Lincoln Electric IM10022 User Manual

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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: [phone] For Service in U.S. and Canada: Call 1.888.935.3877

FAX: [phone] WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [e-mail]

IP 23

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

i

SAFETY

i

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

ii

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

to

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.

iv

SAFETY

iv

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.

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.

vv

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.

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-

1.

tions

_________________________

1

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

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.

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

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

55

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)

3

2

)

}

COPPER GROUNDING

IN

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)

1

2

)

DEPTH

46.60 in

1184 mm

TIME-DELAY FUSE

OR BREAKER

AMPS

100

90
90
80
70

WEIGHT

800 lbs.

363 kg.

2

Insulation Class: Class F(155°C)

1

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

2

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.

3

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

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.

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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

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

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

I

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

A

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

POWER WAVE®AC/DC 1000®SD

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

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

A-7

SD

®

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

Weld Cable

K1811-XX

Sense Lead

Work

POWER WAVE®AC/DC 1000®SD

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