Lincoln Electric MC04-216 User Manual

Description

Output Input

Power Wave®AC/DC 1000™

Increase Productivity, Quality and Flexibility

AUTOMATED SOLUTIONS

The Power Wave AC/DC 1000 is the first power source to introduce Waveform Control Technology™ to submerged arc welding. Variable frequency and amplitude AC, DC positive or DC negative output allows the user to control the deposition rate and penetration. An operator can increase weld speeds, yield higher quality welds and improve efficiencies in a single or multi-arc environment. The phase angle and frequency of different machines can also be synchronized to balance the interactions between multiple arcs and minimize arc blow. Depending on the output, a welding arc may be driven by a single machine or multiple machines in parallel for applications that require more than 1000 amps of continuous operation.

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TECHNICAL SPECIFICATIONS

Recommended General Options

Recommended Wire Feeders

• Eliminate downtime with easy polarity switching –– no hardware reconfiguration required.

• Stable and independent arc controls for multiple arc applications.

• Improved efficiency and reliability with cooler operation through patented Coaxial Transformer Technology™.

• 95% power factor correction enables connection of more machines on the same plant infrastructure for lower installation costs compared to other machines.

• Remote process monitoring and control through ArcLink, Ethernet, and DeviceNet communication.

• Consistent operation over ± 10% input voltage variation through built-in line voltage compensation and reliable input voltage connection.

• Manufactured under a quality system certified to ISO 9001 requirements and ISO 14001 environmental standards.

• Three-year warranty on parts and labor.

PHASE

Power Feed 10A Controller K2362-1 (requires either the K2312-1 Power Feed 10SF Wire Feed Head for fixed hard automation, or the K2370-1 Power Feed 10S Head for mounting a Lincoln TC-3 Travel Carriage), Power Feed 10SM Motor Conversion Kit K2311-1 (Other options may apply).

K2344-1 Power Wave AC/DC 1000 460/500/575/3/60 K2344-2 Power Wave AC/DC 1000 400/460/500/575/3/50/60

System Interface, Interface Control Cable (22-pin), ArcLink Cable (5-pin), Feeder Control Cable (14-pin), TC-3 Self-Propelled Travel Carriage, CE Filter

(1)

Rated Output Dimensions Net

Product Product Input Current/Voltage/ Input Current Output H x W x D Weight

Name Number Voltage Duty Cycle @Rated Output Range in (mm) lbs (kg)

Power Wave AC/DC 1000 K2344-1 460/500/575/3/60 1000/44/100% 68/62/54 100-1000A 43.5 x 19.2 x 33 600

(1105 x 488 x 838) (272)

Power Wave AC/DC 1000

(1)

K2344-2

(1)

380/400/460/500/575/3/50/60 1000/44/100% 82/79/69/62/55 100-1000A 43.5 x 19.2 x 33 650

(1105 x 488 x 838) (295)

Submerged Arc

Processes

(1)

External Filter is required to meet CE conducted emission requirements. The K2444-1 must be used with the K2344-2.

Publication E10.96 1/05

Web Update 1/06

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Power Wave AC/DC 1000

A CLOSER LOOK

[2]

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WHAT IS NEXTWELD®?

Nextweld integrates Lincoln’s technologies, processes and products to create a comprehensive, flexible, user-friendly welding system that can increase efficiency and reduce fabrication costs. Waveform Control Technology™ and digital communications

provide the foundation for Nextweld innovations like Pulse-OnPulse™, Power Mode™, STT

and ArcLink®. Look for Nextweld products for ultimate arc control, high efficiency/reliability and seamless system integration.

Waveform Control Technology™

Driving Superior Welding Performance

Lincoln’s Waveform Control Technology controls and shapes the output waveforms (or weld modes) to adapt to virtually any application, material or weld position. In addition, you can have our Application Engineering department add or customize standard waveform programs.

For more information see Nextweld Document NX-1.10

Waveform Control Technology

• Ultimate arc control — Many aspects of the waveform may be varied as a function of time in order to customize the arc exactly to your specifications.

• Dynamically controlled output — Arc Current, Voltage or Power may be controlled and regulated automatically so adjustments and corrections are made as they arise.

