PARALLELING CONNECTION DIAGRAM

Power Wave

K2803-1

AC/DC 1000

Power Wave

K2803-1

AC/DC 1000

K1785-XX 14-Pin Cable

Electrode Weld Cable

chin

Ma llel

Para

agr

Connection D

K1811-XX

Sense Lead

K2814-1

MAXsa™ 10

Electrode

Weld Cable

K2683-XX

Arclink Cable

K1785-XX

14-Pin Cable

67 Lead

K2370-2

MAXsa™ 22

Work Weld Cable

POWER WAVE®AC/DC 1000®SD

K231-XX

Work

Contact Nozzle

Page 23

A-14

INSTALLATION

PARALLEL CONNECTION CHECKLIST (See Figure A.8)

Place the Power Wave

AC/DC 1000®SD units in a suitable operating location.

Mount MAXsa™ 10 Controller.

Install MAXsa™ 22 Wire Drive and other accessories in their operating location.

The MAXsa™ Controller must be connected to the Master Power Source. Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave and MAXsa™ 10 controller.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 controller and the MAXsa™ 22 feeder.

Connect a K1785-xx Wire Feeder Control Cable (14 pin) between the two power sources (top connectors).

A-14

Install Electrode Sense Lead (67) at the feeder and the Work Sense Lead (21) from the Lead Power Wave AC/DC 1000®SD Master per guidelines.

Connect / Install welding cables to both the “master” and “slave” machine per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave

AC/DC 1000®SD front panels and configure DIP switch settings per the decal on the

panel. (See Figure A.4).

Connect input power to Power Wave

Turn on Power Wave

AC/DC 1000®SD, and verify all system Status Lights are solid green.

AC/DC 1000®SD units per recommended guidelines.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

For tandem setups, run the subarc cell configurator from PC Tools (See Section C of this manual or go to www.powerwavesoftware.com).

Select a Welding process and configure starting and ending options.

POWER WAVE®AC/DC 1000®SD

Page 24

A-15

INSTALLATION

FIGURE A.9 - MAXsa™ 19 CONNECTION DIAGRAM

A-15

PLC Contro

User Interface

ceNet Cable Networ

Devi

K2683-XX Arclink Cable

ller

K1785-XX 14-Pin Cable

K1811-XX Sense Lead

K2626-2 MAXsa™ 19

Work

K2312-2 MAXsa™ 29

67 Lead

K231-XX Contact Nozzle

Electrode Weld Cable

Work Weld Cable

K2803-1 Power Wave AC/DC 1000

POWER WAVE®AC/DC 1000®SD

Page 25

A-16

INSTALLATION

MAXsa™ 19 SYSTEM CHECKLIST (See Figure A.9)

Place the Power Wave

AC/DC 1000®SD in a suitable operating location.

DeviceNet PLC controlled systems: Mount DeviceNet PLC controller and User Interface.

Mount MAXsa™ 19 in itʼs operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave

AC/DC 1000®SD and

MAXsa™ 19.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 19 and the MAXsa™ 29.

DeviceNet PLC controlled systems: Connect each Arc Master power source to the PLC via the DeviceNet network.

Install Work Voltage Sense Lead (21) from Power Wave

AC/DC 1000®SD per recomennded guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave

AC/DC 1000®SD front panels and configure DIP switch settings per the decal on the

panel. Factory setting is “Master-Lead”.(See Figure A.4).

A-16

Connect input power to Power Wave

Turn on Power Wave

AC/DC 1000®SD and verify all system Status Lights are solid green.

AC/DC 1000®SD per recommended guidelines.

DeviceNet PLC controlled systems: Run Weld Manager. For each Arc Master connect to the power source. Under Network Settings -> DeviceNet-> Configuration, configure the DeviceNet MAC address and baud rate.

Run Weld Manager. For each Arc Master connect to the power source. Under Feeder Settings -> Wire Feeder, verify the appropriate Feeder and gear ratio are selected.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Select a Welding process and configure starting and ending options.

POWER WAVE®AC/DC 1000®SD

Page 26

A-17

INSTALLATION

A-17

ELECTRODE AND WORK CONNECTIONS

General Guidelines

The unique switching structure of the Power Wave AC/DC 1000®SD allows it to produce DC positive, DC negative or AC output waveforms without repositioning the work and electrode leads. Additionally, no DIP switch changes are required to switch between the different polarities. All of this is controlled internally by the Power Wave sively on the weld mode selection.

The following recommendations apply to all output polarities and weld modes:

• Select the appropriate size cables per the "Output Cable Guidelines" below. Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance. Always use the largest welding cables (electrode and work) that are practical, and be sure all connections are clean and tight.

AC/DC 1000 SD, and based exclu-

Work Connections

Connect cable(s) of sufficient size and length (Per Table A.1) between the "WORK" studs (located behind the cover on the lower left rear corner) and the work piece. Be sure the connection to the work makes

tight metal-to-metal electrical contact.

