Lincoln Electric IM848 User Manual

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POWER WAVE AC/DC 1000

IM848-A

June, 2009

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 I NST AL L ,

OPERATE OR REPAI R THI S EQUI PMENT WI T HOUT RE ADING THIS MANUAL AND T HE SAFETY PRECAUTI ONS CONT AI NE D T HROUGHOUT . And,

most importantly, think before you act and be careful.

11124, 11226

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

IEC 60974-1

OPE RAT OR’ S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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.

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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.

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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.

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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.

Mar ʻ95

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 skin or wet clothing. Wear dry, hole-free

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.

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 produc e fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

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.

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.

Jan ‘09

iii

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.

Jan ‘09

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie du corps.

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

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils 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 dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc 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

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

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

LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

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

SAFETY

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

“Product Registration”. 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 “Quick Links” and then

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.

viii

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

Input Fuse and Supply Wire Considerations.................................................................A-3

Input Voltage Selection and Ground Connections ........................................................A-3

Connection/Input Access Door, Connection Diagrams System ....................................A-3

System Connection .......................................................................................................A-4

Recommended Equipment............................................................................................A-5

Optional Equipment.......................................................................................................A-6

Connection Diagrams and Check List ...........................................................A-7 thru A-14

Electrode and Work Connection .................................................................................A-15

Cable Inductance, And its Effects On Welding ...........................................................A-16

Remote Sense Lead Specifications ............................................................A-16 thru A-18

Control Cable Connections Between Power Source and Wire Feeder .............A-19, A-20

External I/O Connector................................................................................................A-21

Cables, Connections and Limitations ................................................................A-21, A-22

Wire Drive Gear Ratio Setting, Ethernet Configuration ......................................................A-23

Devicenet Configuration, Internal Controls, Settings and Descriptions ..............A-24 thru A-28

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viii

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

Safety Precautions, Definition of Welding Modes ................................................................B-1

Graphic Symbols ..................................................................................................................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,B-5

Case Rear Components.......................................................................................................B-6

Power-Up Sequence ............................................................................................................B-6

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, AC Adjustment, Wave Balance, DC Offset, Frequence ..........B-10

Multiple Arc AC adjustments for systems equipped with K2282-1 System Interface .........B-11

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

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

________________________________________________________________________

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

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

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

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

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TABLE OF CONTENTS

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

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

Troubleshooting Guide...........................................................................E-2 thru E-11

Using the Status LED to Troubleshoot System Problem.....................................E-12

Error Codes................................................................................................E-13, E-14

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

________________________________________________________________________

Parts List.................................................................................................................P-509

________________________________________________________________________

A-1

SPECIFICATIONS

TECHNICAL SPECIFICATIONS - POWER WAVE® AC/DC 1000 (K2344-1, K2344-2)

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

K2344-1 K2344-2

--- 82

--- 79 68 69 62 62 54 55

AUXILIARY POWER

(CIRCUIT BREAKER

PROTECTED)

OUTPUT

CONDITIONS

1000A@44V.

100% Duty Cycle

OUTPUT

IDLE

POWER

WATTS

225

PROCESS CURRENT RANGES (AC or DC)

POWER FACTOR

@ RATED OUTPUT

.95

EFFICIENCY

@ RATED OUTPUT

86%

A-1

25 to 100

VRMS

MODEL

K2344-1

K2344-2

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

CONFORMITY MARK

CSA

EN 60974-1 CSA

C/UL

SAW-DC+ Output Range SAW-DC- 200-1000 Average Amps SAW-AC

TYPE 90°C

COPPER WIRE3IN

CONDUIT

AWG (mm2)

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

COPPER GROUNDING

CONDUCTOR

AWG (mm

PHYSICAL DIMENSIONS

HEIGHT

43.5 in

1105 mm

43.5 in

1105 mm

WIDTH

19.2 in

488 mm

19.2 in

488 mm

TEMPERATURE RANGES

}

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

)

DEPTH

33 in

838 mm

33 in

838 mm

TIME-DELAY FUSE

OR BREAKER

AMPS

100

90 90 80 70

WEIGHT

600 lbs.

272 kg.

650 lbs.

296 kg.

