Lincoln Electric POWER WAVE 11124, POWER WAVE 11226 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 operat io n on your part. DO

NOT IN ST ALL, OPERAT E OR
REP A I R THIS EQU I P MENT
WIT H O UT REA D I NG THI S
MAN U A L A N D THE SAFET Y
PRE CAUT IONS CON TAIN ED
THR O U GHOUT . And , mos t

importantly, think before you act
and be careful.

11124, 11226

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

IEC 60974-1

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

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

i

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.

Mar ‘95

ii

SAFETY

ii

ELE CTR IC 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. We ar 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
mu s t be pe r for m ed u n der el ect r ical ly ha z ard o us
con ditions (in damp locat ions 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,
elect rode reel, welding he ad, 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. N ev er simul ta neously to uch elec tr ically “ ho t” par ts 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. Weldin g may produce fum es and gases
hazardous to health. Avoid breathing these
fumes and gases . W he n w elding, 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

we l ding w i th el e ctr o des whic h r equi re spe c ial
ve n til atio n su c h as stain les s or ha rd fa cin g (see
in str uct ion s on con tai ner or MS DS) or o n le ad o r
cadmi um plate d steel and other metals or co atings
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 circum­st a nce s, ou tdoo rs, a r esp irat or m a y be re qui red .
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 o r d ea th . A lw ay s u se enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

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

equipment and the consumables to be used, including the
ma t eria l s afe t y dat a s heet ( M SDS ) a nd fol low yo u r
employer’s safety practices. MSDS forms are available from
yo u r wel d ing d ist r ibu t or o r from t he m a nuf a ctu r er.

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

Re m embe r th a t we l din g spa r ks an d ho t
materials from welding can easily go through small cracks
an d op ening s to adj ac ent are as. Av oid weldi ng n ear
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
Standar d Z49.1) and t he operating informati on 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
Co n tain ers a nd P i pin g Tha t Hav e Hel d Haz ardo us
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
incre ase the possibility of the welding cur rent pas sing
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. U se on l y co m pres sed ga s cy l ind e rs
containing the correct shielding gas for the
pr o cess u s ed and pr ope r ly ope r ati n g
re g ulat ors d esig ned f o r th e ga s an d

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

7.b. Alw ay s k ee p cylinders in an u pr ig ht position securel y
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. R ea d an d f oll ow the in struc tions on com press ed 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 acco rdance with the U.S. Nation al
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

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.

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

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.

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.

v

SAFETY

v

vi

SAFETY

vi

TThhaannkk YYoouu

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 customer’s 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

________________________________________________________________________________

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

________________________________________________________________________________

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

________________________________________________________________________

ix

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

________________________________________________________________________

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

________________________________________________________________________

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

________________________________________________________________________

ix

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

RMS

V

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

C/UL

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

TYPE 90°C

COPPER WIRE

CONDUIT

AWG (mm

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

3

2

)

COPPER GROUNDING

IN

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)

2

)

DEPTH

33 in

838 mm

33 in

838 mm

1

TIME-DELAY FUSE

OR BREAKER

AMPS

100

90
90
80
70

WEIGHT

600 lbs.

272 kg.

650 lbs.

296 kg.

2

OPERATING TEMPERATURE RANGE

32°F to 104°F(0°C to 40°C)

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.

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.

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

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

XA

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

S26047

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

VOLTAGE=440-460V

'A'

A

500V

U / L1

V / L2

CR1

W / L3

INPUT SUPPLY CONNECTION DIAGRAM

550-575V

ELECTRIC

SHOCK

CAN KILL

WARNING

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

440-460V

VOLTAGE=500V

'A'

500V

550-575V

440-460V

VOLTAGE=550-575V

'A'

500V
550-575V

440-460V

VOLTAGE=380-415V

'A'

500V
550-575V

440-460V

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

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

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.

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

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 ‘A’) 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")

POWER WAVE® AC/DC 1000

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 arc’s "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 arc’s 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

4

Tandem Arc

4

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

1

1

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

2

1

1

2

1

2,4

1

1

1

2

2

2

2

2

2

2,4

2

3

1

3

2

3

3

2

3

---

1

PLC (w/ User

Interface)

DeviceNet Cables

and Accessories

System Interface

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.