NOTE: For parallel and/or multiple arc applications

with excessive ground path lengths, a common work connection bus should be used. The common work connection serves to minimize voltage drops associated with resistive losses in the ground paths. It should be made out of copper, and located as close as possible to the power sources (See Figure A.10).

FIGURE A.10

Note: Excessive heat in the weld circuit indicates

undersized cables and/or bad connections.

• Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil excess cable. Route the electrode and work cables

in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit.

• Always weld in a direction away from the work

(ground) connection.

TABLE A.1 - Output Cable Guidelines

Total Cable Length

ft (m)

Electrode and Work

Combined

0 (0) to 250 (76.2)

Duty Cycle

80%

100%

Number of

Parallel Cables

Cable Size

Copper

4/0 (120 mm

3/0 (95 mm

Electrode Connections

Connect cable(s) of sufficient size and length (Per Table A.1) to the "ELECTRODE" studs on the power source (located behind the cover plate on the lower right rear corner). Connect the other end of the electrode cable(s) to the tab of the contact nozzle. Be sure the connection to the nozzle makes tight metal-tometal electrical contact.

COMMON CONNECTION

(LOCAT ED CLOSE TO

POWER SOUR

WORK PI

)

CES)

ECE

POWER WAVE®AC/DC 1000®SD

Page 27

A-18

INSTALLATION

A-18

CABLE INDUCTANCE, AND ITS EFFECTS ON WELDING

Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (see Figure A.11). To minimize inductance always use the appropriate size cables, and whenever possible, run the electrode and work cables in close proximity to one another to minimize the loop area. Since the most significant factor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long work piece lengths, a sliding ground should be considered to keep the total welding loop length as short as possible.

FIGURE A.11

POWER WAVE

WORK

REMOTE SENSE LEAD CONNECTIONS

Voltage Sensing Overview

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the wire feeder control cable (K1785) and accessible at the wire drive. It should always be connected to the Contact Assembly where the Weld Cable is connected. Enabling or disabling electrode voltage sensing is application specific, and automatically configured through software.

Work Voltage Sensing

The use of a remote work voltage sense lead is always required. The Power Wave is shipped from the factory with the remote work voltage sense lead enabled. It must be attached to the work as close to the weld as practical, but out of the weld current path. For more information regarding the placement of remote work voltage sense leads, see the section entitled "Voltage Sensing Considerations for Multiple Arc Systems." The remote WORK sense lead (21) can be accessed at the four-pin WORK sense lead connector located on the back panel of the Power Wave AC/DC 1000 SD.

NOTE: All of the machines of a given arc group

(Master and Slaves) will relate to the Voltage Sense Lead of the Master machine.

AC/DC 1000®SD

CAUTION

Never connect the WORK sense lead at two different locations.

The best arc performance occurs when the Power

Wave arc conditions. Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder, and have a dramatic effect on performance. To counteract this negative effect, remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board.

There are several different sense lead configurations that can be used depending on the application. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.

AC/DC 1000®SD has accurate data about the

CAUTION

If the remote voltage sensing is enabled but the sense leads are missing, improperly connected extremely high welding outputs may occur.

------------------------------------------------------------------------

POWER WAVE®AC/DC 1000®SD

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

Page 28

A-19

VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS

INSTALLATION

A-19

Special care must be taken when more than one arc is welding simultaneously on a single part. Remote sensing is required in Multi-arc applications

• Avoid common current paths. Current from adja-

cent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources, and result in arc interference.

• Position the sense leads out of the path of the weld current. Especially any current paths common

to adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources, and result in arc interference.

FIGURE A.12 MULTI-ARC LONGITUDINAL WELDS

DIRECTION OF TRAVEL

• For longitudinal applications, connect all work

leads at one end of the weldment, and all of the work voltage sense leads at the opposite end of the weldment. Perform welding in the direction away from the work leads and toward the sense leads. See Figure A.12.

• For circumferential applications, connect all work

leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path. See Figure A.13

CONNECT ALL WORK SENSE LEADS AT THE END OF THE WELD.

CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD.

POWER WAVE®AC/DC 1000®SD

Page 29

A-20

INSTALLATION

FIGURE A.13 MULTI-ARC CIRCUMFIRENTIAL WELDS

POWER SOURCE #1

POWER SOURCE #2

A-20

POWER SOURCE #1

POWER SOURCE #2

POWER WAVE®AC/DC 1000®SD

Page 30

A-21

INSTALLATION

A-21

CONTROL CABLE CONNECTIONS

GENERAL GUIDELINES

These guidelines apply to all communication cables including optional DeviceNet and Ethernet connections.

• Genuine Lincoln control cables should be used at all times (except as noted otherwise). Lincoln

cables are specifically designed forthe communication and power needs of the Power Wave MAXsa™ systems. Most are designed to be connected end to endfor ease of operation.

• Always use the shortest cable lengths possi- ble. DO NOT coil excess cable. It is recommended that the total length of control cable does not exceed 100ʼ (30.5M). The use of non-standard cables in excess of 25ʼ (7.5M) can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems).