OPERATING TEMPERATURE RANGE

32°F to 104°F(0°C to 40°C)

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.

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to 85°C)

* 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. (K2444-1 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

Output Range (Amperes

200 - 1000

Wire Feed Speed Range

21 - 300 ipm (.53 – 7.62 m/minute)

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

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 AC/DC 1000 with accessories attached to it.

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. Do not use air filters on the air intake because the air flow will be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

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 machine cannot be stacked.

ENVIRONMENTAL LIMITATIONS

Do not use the Power Wave AC/DC 1000 in an outdoor environment. The Power Wave AC/DC 1000 power source 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 1000 is Industrial, Scientific and Medical (ISM) group 2, class A. The Power Wave AC/DC 1000 is for industrial use only.

Locate the Power Wave away from radio controlled machinery.

CAUTION

The normal operation of the Power Wave AC/DC 1000 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

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

POWER WAVE® AC/DC 1000

A-3

INSTALLATION

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

A-3

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.

ELECTRIC SHOCK can kill.

• Only a qualified electrician should connect the input leads to the Power Wave. Connections 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.

Reconnect Diagram for K2344-1 Power Wave AC/DC 1000

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

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 Reconnect Diagram K23441 and K2344-2 shown below. If the Auxiliary lead (indicated as ʻAʼ) is placed in the wrong position, there are two possible results. If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary lead is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit breakers in the reconnect area will open. If this occurs, turn off the input voltage, properly conne iliary lead, reset the breakers, and try again.

ct the aux-

Reconnect Diagram for K2344-2 Power Wave AC/DC 1000 ("CE – ready")

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 cov ers removed

Disconnect input powe r before servic ing

Do not touch electric ally live parts

Only qualified persons should install, use or service this equipment

VOLTAGE=440-460V

440-460V

'A'

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'

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

POWER WAVE® AC/DC 1000

S26047

A-4

INSTALLATION

SYSTEM CONNECTION

System Overview

The Power Wave AC/DC 1000 power source is designed to be a part of a modular welding system typically controlled by a Power Feed 10A Controller or 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 multiple parallel machines are required, one is designated as the Master and the rest as Slaves. The Master controls the AC switching for the arc group, and the Slaves respond accordingly.

When employed in a multi-arc AC system it is beneficial to synchronize the arcs 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 optional Power Wave System Interface provides the means to synchronize the AC wave shapes of up to four different arcs to a common carrier frequency. This frequency can range from 10 hertz to 300 hertz, with the most practical range being 10 to 100 hertz. It can also control the phase angle between arcs to reduce the effects of welding related issues such as "Arc Blow". The arc to arc phase relationship is determined by the timing of each arcʼs "sync" signal relative to the "sync" signal of ARC 1.

A-4

A PLC interface is an alternate method of control for larger systems. The PLC is typically connected via DeviceNet directly to the Power Wave System Interface, and the Master power source of each arc group in the system.

The following list of Recommended and Optional equipment is included as a reference for the following connection diagrams. The connection diagrams describe the layout of three typical systems. Each diagram has a step by step Installation Checklist. Additionally, a dedicated diagram has been provided detailing the parallel connection of machines for extra output capacity which can be applied to the system diagrams as required.

In a typical multi-arc system, each arc is controlled by its own Power Feed 10A 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 Power Feed 10A Controller for ARC 1, which must be connected to its Master through the Power Wave System Interface (see multi-arc Connection Diagrams on the next few pages).

POWER WAVE® AC/DC 1000

A-5

System

Identifier

Part No.

INSTALLATION

RECOMMENDED EQUIPMENT

Description

Single Arc

Tandem Arc

Triple Arc

A-5

3,4

Power Source

Weld Cables

Head

Torch

Power Source to

Head

Control Cable

User Interface

ArcLink Digital

Communication

Cable

K2344-1

-or-

K2344-2

K2163-xx

-or-

K1842-xx

K2370-1

-or-

K2312-1

K231-xxx

K1785-xx

K2362-1

K1543-xx 5

Power Wave AC/DC 1000 Power Source

Welding Power Cables

Power Source to contact Nozzle,

and Power Source to Work

K2163 Series cables sold in pairs.

K1842 Series cables sold individually.