• Different parts of the waveform and wire feed speed may be modulated at varying rates to accomplish a constant average condition (Constant Voltage, Constant Current, etc.).

Refer to Publication NX-2.30 Nextweld AC/DC submerged arc

process document for more details.

Variable Frequency – Control Arc Stability

The Power Wave AC/DC 1000™ has the widest range of wave frequency adjustment (10 - 100 Hz) in the industry. Adjust frequency with the turn of a knob to maximize arc stability.

Turn Frequency down for more penetration (less energy) with a less stable arc.

Turn Frequency up for a more stable arc with less penetration (more energy in less time).

Waveforms are easily changed through graphical interface

System Interface

Power Wave AC/DC 1000

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[3]

A CLOSER LOOK

Variable Balance – Control Deposition

By setting the correct wave balance (that is, the ratio between positive and negative waveforms), the operator is able to work faster and fill the weld joint with fewer passes. The Power Wave AC/DC 1000™ has wave balance range of 25% to 75%.

The more positive the wave, the more penetration.

The more negative the wave, the greater the weld deposition.

DC Offset (Variable Amplitude) – Control Penetration

Wave amplitude and the duration of positive and negative cycles are independently adjustable, so the operator can obtain deep/shallow penetration and higher/lower deposition rates, depending on the application. The Power Wave AC/DC 1000 has the widest range of variable amplitude, or DC offset, (-25% to 25%) in the industry.

Increasing the negative amplitude (offset) decreases penetration.

Multi-Arc Environment

In a multiple arc welding, as many as five arcs operate in a single weld puddle. Changes to the positive/negative polarity phases and/or cycle balances of the AC waveform enable the operator to control deposition rate, penetration and travel speed without a change in voltage or current settings. Using the Power Wave AC/DC 1000 in a multi-arc system can increase your weld speeds, yield higher quality welds and improve efficiencies.

Phase Relationship – Controlling Arc Blow

In a multi-arc environment, arc interaction plays an important role in the behavior of the weld. Two positive electrodes pull together, as do two negative electrodes, while a positive and negative repel each other, causing arc blow. The Power Wave AC/DC 1000 balances the "push" and "pull" of the multi-arc relationship using phase shifting to prevent arc blow.

By phase shifting the AC waveforms, the amount of "push" and "pull" of the arc interactions can be balanced using alternating current to avoid arc blow.

Increasing the positive amplitude (offset) increases penetration.

Applications

Whether it is a cross country pipeline or an offshore platform, the Power Wave AC/DC 1000 is meeting and exceeding expectations around the world.

Power Wave AC/DC 1000

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[4]

A CLOSER LOOK

75% DC NEGATIVE BALANCED AC LEAD ARC 75% DC NEGATIVE BALANCED AC TRAIL ARC

BALANCED AC LEAD ARC BALANCED AC TRAIL ARC

STANDARD

TECHNOLOGY

75% DC NEGATIVE LEAD ARC

75% DC NEGATIVE TRAIL ARC WITH

30% DC NEGATIVE AMPLITUDE OFFSET

2 ARCS

3 ARCS

2 Arc

3 Arc

2 Arc

2 Arc 3 Arc

Multi-Arc Submerged Arc Welding

AC/DC 1000

Small diameter circumferential welds, pipe doubleending, storage tanks, seam welders

Large diameter circumferential welds [40”(1m) and up], spiral pipe mills, bridge girders, pressure vessels, wind mill towers.

Long straight welds, pipe mills, panel lines.

Single Arc

Tandem Arc

Multiple Arcs (3 to 5)

Lead Arc — DC+ Deep Penetration

Trailing Arcs — AC Greater negative components produces greater deposition and a flattened bead shape

Variable Positive/Negative Proportions — Optimize Welding

Variable Frequency and Phase Relationship — Reduce Arc Blow

Arc Performance

The capabilities of the Power Wave AC/DC 1000™ in a multi-arc environment offer digital control over the critical welding variables for optimum performance whatever your needs require. As shown below, these digital controls can be used for each arc to provide unprecedented arc welding characteristics.

Productivity Comparison

The Power Wave AC/DC 1000 delivers optimized productivity through the ability to adjust phase relationships between the arcs. Multiple arcs can be tuned to work together rather than interfere with each other.

Productivity Improvement

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