• Best results will be obtained when the control

cables are routed separate from the weld cables. This minimizes the possibility of interfer-

ence between the high currents flowing through the weld cables and the low level signals in the control cables.

COMMON EQUIPMENT CONNECTIONS

Connection Between MAXsa™ Controller and MAXsa™ series Wire Drive (K1785-xx)

The 14 pin Wire Drive Control Cable (K1785-xx) connects the Controller (MAXsa™ 10 or MAXsa™ 19) to the Wire Drive (MAXsa™ 22 or MAXsa™ 29). This cable should be kept as short as possible.

Connection Between Power Source and the MAXsa™ Controller (K2683-xx - ArcLink Control Cable).

Single and tandem arc systems are typically controlled by a MAXsa™ 10 Controller. In a tandem, or multi-arc system, each arc requires its own dedicated controller.

NOTE

Connections Between Power Source and Optional DeviceNet Programmable Logic Controller(PLC).

It is sometimes more practical and cost effective to use a custom PLC interface to control a multi-arc system (refer to the "DeviceNet Configuration" section for interface information). The Power Wave

1000

SD is equipped with a 5-pin DeviceNet mini

style receptacle for this purpose. The receptacle is

located on the rear panel of the machine See Figure

B.3 The DeviceNet cable is keyed and polarized to prevent improper connection.

NOTE: DeviceNet cables should not be routed

with weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field.

In a typical system, a DeviceNet connection is made between the master power source of each arc, and the PLC interface. DeviceNet cables must be sourced locally by the customer. For additional guidelines refer to the "DeviceNet Cable Planning and Installation Manual" (Allen Bradley publication DN-6.7.2).

Connections Between Parallel Power Sources (K1785-xx - Control Cable).

To increase the output capacity for a given arc, the

output studs of multiple Power Wave

AC/DC 1000 SD machines can be connected in parallel. The parallel machines utilize a master/slave control scheme to distribute the load evenly and to coordinate AC switching. K1785-xx cables connect the paralleled machines via the synchronizing connectors on the back of the machine. The system is currently limited to a maximum of 2 slaves per master, or a total of 3 machines per arc.

Connections Between Power Sources in Multi-Arc Applications (K1785-xx - Control Cable).

Synchronizing Connectors are available on the rear panel of the machine for Multi-Arc applications using the K1875-xx control cables. The system is currently limited to six(6) arcs, or a “Lead” and five “Trail” arcs.

AC/DC

The 5-pin ArcLink control cable connects the power source to the MAXsa™ 10. If there is more than one power source per arc, it connects from the MAXsa™ 10 to the power source designated as the Master for that arc. The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing (67).

POWER WAVE®AC/DC 1000®SD

Page 31

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several

seconds after the welding ceases.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of single knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

COMMON WELDING ABBREVIATIONS

SAW

• Submerged Arc Welding

GRAPHIC SYMBOLS THAT

APPEAR ON

THIS MACHINE OR IN THIS

MANUAL

WORK SENSE LEAD CONNECTOR

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning of this manual.

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding process variables to be set by the operator.

COMMUNICATIONS PROTOCOL

Device

15V 10A

NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI

NEUTRO CONECTADO AL CHASIS

MULTI-ARC CONNECTOR

PARALLEL ARC CONNECTOR

ETHERNET CONNECTOR

ARC LINK CONNECTOR

DEVICENET CONNECTOR

115VAC RECEPTACLE

L15129-4

POWER WAVE®AC/DC 1000®SD

Page 32

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

B-2

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

POWER WAVE®AC/DC 1000®SD

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

Page 33

B-3

OPERATION

PRODUCT SUMMARY

The Power Wave®AC/DC 1000®SD is a high performance, digitally controlled inverter welding power source. It is capable of producing a variable frequency and amplitude AC output, DC positive output, or DC negative output without the need for external reconnection. It utilizes complex, high-speed waveform control to support a variety of constant current and constant voltage welding modes in each of its output configurations.

The Power Wave®AC/DC 1000®SD power source is designed to be a part of a modular welding system. Each welding arc may be driven by a single machine, or by a number of machines in parallel. In multiple arc applications the phase angle and frequency of different machines can be synchronized by interconnecting the units with a control cable to improve performance and reduce the effects of arc blow.

B-3

Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives and MAXsa™ 10 or MAXsa™ 19 Controllers may be used

with a K2803-1 Power Wave

AC/DC 1000®SD in a Multi Arc system. Other Lincoln or non-Lincoln Wire Drives can only be used with custom interfaces.

The Power Wave

AC/DC 1000®SD will support a maximum average output current of 1000 Amps at 100% Duty Cycle.