See Price Book for details and bulk cable

availability.

Power Feed 10S Head for 3/32 to 7/32 in. solid

wire (includes hopper, wire straightener, cross

seam adjuster, head mounting hardware, and 2 -

5ft 4/0 weld cables).

Power Feed 10S Head for 3/32 to 7/32 in. solid

wire (fixture builder's head, with wire straightener -

insulators not included).

Submerged Arc Contact Nozzle Assembly

Feeder Control Cable (14 pin).

Power Feed 10A Controller

ArcLink Control Cables (5 pin).

Single Arc:

(1) PF-10A Controller to the power source

Tandem Arc:

(1) Lead Arc to System Interface (2)System Interface to Lead Arc PF-10A Controller (3) Trail Arc to Trail Arc PF-10A Controller

Triple Arc:

(1) Lead Arc to System Interface

Refer to "Output Cable Guidelines" for recommended size and quantity

2,4

---

PLC (w/ User

Interface)

DeviceNet Cables

and Accessories

System Interface

to Power Source

Control Cable

Notes:

1. "Recommended Quantity" assumes one power source per arc. Multiple power sources may be used to increase the output capacity per arc (see "Connection Diagram - Parallel Machines").

2. Control Cable connections only required at the Master of each parallel power source arc grouping.

3. Can be expanded to 4 or more arcs (Note: The System Interface can currently only synchronize up to four AC arc groupings).

4. The triple arc system is an economical breakpoint for a PLC Interface. It does not preclude the use of a PLC for single or tandem arc systems, nor PF-10A's from being used to control multiple arc systems with greater than two arcs.

5. Cables can be connected end to end to extend length.

Customer

Supplied

Automation

Department or

Customer

Supplied

K2282-1

K1795-xx 5

Programmable Logic Controller

(DeviceNet compatible)

DeviceNet Cables, Tees, and Terminators (5 pin)

sealed "mini style") form a trunk style network connecting PLC to each power source and the System

Interface.

For additional information refer to the "DeviceNet

Cable Planning and Installation Manual" (Allen

Bradley publication DN-6.7.2).

Power Wave System Interface provides the

means to synchronize the AC wave shapes of up

to four different arcs to a common carrier frequen-

cy, and control the phase angle between them to

reduce the effects of "Arc Blow".

Control Cable (22 pin) connects between each

power source and the System Interface.

---

Cables, Tees,

and

Terminators

--as required

per Triple Arc

Connection

Diagram

POWER WAVE® AC/DC 1000

A-6

System

Identifier

Part No.

INSTALLATION

OPTIONAL EQUIPMENT

Description

A-6

Ethernet Network

Equipment

Personal

Computer

Travel Carriage

Travel Carriage (High Capacity)

Controller

Mounting Bracket

User Interface

Horizontal

Adjuster

Vertical Adjuster

Wire Reel

Mounting (single)

Customer

Supplied

Customer

Supplied

K325-x

K325-HCx

K2462-1

K96

K29

K299

Ethernet Switch, Cables, etc. required for arcs > 1000A, or for use of Power Wave

Submerged Arc Utilities software package.

IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater)

required for use with Power Wave Submerged Arc Utilities software package.

TC-3 Self-Propelled Travel Carriage for traversing standard carriage

beam (per G1458)

TC-3 Self-Propelled High Capacity Travel Carriage for traversing standard carriage

beam (per G1458)

PF-10A Mounting Bracket mounts PF-10A Controller to left side of TC-3 carriage. Brackets can be cascaded to accommodate more than one controller.

Note: Bracket uses mounting holes reserved for K299 Wire Reel Assembly

(see Wire Reel Mounting options for additional information).

Horizontal Lift Adjuster provides 2" (51mm) crank adjustment of horizontal head position.

Vertical Lift Adjuster provides 4" (102mm) crank adjustment of vertical head position. Also provides 3.37" (95mm) in-and-out horizontal adjustment with movable stops for repeatability.

Wire Reel Assembly accommodates one 50-60 lb (22.7-27.2 kg) coil, includes mounting spindle and braking system. Mounts to left side of TC-3 Std. or High Capacity Travel Carriage (K325-x).