---

---

---

---

---

4

1

Cables, Tees,

and

---

Terminators

as required

per Triple Arc

Connection

Diagram

2

1

2

2

2

1

2

3

POWER WAVE® AC/DC 1000

4

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
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

Wire Feeder (14 Pin)

A

rclink (5 Pin)

Arclink Connection

K

2362-1

Wire Reel
and Mounting

Work Piece

K

231-XXX

Head

* Work Cable(s)

* Electrode Cable(s)

K1785-XX
Wire Feeder
Control Cable

K1543-XX
Arclink Control Cable

Work Sense
Lead (21)

Electrode Sense
Lead (67)

67 Lead

21 Lead

14 Pin Connector

Flux Hopper
C

onnection

T

ravel Carriage

Connection

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

Work Studs

E

lectrode Studs

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

INSTALLATION

A-7

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)

(1)

POWER WAVE® AC/DC 1000

A-9

AA

RR

CC

22

AA

RR

CC

11

AA

RR

CC

11

A

A

R

R

CC

22

AA

RR

CC

11

AA

RR

CC

22

A

A

RR

CC

11

AA

RR

CC

22

SS

Y

Y

SS

TT

EE

MM

II

NN

TT

EE

RR

FF

AA

CC

EE

Master Input (S12)
Connects to System

Interface

Arclink Connection

21 Lead

67 Lead

* Work Cables

K1785-XX
Wire Feeder

Control Cabl

es

K1795-XX Cables

* Electrode Cables

Arc

link (5 Pin)

Wire Feeder
(

14 Pin)

K2282-1

K

236

2-1

Head

K

231-

XXX

Work Piece

14 Pin Connector

Work Studs

Electrode Studs

Arc

lin

k Out put

Work Sense
Lead (21)

Electrod

e
Sense
Lead (67)

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

K15

43-XX

Arc

lin

k Contro

l Ca

bl

es

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

Arc

link Input

Wir

e Reel

and Mo

untings

Flux Hopper
Connection

Travel Carr

iage

Connection

INSTALLATION

A-9

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)

(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

AA

RR

CC

11

AA

RR

CC

2

2

AA

RR

CC

22

AA

RR

CC

33

AA

RR

CC

11

AA

RR

CC

3

3

AA

RR

CC

11

AA

RR

CC

22

AA

RR

CC

33

SS

YY

SS

TT

EE

MM

II

NN

TT

EE

RR

FF

A

A

CC

EE

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

67 Lead

21 Lead

14 Pin Co

nnector

* Work Cables

Work P

iece

Work

S

ense L

eads (2

1)

* E

lectrod

e Cables

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

Head

K

231-

XXX

DeviceNet Cable Network

K179

5-XX Cabl

es

K

154

3-XX

Arclink Co

ntrol Cab

le

K1785-

XX

Wire Feeder

Control Cables

Arclink Input

Wir

e Feeder

(14 Pin)

Arclink (5

P

in)

Work Stu

ds

Electrod

e Studs

Wire Reel

and Mountings

PLC Contro

ller

E

lectrod

e Sense L

ead (6

7)

Master Input (S1

2)

Connects to System

Interface

K2282-1

User Interface

DeviceNet

Device

Net

(5 Pin)

INSTALLATION

A-11

POWER WAVE® AC/DC 1000

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)

(1)

(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

MM

AA

SS

TT

EE

RR

SS

LL

AA

VV

EE

K

179

5-XX C

ables

Connection Diagram - Parallel

Machines

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

Connect additional

SLAVE

machines as required to reach
desired capacity.

Note: Each arc is limited to 5

SLAVE machines per MASTER

(6 machines total)

S

12 (Input)

S13 (Output)

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

E

thernet

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

Weld Manager and

SubarcCellConfig

software utilities.

C

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

*

Electrode

Cables

* Work Cables

Work

E

lectrode

Front view o

f

machines

Rea

r view of machines

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

Ethernet S

witch

INSTALLATION

A-13

POWER WAVE® AC/DC 1000