COMMON EQUIPMENT PACKAGES

BASIC PACKAGE

K2803-1 Power Wave

K2370-2 MAXsa™ 22 Wire Drive

K2814-1 MAX sa™ 10 Co ntro lle r / Us er

Interface

AC/DC 1000®SD

The Power Wave

AC/DC 1000®SD is primarily designed to interface with compatible ArcLink equipment. However, it can also communicate with other industrial machines and monitoring equipment via DeviceNet, or Ethernet. The result is a highly integrated and flexible welding cell.

RECOMMENDED PROCESSES

The Power Wave®AC/DC 1000®SD is designed for submerged arc welding (SAW). Due to its modular design the Power Wave

AC/DC 1000®SD can operate on either single arc or in multi-arc applications with up to six arcs. Each machine is factory preprogrammed with multiple welding procedures to support all types of submerged arc welding. The

Power Wave

AC/DC 1000®SD carries an output rating of 1000 amps, 44 volts (at 100% duty cycle). If higher currents are required machines can be easily paralleled for up to 3000 amps on each arc.

PROCESS LIMITATIONS

The Power Wave®AC/DC 1000®SD is suitable only for the Submerged Arc Process (SAW).

K2683-xx Control Cable (5 pin – 5 pin) - power

source to controller.

K1785-xx Control Cable (14 pin – 14 pin) -

Controller to Wire Drive.

OPTIONAL KITS

K1785-xx Control Cable (14 pin – 14 pin) - for

paralleling / multiple arc applications.

K2312-2 MAXsa™ 29 Wire Drive (for fixture

builders).

K2311-1

Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5 wire feeder gear boxes).

K2444-1 CE, C-Tick Filter Kit

K2626-2 MAXsa™ 19 Controller (for fixture

builders that do not require the MAXsa™ 10 Controller).

RECOMMENDED EQUIPMENT

(See Installation Section)

EQUIPMENT LIMITATIONS

The Power Wave®AC/DC 1000®SD can be used in outdoor environments. The Operating Temperature Range is 14°F to 104°F(-10°C to +40°C).

POWER WAVE®AC/DC 1000®SD

Page 34

B-4

OPERATION

B-4

CASE FRONT CONTROLS

1. Power Switch: Controls input power to the Power

2. Status Light: A two color LED that indicates

3. Thermal Light: A yellow light that comes ON when

Wave equipment that may be connected to it.

system errors. Normal operation is steady green. Flashing green or red/green indicates a system error. See the Troubleshooting Section.

NOTE: The Power Wave

an over temperature situation occurs. The machine output is disabled until the machine cools down and the thermal light goes OFF. NOTE: The Thermal Light may also indicate a

AC/DC 1000®SD and any auxiliary

Status Light will flash green for up to 60 seconds at power up as the machine runs through a self test routine, and then go to steady green.

problem with the AC Switch portion of the power source. See the Troubleshooting

Section.

FIGURE B.1 - CASE FRONT

FIGURE B.2 - INPUT SECTION (LEFT SIDE)

INPUT POWER SECTION

1. Input Contactor: Connection point for incoming 3

phase power. See the Installation Section for input wiring and fusing information.

2. Case Ground: Used to provide an “earth ground” for the frame of the welder. Consult your local and national electrical codes for proper grounding information.

3. Auxiliary Reconnect: Select the proper tap based on the supply voltage.

4. Fuse (F1): Protection for the primary side of the auxiliary transformer

5. Cord Connector: Input power cord strain relief.

L15129-2

380-

415V

440460V

POWER WAVE®AC/DC 1000®SD

500V

550575V

Page 35

B-5

OPERATION

CASE BACK COMPONENTS (See Figure B.3)

1. 10 Amp Circuit Breaker (CB1): Protects the 40VDC wire feeder power supply.

2. 10 amp Circuit Breaker (CB-2): Protects the 115VAC Auxiliary Power Receptacle.

3. Work Sense Lead Connector(4 Pin): Connection point for the #21 lead.

4. Arclink Connector (5 Pin): Provides power and communication to the controller.

5. Devicenet Connector: Provides Devicenet communication to remote equipment.

6. Output Studs (2) (WORK): Connection point for welding cable(s) to the work piece.

7. Output Studs (2) (ELECTRODE): Connection point for welding cables to the Wire Drive.

8. Auxiliary Output Receptacle: Provides 10 amps of 115VAC power.

9. Ethernet Connector (RJ-45): Provides Ethernet communication to remote equipment.

10. Master Input: From Lead or previous trail arc in a Multi-arc system

B-5

11. Master Output: To subsequent trail arc in a Multi-arc system.

12. Parallel Input: From Master or previous Slave in a parallel machine set up.

13. Parallel Output: To Slave in a parallel machine set up

POWER WAVE®AC/DC 1000®SD

Page 36

B-6

OPERATION

FIGURE B.3 - CASE BACK COMPONENTS

B-6

COMMUNICATIONS PROTOCOL

Device

115V AC

10 A 40V

10 A

L15129-1

Stud Cover Doors Removed

for Clarity

POWER WAVE®AC/DC 1000®SD

Page 37

B-7

OPERATION

POWER-UP SEQUENCE

When power is applied to the Power Wave®AC/DC

1000

SD, the status lights will flash green for up to 60

seconds. During this time the Power Wave

1000

SD is performing a self test, and mapping

AC/DC

(identifying) each component in the local ArcLink system. The status lights will also flash green as a result of a system reset or configuration change during operation. When the status lights become steady green the system is ready for use

If the status lights do not become steady green consult the troubleshooting section of this manual for further instruction.