Cannot be mounted to TC-3 when K2462-1 PF-10A Mounting Bracket is used (use K390 instead).

Wire Reel

Mounting (dual)

Mounting for Dual

Head

Flux Hopper

Remote Wire

Drive Module

K390

K387

K219

K389

K2626-1

Electrode Reels and Mountings for mounting up to two 50-60 lb (22.7-27.2 kg) coils, includes mounting spindle and braking system. Mounts to top of TC-3 High Capacity Travel Carriage (K325-HCx). Does not interfere with K2462-1 PF-10A Mounting Bracket.

Tandem Arc Framework includes hex style framework and mounting hardware to attach two PF-10S or PF-10SF heads directly to a high capacity TC-3 carriage, or user supplied fixture or gantry.

Flux Hopper with electric flux valve for Submerged Arc welding.

Flux Hopper with electric flux valve, for K387 tandem mounting. Mounts directly to hex

crossbar.

For wire drive applications greater than 100ft.

POWER WAVE® AC/DC 1000

A-7

INSTALLATION

Connection Diagram- Typical Single Arc System (Power Feed 10A Controller)

A-7

Electrode Studs

Work Stu ds

Arclink (5 Pin)

K1543-XX Arclink Control Cable

2362-1

Wire Feeder (14 Pin)

Travel Carriage Connection

Flux Hopper Connection

Arclink Connection

* Work Cable(s)

* Electrode Cable(s)

* Refer to "Output Cable Guidelines" for recommended cable size.

67 Lead

K1785-XX Wire Feeder Control Cable

21 Lead

Head

K231-XXX

Work Piece

14 Pin Connector

Wire Reel and Mounting

Electrode Sense Lead (67)

Work Sense Lead (21)

POWER WAVE® AC/DC 1000

A-8

INSTALLATION

STEP BY STEP INSTALLATION CHECKLIST

SINGLE ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE)

(as shown in the Connection Diagram "Typical Single Arc System")

Place Power Wave in suitable operating location.

Mount PF10A Controller.

Install PF10S Wire Drive and other accessories in their operating location.

A-8

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the Power Wave and Wire Drive.

Connect K1543-xx ArcLink Control Cable (5 pin) between Power Wave and PF10A.

Configure / Install sense leads.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open all Power Wave front panel and configure DIP switch settings per "Internal Controls" section.

Connect input power to Power Wave per recommended guidelines.

Turn on Power Wave, and verify all system Status Lights are solid green.

NOTES:

(1) ArcLink and Wire Feeder control cable connections are only required at the Master power source of each

arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."

(1)

POWER WAVE® AC/DC 1000

A-9

INSTALLATION

Connection Diagram- Typical Tandem Arc System ( Power Feed 10A Controller)

Wire Feeder (14 Pin)

link (5 Pin)

Arc

Master Input (S12) Connects to System

Interface

Work Studs

K1795-XX Cables

A-9

Electrode Studs

Wir

e Reel

and Mountings

K1785-XX Wire Feeder

Control Cabl

* Work Cables

14 Pin Connector

67 Lead

21 Lead

K2362-1

Head

231-

XXX

Work Piece

Electrod Sense Lead (67)

Work Sense Lead (21)

K15

Arclin

Arc

43-XX

k Contro

l Ca

Arclink Connection

link Input

k Output

lin

Arc

K2282-1

Travel Carr

Connection

Flux Hopper Connection

* Electrode Cables

iage

* Refer to "Output Cable guidelines" for recommended cable size.

POWER WAVE® AC/DC 1000

A-10

INSTALLATION

STEP BY STEP INSTALLATION CHECKLIST

TANDEM ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE PER ARC)

(as shown in the Connection Diagram "Typical Tandem Arc System”)

Place Power Waves in suitable operating location.

Mount PF10A Controllers.

Install PF10S Wire Drives and other accessories in their operating location.

Mount Power Wave System Interface.

A-10

Connect K1785-xx Wire Feeder Control Cable (14 pin) between each Power Wave and Wire Drive.

Connect K1543-xx ArcLink Control Cables (5 pin) from Power Wave #1 to the System Interface input, and from the System Interface output to the PF10A Controller for ARC #1.