DUTY CYCLE

The Power Wave®AC/DC 1000®SD is capable of welding 1000Amps, @ 44 Volts, at a 100% duty cycle.

COMMON WELDING PROCEDURES

MAKING A WELD

B-7

Consult the User Interface documentation for more detailed set up information. (MAXsa™ 10, Command Center, PLC, Robot etc..)

First, consider the desired welding procedures and the part to be welded. Choose an electrode material, diameter, and flux.

Second, find the program in the welding software that best matches the desired welding process. The standard software shipped with the Power Wave AC/DC 1000®SD encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales representative.

To make a weld, the Power Wave

AC/DC 1000®SD needs to know the desired welding parameters. Waveform Control Technology™ allows full customization of Strike, Run-in, Crater and other parameters for exacting performance.

OVERVIEW OF THE AC/DC SUBMERGED ARC PROCESS

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

The steps for operating the Power Wave

1000

SD will vary depending upon the user interface

AC/DC

of the welding system. The flexibility of the system lets the user customize operation for the best performance.

FIGURE B.4 - AC/DC SUBMERGED ARC PROCESS

Output waveform variations made possible by Waveform Cont

Pulse Width

Frequency

sitive

Current

Nega

Curr

tive ent

The Power Wave®AC/DC 1000®SD combines the advantages of AC and DC Submerged Arc Welding (SAW) into a single power source. The limiting factor of AC-SAW welding has traditionally been the time it takes to transition from positive to negative polarity. This lag through the zero crossing can cause arc instability, penetration, and deposition problems in

certain applications. The Power Wave

AC/DC 1000 SD utilizes the speed of an inverter based power source, and the flexibility of Waveform Control Technology™ to address this issue.

By adjusting the Frequency, Wave Balance and Offset of the AC waveform the operator can now control the balance (relationship) between the penetration of DC positive and the deposition of DC negative while taking full advantage of the reduction in arc blow associated with AC.

Transition

di/dT

Rate

rol T

Time

echnology

Depending on the process, different parts of the output waveform and wire feed speed may be modulat ed at varying rates to achieve a smooth and stable arc.

POWER WAVE®AC/DC 1000®SD

Page 38

B-8

OPERATION

B-8

MULTIPLE ARC SYSTEM CONSIDERATIONS

Large scale SAW applications often employ multiple arcs to increase deposition rates. In multiple arc systems, magnetic forces created by like and opposing weld currents of adjacent arcs can result in arc interaction that can physically push or pull the arc columns together. See Figure B.5. To counteract this effect, the phase relationship between adjacent arcs can be set to alternate and equalize the duration of magnetic push and pull forces. This is accomplished through the synchronizing cables (K1785-xx). Ideally, the net result is a cancellation of the interacting forces. See Figure B.6.

FIG. B.5 - ARC INTERFERENCE

BASIC MODES OF OPERATION

CONSTANT CURRENT (CC)

• Operator presets Current and desired Voltage.

• The Power Source:

- Goal is to maintain a constant arc length.

- Drives a constant Current.

- Synergically Controls WFS to Maintain Voltage at the desired Set point.

• Arc Length is proportional to Voltage.

• Traditionally used for larger diameter wires and slower travel speeds.

FIGURE B.7 - CONSTANT CURRENT

AMPS

CURRENT HELD CONSTANT

WIRE FEED SPEED

AND

WIRE FEED SPEED VARIED

MAINTAIN CONSTANT ARC LENGTH

Extension Heating= Vir

Arc Length= Varc

Total Electrical Stick out V= Vir+Varc

PULL

PUSH

PULL

FIG. B.6 SYNCHRONIZED ARCS

Lead A rc

Trail Arc

Negative

Positive Negative

Positive Positive

PULL

PUSH

Positive

PUSH

Negative Negative

PULL

Positive

PUSH

CAUTION

Never simultaneously touch electrically "hot" parts in the electrode circuits of two different welders. The electrode to electrode no load voltage of multiple arc systems with opposite polarities can be double the no load voltage of each arc. Consult the Safety information located at the front of the Instruction Manual for additional information.

------------------------------------------------------------------------

CONSTANT VOLTAGE (CV)

• Operator presets Wire Feed Speed and desired Voltage

• The Power Source:

- Goal is to maintain a constant arc length.

- Commands constant wire feed speed

- Synergically Controls Current to Maintain Voltage at the desired Set point

• Arc Length is proportional to Voltage

• Traditionally used for smaller diameter wires and faster travel speeds.

FIGURE B.8

AMPS

CURRENT VARIED

AND

Extension Heating= Vir

Arc Length= Varc

Total Electrical Stick out V= Vir+Varc

WIRE FEED SPEED

WIRE FEED SPEED HELD CONSTANT

MAINTAIN CONSTANT ARC LENGTH

POWER WAVE®AC/DC 1000®SD

Page 39

B-9 WELD SEQUENCE

OPERATION

END OPTIONS

B-9

The weld sequence defines the weld procedure from beginning to end. The Power Wave

AC/DC 1000®SD not only provides adjustment of basic welding parameters, but also allows the operator to fine tune the start and finish of each weld for superior performance.

All adjustments are made through the user interface. Because of the different configuration options, your system may not have all of the following adjustments. Regardless of availability, all controls are described below.

START OPTIONS

The Delay, Strike, Start, and Upslope parameters are used at the beginning of the weld sequence to establish a stable arc and provide a smooth transition to the welding parameters.

• ARC DELAY inhibits the wire feed for up to 5 sec-

onds to provide an accurate weld start point. Typically used in multi-arc systems.

• Strike settings are valid from the beginning of the

sequence (Start Button Pressed) until the arc is established. They control Run-in (speed at which the wire approaches the workpiece), and provide the power to establish the arc.

Typically output levels are increased and WFS is reduced during the Strike portion of the weld sequence

• Start values allow the arc to become stabilized once

it is established.

Extended Start times or improperly set parameters can result poor starting

• Upslope determines the amount of time it takes to

ramp from the Start parameters to the Weld parameters. The transition is linear and may be up or down depending on the relationship between the Start and Weld settings.

FIGURE B.9 WELD SEQUENCE

The Downslope, Crater, Burnback and Restrike Timer parameters are used to define the end of the

weld sequence.

• Downslope determines the amount of time it takes

to ramp from the Weld parameters to the Crater parameters. The transition is linear and may be up or down depending on the relationship between the Weld and Crater settings.

• Crater parameters are typically used to fill the crater

at the end of the weld, and include both time and output settings.

• Burnback defines the amount of time the output

remains on after the wire has stopped. This feature is used to prevent the wire from sticking in the weld puddle, and condition the end of the wire for the next weld. A Burnback time of 0.4 sec is sufficient in most applications. The output level for Burnback is the same level as the last active weld sequence state (either Weld or Crater).

• Restrike Timer is used to protect the welding

system and/or work piece being welded. If the arc goes out for any reason (short circuit or open

circuit), the Power Wave

AC/DC 1000®SD will enter a Re-strike state and automatically manipulate the WFS and output in an attempt to re-establish the arc. The Re-strike timer determines how long the system will attempt to re-establish the arc before it shuts down.

• A Re-strike time of 1 to 2 sec is sufficient in most applications.

• A Re-Strike setting of “OFF” allows for infinite restriking attempts until a shutdown occurs.

Arc Start

Output

Pressed

StartButton

Delay

Strike

to Feed

Wire Begins

Wire Touches

Start

Plate

Timer

Endof Start

Upslope

End of

Upslope

Weld

POWER WAVE®AC/DC 1000®SD

Downslope

Pressed

Stop Button

Crater

End of

Downslope

Burnback

Timer

EndofCrater

Endof

Time

Burnback

Page 40

B-10

OPERATION

B-10

WELD PROCESS ADJUSTMENTS

Depending on the weld mode, there are a number of adjustments that can be made, including but not limited to Current, Voltage and WFS. These adjustments apply to either AC or DC processes, and control the basic parameters of the weld.

AC ADJUSTMENTS

In addition to the basic weld parameters, there are a number of unique adjustments related to the AC waveform of the Power Wave

AC/DC 1000®SD. These adjustments enable the operator to balance the relationship between penetration and deposition to tailor the output for specific applications.

WAVE BALANCE

• Refers to amount of time the waveform spends in DC+ portion of the cycle.

FIGURE B.10 - WAVE BALANCE

DC OFFSET

• Refers to +/- shift of the current waveform with respect to the zero crossing.

FIGURE B.11 - DC OFFSET

Positive Offset

1000

Nominal Offset

500

-500

-1000

More Penetration

Less Deposition

Negative Offset

Less Penetrati on More Deposition

• Use Offset to control the penetration and deposition of a given process. See Figure B.11.

FREQUENCY

1000

Nominal Balance

500

-500

-1000

Increased Balance

More Penetrat ion

Less Deposition

Decreased Balance

Less Penetrati on More Deposition

• Use Wave Balance to control the penetration and deposition of a given process. See Figure B.10.

• Power Wave®AC/DC 1000®SD can produce Output Frequencies from 20 - 100Hz

FIGURE B.12 - FREQUENCY

1000

500

-500

-1000

Use Frequency to fin e tune stabi lity of

imbalanced waveforms and multipl e arc syst ems

Decrease

Increase

• Use Frequency to help provide stability.

• Higher frequencies in multiple arc setups can help reduce arc interaction.

• Lower frequencies will help overcome output limitations due to inductance in the Weld Circuit. See Figure B.12.