Connect K1543-xx ArcLink Control Cable (5 pin) between Power Wave #2 and the PF10A Controller for ARC

(1)

#2.

Connect K1795-xx System Control Cables (22 pin) between each Power Wave and the System Interface.

Configure / Install sense leads.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open all Power Wave front panels and configure DIP switch settings per "Internal Controls" section.

Connect input power to Power Waves per recommended guidelines.

Turn on Power Waves, and verify all system Status Lights are solid green.

NOTES:

(1) ArcLink and Wire Feeder control cable connections are only required at the Master power source of each

arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."

(1)

(2)

(2) The "ARC" (formerly "PHASE") connections from the System Interface are only required for the Master

power source of each arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."

POWER WAVE® AC/DC 1000

A-11

INSTALLATION

A-11

ead (6

K2282-1

DeviceNet

5-XX Cabl

K179

3-XX

154 K

ntrol Cab

Arclink Co

Arclink Input

Master Input (S1

Connects to System

Interface

in) P

e Feeder

(14 Pin)

Wir

Arclink (5

Net

(5 Pin)

Device

Work Stu

e Cables

lectrod

* E

Wire Feeder

K1785-

Control Cables

e Sense L

lectrod E

eads (2

ense L S

Work

Wire Reel

and Mountings

Head

* Work Cables

XXX

231-

iece

nnector

Work P

21 Lead

14 Pin Co

ller

Connection Diagram- Typical Triple Arc System (DeviceNet PLC Controller)

PLC Contro

User Interface

DeviceNet Cable Network

e Studs

Electrod

POWER WAVE® AC/DC 1000

67 Lead

* Refer to "Output Cable Guidelines" for recommended cable size.

A-12

INSTALLATION

STEP BY STEP INSTALLATION CHECKLIST

TRIPLE ARC SYSTEM CHECKLIST – (DEVICENET PLC CONTROLLED, 1 POWER SOURCE PER ARC)

(as shown in the Connection Diagram "Typical Triple Arc System”)

Place Power Waves in suitable operating location.

Mount DeviceNet PLC Controller and User Interface.

Install PF10S Wire Drives and other accessories in their operating location.

Mount Power Wave System Interface.

A-12

Connect K1785-xx Wire Feeder Control Cable (14 pin) between each Power Wave and Wire Drive.

Connect K1543-xx ArcLink Control Cable (5 pin) from ARC #1 power source to the System Interface input.

Connect K1795-xx System Control Cables (22 pin) between each Power Wave and the appropriate System Interface "ARC" (formerly "PHASE") outputs.

Connect the System Interface and each power source to the PLC via the DeviceNet network.

Configure / Install sense leads.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open all Power Wave front panels and configure DIP switch settings (including the DeviceNet MAC ID and Baud Rate settings) per "Internal Controls" section.

Connect input power to Power Waves per recommended guidelines.

Turn on Power Waves, and verify all system Status Lights are solid green.

NOTES:

(1) ArcLink, DeviceNet and Wire Feeder control cable connections are only required at the Master power source

of each arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."

(2)

(1)

(2) The "ARC" (formerly "PHASE") connections from the System Interface are only required for the Master

power source of each arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."

POWER WAVE® AC/DC 1000

A-13

INSTALLATION

A-13

Ethernet

Work

Connect to optional K2282-1 System Interface for Synchronized Multiple Arc Applications

Connection Diagram - Parallel

(Example depicts a single arc grouping, and may be repeated for each arc in the system)

Front view o

* Work Cables

lectrode

Machines

machines

Common bus connections recommended for excessive cable length applications. (Locate close to power sources.)

* Electrode Cables

12 (Input)

Rea

r view of machines

Ethernet S

Note: Ethernet connectivity allows machines to share critical parameter information. Proper configuration requires the use of

Weld Manager and

the

Connect additional machines as required to reach

179

5-XX C

ables

S13 (Output)

desired capacity.

Note: Each arc is limited to 5

SLAVE machines per MASTER

(6 machines total)

SLAVE

SubarcCellConfig

witch

software utilities.

* Refer to "Output Cable Guidelines" for recommended cable size.

POWER WAVE® AC/DC 1000

+ 51 hidden pages