POWER WAVE®AC/DC 1000®SD

Page 41

B-11

OPERATION

PHASE ADJUSTMENT FOR MULTIPLE ARC SYSTEMS

Phase

• The phase relationship between the arcs helps to

minimize the magnetic interaction between adjacent arcs. It is essentially a time offset between the waveforms of different arcs, and is set in terms of an angle from 0 to 360°, representing no offset to a full period offset. The offset of each arc is set independently with respect to the lead arc of the system (ARC 1).

Recommendations:

• For balanced waveforms a phase relationship of 90° should be maintained between adjacent arcs.

TABLE B.1 - PHASE RELATIONSHIP

B-11

ARC 1

Lead

2 Arc

System

3 Arc

System

4 Arc

System

5 Arc

System

6 Arc

System

ARC 2

Trail

ARC 3

Trail

0° 90° X X X X

0° 90° 180° X X X

0° 90° 180° 270° X X

0° 90° 180° 270° 0° X

0° 90° 180° 270° 0° 90°

• For unbalanced waveforms:

– Avoid switching at same time. – Break up long periods of unchanged polarity

relative to adjacent arcs.

PHASE RELATIONSHIP

ARC 1

ARC 2

Use Phase Relationship to minimize ar c blow

500

in multip le arc systems.

(Bal anced two arc sy stem show n)

0°

(PULL)

(PUSH/PULL )

90°

ARC 4

Trail

ARC 5

Trail

180°

(PUSH)

ARC 6

Trail

-500

BAD GOOD

Best resu lts obta ined by alter nating and equ alizing the duration of

magneti c forces bet ween adjacent arcs.

BAD

POWER WAVE®AC/DC 1000®SD

Page 42

C-1

ACCESSORIES

OPTIONS AND ACCESSORIES are

available at www.lincolnelectric.com

Follow these steps:

1. Go to www.lincolnelectric.com

2. In the Search field type E9.181 and click on the Search icon (or hit ʻEnterʼ on the keyboard).

3. On the Results page, scroll down to the

Equipment list and click on E9.181.

All of the information for the Power Wave accessories can be found in this document.

System

SOFTWARE TOOLS

C-1

Power Wave

AC/DC 1000®SD software tools and other documents related to the integration, configuration, and

operation of the system is available at www.powerwavesoftware.com. Power Wave includes the following items and all of the documentation to support them.

Name Purpose

Weld Manager Setup Ethernet address information, and apply security settings.

Utility to diagnose Power Wave

problems, read system information, calibrate output voltage and current, test sense leads, and diagnose feed head issues. Can also setup and verify DeviceNet operation.

• Gear Box / Feeder Selection

• Memory Lables

• DeviceNet setup and Verification

• UI setup (Lockout and Limits)

• Ethernet setup and Verification

• Diagnostic

-snapshot

-weldview

-error lookup

-inductance test

-sense lead test

• Calibration (I,V,WFS)

• Cable Test

-inductance

-sense leads

Submerged Arc Utilities

Command Center AC/DC system tool to observe and log welding operation, verify

DeviceNet welding configuration, and facilitate quality analysis.

Submerged Arc Cell Configuration Used to configure and verify a multi-arc or parallel connected power

source (more than one Power Wave

per arc) systems.

• Multi Arc setup

• Generators Command Center connection file

• Setup Verification

-output cables (cables crossed)

-software versions (Master to slave and Arc to Arc)

-I/O verification (Master to Master and Master to slave)

-sense lead

-inductance test

POWER WAVE®AC/DC 1000®SD

Page 43

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only Qualified personnel should perform this maintenance.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing out the machine, using a low-pressure airstream, to remove accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in the machine.

The rear portion of the machine that contains the filter and the cooling fans slides out for easy access. Removing the four(4) clips and pulling back on the rear portion of the machine will provide access for cleaning the machine and checking the filter. The filter may be removed from the right side of the machine. See Figure A.1.

CALIBRATION SPECIFICATION

Output Voltage and Current 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, use the calibration section of the Weld Manager Utility to make the appropriate adjustments.

The calibration procedure itself requires the use of a grid (Resistive Load Bank), 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. The Weld Manager Utility includes detailed instructions, and is available on the internet at powerwavesoftware.com under Power Wave

Submerged Arc Utilities.

PERIODIC MAINTENANCE

Calibration of the Power Wave®AC/DC 1000®SD is critical to its operation. 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.

POWER WAVE®AC/DC 1000®SD

Page 44

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

E-1

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE®AC/DC 1000®SD

Page 45

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave®AC/DC 1000®SD is equipped with one externally mounted status light. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to

the system, check the power source status light for error sequences as noted below.

Included in this section is information about the power source Status LED and some basic troubleshooting charts for both machine and weld performance.

The STATUS LIGHT is a dual-color LED that indicates system errors. Normal operation is steady green. Error conditions are indicated in the following Table E.1.

TABLE E.1

E-2

Light

Condition

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Meaning

System OK. Power source is operational, and is communicating normally with all healthy peripheral equipment connected to its ArcLink network.

Occurs during power up or a system reset, and indicates the POWER WAVE is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.

Under normal conditions indicates Auto-mapping has failed. Also used by

Weld Manager and Submerged Arc Cell Setup (available at www.powerwavesoftware.com) to identify the selected machine when connecting to a

specific IP address.

Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are present. Read the error code(s) before the

machine is turned off.

Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light. Only active error conditions will be accessible through the Status Light.

Error codes can also be retrieved with Weld Manager under System Status (available at www.powerwavesoftware.com). This is the preferred method, since it can access historical information contained in the error log.

To clear the active error(s), turn power source off, and back on to reset.

Steady Red

Blinking Red

Not applicable.

CAUTION

POWER WAVE®AC/DC 1000®SD

Page 46

E-3

Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWER WAVE

The following is a partial list of possible error codes for the Power Wave®AC/DC 1000®SD. For a complete listing consult the Service Manual for this machine.

TROUBLESHOOTING

E-3

POWER SOURCE–––WELD CONTROLLER

Error Code #

31 Primary (Input) overcurrent error.

LECO

(FANUC#)

Excessive Primary current present. May be related to a switch board or output rectifier failure.

Indication

32 Capacitor “A” under voltage

(right side facing the Switch PC Board)

33 Capacitor bank "B" under voltage

(left side facing the Switch PC Board)

34 Capacitor "A" over voltage

(right side facing the Switch PC Board)

35 Capacitor "B" over voltage

(left side facing the Switch PC Board)

36 Thermal error

37 Softstart (pre-charge) error

39 Misc. hardware fault

43 Capacitor delta error

Low voltage on the main capacitors. May be caused by improper input configuration, or an open/short circuit in the primary side of the machine.

Excess voltage on the main capacitors. May be caused by improper input configuration, excessive line voltage, or improper capacitor balance (see Error 43)

Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine. Also acts with a malfunction.

Capacitor precharge failed. Usually accompanied by codes 32 and 33.

Unknown glitch has occurred on the fault interrupt circuitry. Sometimes caused by primary over current fault, or intermittent connections in the thermostat circuit.

The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors 32-35. May be caused by an open or short in the primary or secondary circuit(s).

A complete list of error codes is available in Weld Manager under Tools -> Lookup Error (available at

Other

see

complete

listing

www.powerwavesoftware.com).

Error codes that contain three or four digits are defined as fatal errors. These codes generally indicate internal errors on the Power Source Control Board. If cycling the input power on the machine does not clear the error, contact the Service Department

CAUTION

POWER WAVE®AC/DC 1000®SD

Page 47

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal covers are removed.

Input fuses keep blowing

Machine will not power up (no lights)

POSSIBLE

CAUSE

BASIC MACHINE PROBLEMS

None

1. Improperly sized input fuses.

2. Improper Weld Procedure requiring output levels in excess of machine rating.

3. Major physical or electrical damage is evident when the sheet metal covers are removed.

1. No Input Power.

RECOMMENDED

COURSE OF ACTION

1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. Make sure fuses are properly sized. See installation section of this manual for recommended sizes.

2. Reduce output current, duty cycle, or both.

3. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. Make sure input supply disconnect has been turned ON. Check input fuses. Make certain that the Power Switch (SW1) on the power source is in the “ON” position.

2. Fuse F1 (in reconnect area) may have blown.

3. Circuit breaker CB1 (on the control panel) may have tripped.

4. Improper input voltage selection (multiple input voltage machines only).

2. Power Down and replace the fuse.

3. Power Down and reset CB1.

4. Power down, check input voltage reconnect according to diagram on reconnect cover.

CAUTION

POWER WAVE®AC/DC 1000®SD

Page 48

F-1

DIAGRAMS

F-1

POWER WAVE®AC/DC 1000®SD

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 49

F-2

Enhanced Diagrams

DIAGRAMS

F-2

POWER WAVE®AC/DC 1000®SD

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 50

F-3

DIMENSION PRINT

F-3

L15150

9.569.56

19.12

19.71

49.13

45.75

19.47

46.60

7.94

33.00

FILTER REMOVAL

MAINTENANCE ACCESS

WIDTH NEEDED FOR FILTER

61.30

FROM SIDE OF MACHINE

22.63

POWER WAVE®AC/DC 1000®SD

Page 51

NOTES

POWER WAVE®AC/DC 1000®SD

Page 52

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 53

 Keep your head out of fumes.  Use ventilation or exhaust to

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

 Gardez la tête à l’écart des fumées.  Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.  Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

 Não opere com as tampas removidas.  Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 54

Need Help?

Lincoln Electric “Rapid Response” Service!

Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 A.M. to 6:00 P.M. (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you by the next business day.

• For Non-U.S. Service: Email globalservice@lincolnelectric.com

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877

FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email globalservice@lincolnelectric.com

Lincoln Electric IM10022 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual