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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

IEC 60974-1

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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

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

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

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

The Above For Gasoline Engines

FOR ENGINE powered equipment.

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

____________________________________________________

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

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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.

____________________________________________________

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

Page 3

SAFETY

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

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

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SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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

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

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

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

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

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

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

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

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.

Page 6

SAFETY

Page 7

SAFETY

Page 8

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.

Page 9

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

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Page 10

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

________________________________________________________________________

Page 11

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

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 WIRE

CONDUIT

AWG (mm

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)

Page 12

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

Page 13

A-3

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'

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

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

Page 14

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

Page 15

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

Page 16

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

Page 17

A-7

Wire Feeder (14 Pin)

rclink (5 Pin)

Arclink Connection

2362-1

Wire Reel and Mounting

Work Piece

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

ravel Carriage

Connection

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

Work Studs

lectrode Studs

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

INSTALLATION

A-7

POWER WAVE® AC/DC 1000

Page 18

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

Page 19

A-9

Master Input (S12) Connects to System

Interface

Arclink Connection

21 Lead

67 Lead

* Work Cables

K1785-XX Wire Feeder

Control Cabl

K1795-XX Cables

* Electrode Cables

Arc

link (5 Pin)

Wire Feeder (

14 Pin)

K2282-1

236

2-1

Head

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

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

Page 20

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

Page 21

A-11

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

67 Lead

21 Lead

14 Pin Co

nnector

* Work Cables

Work P

iece

Work

ense L

eads (2

* E

lectrod

e Cables

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

Head

231-

XXX

DeviceNet Cable Network

K179

5-XX Cabl

154

3-XX

Arclink Co

ntrol Cab

K1785-

Wire Feeder

Control Cables

Arclink Input

Wir

e Feeder

(14 Pin)

Arclink (5

in)

Work Stu

Electrod

e Studs

Wire Reel

and Mountings

PLC Contro

ller

lectrod

e Sense L

ead (6

Master Input (S1

Connects to System

Interface

K2282-1

User Interface

DeviceNet

Device

Net

(5 Pin)

INSTALLATION

A-11

POWER WAVE® AC/DC 1000

Page 22

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

Page 23

A-13

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)

12 (Input)

S13 (Output)

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

thernet

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

Weld Manager and

SubarcCellConfig

software utilities.

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

Electrode

Cables

* Work Cables

Work

lectrode

Front view o

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

Page 24

A-14

INSTALLATION

STEP BY STEP INSTALLATION CHECKLIST

EXTRA CAPACITY PARALLEL CONNECTION

(as shown in the Connection Diagram "Parallel Machines”) Follow all steps of Single, Tandem, or Triple Arc checklists. Be sure input power is disconnected prior to following the remaining steps. Control Cable Connections:

PF-10S Connections:

Each PF-10S must be connected to the Master power source of its associated arc.

PF-10A Controlled Systems:

Each PF-10A Controller must be connected to the Master power source of its arc via a K1543-xx ArcLink Control Cable (5 pin), but should not be connected to the Slave(s).

In a multi-arc system, the System Interface must also be connected to the ARC #1 Master power source via a K1543-xx ArcLink Control Cable (5 pin).

A-14

DeviceNet PLC Controlled Systems:

Only the Master power source of each arc should be connected to the PLC Controller via the DeviceNet network.

In a multi-arc system, the System Interface must connected to the PLC via the DeviceNet network. It must also be connected to the ARC #1 Master power source via a K1543-xx ArcLink Control Cable (5 pin).

Connect K1795-xx System Control Cables (22 pin) between the Master and Slaves of each arc grouping per the Parallel Machines Connection Diagram.

Connect / Install welding cables per the recommended "Output Cable Guidelines" and the "Parallel Machines Connection Diagram" for each arc grouping.

Configure / Install sense leads (the sense lead configuration of all machines in a given parallel arc grouping must be the same).

Open Power Wave front panels and configure DIP switch settings per "Internal Controls" section. Connect Power Wave to LAN (Local Area Network). See "Connection Between Power Source and Ethernet

Network." Connect input power to Power Waves per recommended guidelines. Turn on Power Waves. Configure network settings using Weld Manager software utility (follow instructions provided). Run the Submerged Arc Cell Configuration software utility to configure the Master / Slave relationships of

each arc grouping (follow instructions provided).

POWER WAVE® AC/DC 1000

Page 25

A-15

WORK PIECE

COMMON CONNECTION

(LOCAT ED CLOSE TO

POWER SOUR

CES)

Common Connection Diagram

INSTALLATION

A-15

ELECTRODE AND WORK CONNECTIONS

General Guidelines

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

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

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

Note: Excessive heat in the weld circuit indicates

undersized cables and/or bad connections.

For parallel applications with excessive electrode cable lengths, a common bus connection should be used. The common electrode connection serves to minimize voltage drops associated with resistive losses in the electrode path. It should be made of copper, and located as close as possible to the power sources. (See "Connection Diagram – Parallel Machines")

Work Connections

Connect a work lead of sufficient size and length (Per Table 1) between the "work" stud (located beneath the spring loaded output cover on the top, front of the machine) and the work piece. For convenience, the work lead can be routed along the left cable tray, and out the back of the machine. Be sure the connection to the work makes tight metal-to-metal electrical contact.

For parallel and/or multiple arc applications with excessive ground path lengths, a common work connection bus should be used. The common work connection serves to minimize voltage drops associated with resistive losses in the ground paths. It should be made out of copper, and located as close as possible to the power sources (See Common Connection Diagram).

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

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

• Always weld in a direction away from the work

(ground) connection.

Total Cable Length

Electrode and Work

0 (0) to 250 (76.2) 0 (0) to 250 (76.2)

Electrode Connections

Connect an electrode cable of sufficient size and length (Per Table A.1) to the "electrode" stud on the power source (located behind the cover plate on the lower left side). For convenience, the cable can be routed down through the two holes in the left cable tray before being connected to the output terminals. Connect the other end of the electrode cable to the wire drive feed plate on the wire feeder. Be sure the connection to the feed plate makes tight metal-tometal electrical contact.

TABLE A.1 - Output Cable Guidelines

ft (m)

Combined

Duty Cycle

80%

100%

Number of

Parallel Cables

2 3

Cable Size

Copper

4/0 (120 mm

3/0 (95 mm

)

POWER WAVE® AC/DC 1000

Page 26

A-16

POWER WAVE

FIGURE A.2

WORK

INSTALLATION

CABLE INDUCTANCE, AND ITS EFFECTS ON WELDING

Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (see Figure A.1 below). To minimize inductance always use the appropriate size cables, and whenever possible, run the electrode and work cables in close proximity to one another to minimize the loop area. Since the most significant factor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long work piece lengths, a sliding ground should be considered to keep the total welding loop length as short as possible.

REMOTE SENSE LEAD CONNECTIONS

A-16

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the wire feeder control cable (K1785) and accessible at the wire drive. It should always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured through software.

Work Voltage Sensing

For most applications the use of a remote work voltage sense lead is recommended. The Power Wave AC/DC 1000 is shipped from the factory with the remote work voltage sense lead enabled. It must be attached to the work as close to the weld as practical, but out of the weld current path. For more information regarding the placement of remote work voltage sense leads, see the section entitled "Voltage Sensing Considerations for Multiple Arc Systems." The remote WORK sense lead (21) can be accessed at one of two locations. Either at the wire drive via the wire feeder control cable (K1785), or at the four-pin WORK sense lead connector located under the spring loaded output cover. Whenever possible, use the WORK sense lead that is built into wire feeder control cable (K1785) since it is closely coupled with the ELECTRODE sense lead and will tend to be more immune to electrical noise. If it is not possible to sense the WORK voltage near the feeder, the four-pin WORK sense lead connector at the power source should be used (a plug and pigtail assembly is provided for this purpose).

Voltage Sensing Overview

The best arc performance occurs when the Power Wave AC/DC 1000 has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder, and have a dramatic effect on performance. To counteract this negative effect, remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board.

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

CAUTION

If the remote voltage sensing is enabled but the sense leads are missing, improperly connected, or if the electrode polarity switch is improperly configured extremely high welding outputs may occur.

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

POWER WAVE® AC/DC 1000

CAUTION

Never connect the WORK sense lead at two different locations.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electro des with yo ur s kin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

Some simplified applications may perform adequately by sensing the work voltage directly at the WORK STUD without the use of a remote work voltage sense lead. If a remote work voltage sense lead is not used, it must be disabled as follows:

1. Turn off power to the power source at the disconnect switch.

2. Remove the front cover from the power source.

Page 27

A-17

1 2 3 4 5 6 7 8

O N

DIRECTION OF TRAVEL

CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD.

CONNECT ALL SENSE LEADS AT THE END OF THE WELD.

c. Locate the 8-position DIP switch on the control

board and look for switch 8 of the DIP switch.

INSTALLATION

A-17

VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS

d. Using a pencil or other small object, slide the

switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.

e. Replace the cover and screws. The PC board will

read the switch at power up, and configure the work voltage sense lead appropriately.

Voltage Sensing for "Slave" machines

If "Slave" machines are configured to use remote voltage sensing they receive these signals directly from the "Master" machine. The K1795 control cable used for parallel connection of machines contains both the ELECTRODE sense lead (67) and the WORK sense lead (21). No other external sense lead connections are required for "Slave" machines.

NOTE: All of the machines of a given arc group

(both Master and Slaves) must have their work voltage sensing configured identically. All must either use a remote lead or sense directly from the stud. For additional information see the "Work Voltage Sensing" section of this document.

FIGURE A.2

Special care must be taken when more than one arc is welding simultaneously on a single part. Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads, but they are strongly recommended.

If Sense Leads ARE NOT Used:

• Avoid common current paths. Current from adja-

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

If Sense Leads ARE Used:

• Position the sense leads out of the path of the

weld current. Especially any current paths com-

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

• For longitudinal applications, connect all work leads at one end of the weldment, and all of the work voltage sense leads at the opposite end of the weldment. Perform welding in the direction away from the work leads and toward the sense leads.

(See Figure A.2)

POWER WAVE® AC/DC 1000

Page 28

A-18

POWER SOURCE #2

POWER SOURCE #1

POWER SOURCE #2

POWER SOURCE #1

INSTALLATION

A-18

• For circumferential applications, connect all work leads on one side of the weld joint, and all of the work volt-

age sense leads on the opposite side, such that they are out of the current path.

POWER WAVE® AC/DC 1000

Page 29

A-19

INSTALLATION

A-19

CONTROL CABLE CONNECTIONS

General Guidelines

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

cables are specifically designed for the communication and power needs of the Power Wave / Power Feed systems. Most are designed to be connected end to end for ease of extension. However, it is recommended that the total length not exceed 100 feet (30.5 m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems). Always use the shortest length of control cable possible, and DO NOT coil excess cable.

Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables. These recommendations apply to all communication cables including optional DeviceNet and Ethernet connections.

COMMON EQUIPMENT CONNECTIONS

Connection Between Power Source and Power Feed 10S Series Wire feeder (K1785 - Control Cable). The 14-pin wire feeder control cable connects

the power source to the wire drive. If there is more than one power source per arc, it connects from the wire drive to the power source designated as the Master. It contains all of the necessary signals to drive the motor and monitor the arc, including the motor power, tachometer, and arc voltage feedback signals. The wire feeder connection on the Power Wave AC/DC 1000 is located under the spring loaded output cover on the case front. The control cable is keyed and polarized to prevent improper connection. For convenience, the control cables can be routed along the right channel of the Power Wave, out the back, and to the wire feeder. Control cables SHOULD NOT be routed through the same (left) channel as the welding cables.

Connection Between Power Source and Power Feed 10A Controller (K1543 – ArcLink Control Cable). Single and tandem arc systems are typically

controlled by a Power Feed 10A Controller (K2362-1). In a tandem, or multi-arc system, each arc requires its own dedicated Power Feed 10A (PF-10A).

The 5-pin ArcLink control cable connects the power source to the PF-10A. If there is more than one power source per arc, it connects from the PF-10A to the power source designated as the Master for that arc. The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The ArcLink connection on the Power Wave AC/DC 1000 is located under the spring loaded output cover on the case front. The control cable is keyed and polarized to prevent improper connection. For convenience, the control cables can be routed along the right channel of the Power Wave, out the back, and to the PF-10A. Control cables SHOULD NOT be routed through the same (left) channel as the welding cables.

In multiple arc systems equipped with a Power Wave System Interface (K2282-1), and controlled by PF-10A controllers, the system interface must be connected to the ArcLink network of the ARC1 Master power source. See the "Tandem Arc Connection Diagram" for detailed information.

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

is sometimes more practical and cost effective to use a custom PLC interface to control a multi-arc system (refer to the "DeviceNet Configuration" section for interface information). The Power Wave AC/DC 1000 is equipped with a 5-pin DeviceNet mini style receptacle for this purpose. The receptacle is located under the spring loaded output cover on the case front. The DeviceNet cable is keyed and polarized to prevent improper connection. For convenience, it can be routed along the right channel of the Power Wave, and out the back. DeviceNet cables SHOULD NOT be routed through the same (left) channel as the welding cables.

In a typical system, a DeviceNet connection is made between the master power source of each arc, and the PLC interface. When a Power Wave System Interface (K2282-1) is used to synchronize the arcs, it must also be connected to the DeviceNet network. For best results, route DeviceNet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field. DeviceNet cables must be sourced locally by the customer. For additional guidelines refer to the "DeviceNet Cable Planning and Installation Manual" (Allen Bradley publication DN-6.7.2).

POWER WAVE® AC/DC 1000

Page 30

A-20

INSTALLATION

A-20

Connections Between Multiple Power Sources Run in Parallel (K1795 - Control Cable). To increase

the output capacity for a given arc, the output studs of multiple Power Wave AC/DC 1000 machines can be connected in parallel. The parallel machines utilize a master/slave control scheme to distribute the load and coordinate AC switching. The 22 pin parallel control cable contains all of the necessary signals to keep the machine outputs synchronized, including polarity, ready, kill, and arc voltage feedback signals. The cable connects between the Master/Slave I/O connectors (S12 & S13) located on the rear of the Power Wave AC/DC 1000. The input connector (S12) is located on the lower left side of the case back (as viewed from the rear), and the output connector (S13) is located on the lower right side. The output connector (S13) on the master connects to the input connector (S12) on the slave. If needed the output connector on the slave machine can be used to connect to the input connector of another slave machine in a daisy chain fashion. This connection scheme can be repeated as required until the desired output capacity is achieved. The system is currently limited to a maximum of 5 slaves per master, or a total of 6 machines per arc.

NOTE: In addition to the parallel control cable, parallel

connected machines also require an Ethernet connection to share critical weld parameter information. For more information refer to the "Connections Between a Power Source and Ethernet Network" section of this document.

NOTE: See Ethernet Configuration section for addi-

tional information.

Connections Between a Power Source and System Interface (K1795 - Control Cable). When

multiple arcs need to be synchronized, a Power Wave System Interface (K2282-1) is required. The system interface provides a dedicated synchronization signal for frequency and balance to each of the four ARC (a.k.a. PHASE) receptacles. The synchronization signals for ARC1 through ARC4 can be phase shifted with respect to one another to reduce the effects of "arc blow" and other welding related issues. The individual synchronization signals are relayed to the master machine of their corresponding arc via a 22 pin control cable. The control cable(s) connect between the individual ARC receptacles on the system interface, and the Master/Slave input connector on the master of each corresponding arc group. The Master/Slave input connector (S12) is located on the lower left side of the case back (as viewed from the rear) of the Power Wave AC/DC 1000.

NOTE: In addition to the 22-pin arc synchronization

cables, the system interface also requires a connection to the system controller either via ArcLink for Power Feed 10A controlled systems (see "Connection Between Power Source and Power Feed 10A Controller" ), or via DeviceNet for PLC controlled systems (see "Connection Between a Power Source and Optional DeviceNet PLC Controller").

Connection Between Power Source and Ethernet Network. Ethernet connections are required for sys-

tems with parallel connected power sources (more than one power source per arc), or to utilize the tools provided in the Power Wave Submerged Arc Utilities software package. To facilitate this, the Power Wave AC/DC 1000 is equipped with an RJ-45 Ethernet connector, which is located under the spring loaded output cover. External Ethernet equipment (cables, switches, etc.) must be supplied by the customer. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid conductor, shielded cat 5 cable, with a drain. The drain should be grounded at the source. The use of cat 5+, cat 5E, cat 6 or stranded cable is not recommended. For best results, route Ethernet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field. For additional guidelines refer to ISO/IEC 11801. Failure to follow these recommendations can result in an Ethernet connection failure during welding.

Connections Between a Power Source and Local PC (RS-232 – Null Modem Cable). For diagnostic

and set up purposes it is sometimes necessary to connect the power source directly to a PC (personal computer). The Power Wave AC/DC 1000 is equipped with an RS-232 DB-25 style serial connector for this purpose. It is located under the spring loaded output cover on the case front. RS-232 cables must be supplied by the user (Radio Shack part # 26-269; Note: USB port adapter - part #26-183 - is also required for PC’s equipped with USB instead of a serial port). For best results, route the RS-232 cable away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field.

POWER WAVE® AC/DC 1000

Page 31

A-21

123

9 10

+15 VDC for Trigger Group

Trigger Input

Dual Procedure Input

4 Step Input

+15 VDC for Cold Inch Group

Cold Inch Forward

Cold Inch Reverse

Gas Purge Input

+15 for shutdown group

Shutdown1 input

Shutdown2 input (Water Fault)

Reserved for future use

INSTALLATION

A-21

EXTERNAL I/O CONNECTOR

The Power Wave AC/DC 1000 is equipped with a terminal strip for making simple input signal connections. (See Figure A.2a) The terminal strip is located underneath the spring-loaded cover, and divided into three groups:

FIGURE A.2a

Trigger group, Cold Inch Group and Shutdown Group. When the Power Wave AC/DC 1000 is controlled via DeviceNet, the Trigger and Cold Inch Groups can interfere with the welding sequence and should not be used.

All inputs use "normally open" logic except the shutdown group. The shutdown inputs use "normally closed" logic, and are always enabled. Shutdown2 is typically used for signaling low flow in the water cooler. Unused shutdowns must be tied to the +15V supply for the shutdown group. Machines are shipped from the factory with jumpers installed on both shutdown inputs. (See Figure A.3)

RECEPTACLE SPECIFICATION

Table A.2 Output Arclink Receptacle S1 (5 pin – MS style)

PIN Lead # Function

A 53 Arclink L B 54 Arclink H C 67A Electrode Voltage Sense D 52 Ground(0v) E 51 +40vdc

Table A.3 Voltage Sense Receptacle S2 (4 pin – Circular Plastic)

PIN Lead # Function

3 21A Work Voltage Sense

Table A.4 RS232 Connector S3 (DB-25 style)

PIN Lead # Function

2 253 RS232 Receive 3 254 RS232 Transmit 4# S3 Pin5 5# S3 Pin4 6 ## S3 Pin20

20 ## S3 Pin6

7 251 RS232 Common

Notes:

1. Activating the Trigger or Cold Inch group inputs on a system without a user interface or other means of configuring the Weld Sequencer will result in default values for Weld Mode, WFS and Work point settings.

2. Trigger and Cold Inch group inputs may be redefined as "Weld Profile Selections" by Production Monitoring software (see Production Monitoring Literature for details)

3. On later machines, pin 12 has been redefined as a gear ratio selection input. See “Setting the Wire Drive Gear Ratio” for further information.

FIGURE A.3

Table A.5 DeviceNet Connector S5 (5 pin - "mini" style)

PIN Lead # Function

2 894 +24vdc DeviceNet 3 893 Common DeviceNet 4 892 DeviceNet H 5 891 DeviceNet L

Table A.6 Wire Drive Interface Receptacle S6 (14 pin – MS style)

Pin Function

A Motor "+" B Motor "-" C +40 VDC for solenoid D Solenoid input E Tach 2A differential signal F Single Tach Input G +15 VDC Tach H Tach common I Work voltage sense lead 21 J Electrode voltage sense lead 67 K Tach 1A differential signal L Tach 1B differential signal M Tach 2B differential signal N Electrode voltage sense lead 67

POWER WAVE® AC/DC 1000

Page 32

A-22

Table A.7 External I/O S7 (12 pin – terminal block)

PIN Lead # Function

1 851 +15vdc for Trigger group 2 852 Trigger input 3 853 Dual procedure input 4 854 4 step input (Disabled as of S25564-19) 5 855 +15vdc for cold inch group (Disabled as of S25564-19) 6 856 cold inch forward 7 857 cold inch reverse 8 858 gas purge input

9 859 +15vdc for shutdown group 10 860 shutdown1 input 11 861 shutdown2 input 12 862 input B

Table A.8 Master / Slave I/O and System Interface Output Receptacles (22 Pin – MS bayonet style)

Pin Master / Slave Input Master / Slave Output Optional System Interface

(S12) (S13) (ARC1, ARC2, ARC3, ARC4) A Reserved for future use Reserved for future use --B Reserved for future use Reserved for future use --C Sync In Reserved for future use Sync Out D Sync In Reserved for future use Sync Out E Ready In Ready In --F Ready In Ready In --G Polarity Out Polarity Out --H Polarity Out Polarity Out --I Ground --- --J Reserved for future use Reserved for future use --K Reserved for future use Reserved for future use --L +40v (COM) Reserved for future use --M +40v ("+") Reserved for future use --N Reserved for future use Reserved for future use --P Reserved for future use Reserved for future use --R Reserved for future use Reserved for future use --S Reserved for future use Reserved for future use --T Drain (ethernet) Drain (ethernet) --U Kill Out Kill Out --V Kill Out Kill Out --W Work voltage sensing (21) Work voltage sensing (21) --X Electrode Voltage Sensing (67) Electrode Voltage Sensing (67) ---

INSTALLATION

A-22

Table A.9 Ethernet Connector S9 (8 pin – RJ-45 Style Connector / cat 5 Cable)

PIN Function

1 Transmit + 2 Transmit 3 Receive + 4 --5 --6 Receive 7 --8 ---

POWER WAVE® AC/DC 1000

Page 33

A-23

S1S1

FEFEEEDHEDHEAADD P.P.CC.. BOA BOARRDD

EXEXTTEERRNNAL I/OAL I/O CCOONNNNEECTORCTOR

JUMPER PIN 5

UMPER PIN 12

INSTALLATION

WIRE DRIVE GEAR RATIO SETTING

Changing the wirefeeder gear ratio requires a gear change in the wire drive, and a configuration change at the power source. The Power Wave AC/DC 1000 can be configured to support up to 4 unique gear ratios. The gear ratio configuration is selected via a DIP switch on the Feed Head PC Board and a jumper on the External I/O connector (S7 - located beneath the spring loaded output cover on the top, front of the machine).

As shipped from the factory, the low speed (high torque) gear is installed. To change the gear ratio of the feeder, see the Wirefeeder Instruction Manual. To achieve the correct speed, the power source must also be configured for the actual gear ratio installed in the wire drive per the instructions below:

TABLE A.9a

Ratio 142:1

95:1 57:1*

Reserved*

(Presently57:1)

Dip Switch #8

(Feed Head PCB - Bank S1)

OFF

External I/O Jumper

(Pin 5 to Pin 12)

* These Gear Ratios options are enabled in

S25564-11 and later Feed Head software.

ETHERNET CONFIGURATION

A-23

NO NO

YES YES

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

WARNING

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

(See Figure A.3a)

1. Turn off power to the power source at the disconnect switch. All configuration changes must be made with the power OFF.

2. Access the Feed Head board and External I/O connector to configure the power source per table A.9a.

3. Replace the cover and screws as required. The Feed Head PC board will "read" the new configuration at power up, and automatically adjust all control parameters for the speed range selected.

FIGURE A.3a

Ethernet capability is provided for data monitoring, or to enable parallel machine operation. To utilize these features the network settings of each Power Wave AC/DC 1000 must be properly configured. This is accomplished through the use of the Weld Manager software utility. Follow the instructions provided with the utility to properly configure the Ethernet address.

When used in a system with parallel machines, the Submerged Arc Cell Configuration software utility must be used to map the master/slave relationships within and between the different arc groups. This utility allows the user to configure the system by selecting from a list of master and slave machines (as determined by their individual dip switch settings).

NOTE: Each machine must be configured as either a

Master or Slave via the dip switches on the Ethernet PC Board. Furthermore, Master machines must be configured for either internal synchronization (stand alone applications), or external synchronization (multiple arc applications utilizing a Power Wave System Interface). See the "Internal Controls" section of this document.

POWER WAVE® AC/DC 1000

Page 34

A-24

CONTROL P.C. BOARD

ETHERNET P.C. BOARD

FEEDHEAD P.C. BOARD

INSTALLATION

DEVICENET CONFIGURATION

For systems controlled via DeviceNet, The MAC ID and baud rate must be properly configured (see the Internal Controls section of this document). Other information regarding basic system integration of the Power Wave AC/DC 1000 with a DeviceNet PLC is provided in the DeviceNet Interface Specification (part of the Power Wave Submerged Arc Utilities software package available on CD from the Lincoln Electric

Company).

A-24

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

INTERNAL CONTROLS

INTERNAL CONTROLS DESCRIPTION

(See figure A.4) The P.C. Boards located behind the Power Wave

AC/DC 1000 front access panel are equipped with DIP switches for custom configuration. To access the DIP switches:

FIGURE A.4

1. Turn off power at the disconnect switch.

2. Remove the screws securing the front access panel.

3. Open the access panel, allowing the weight of the panel to be carried by the hinge tab at the bottom. Make sure the weight of the access panel is supported by the hinge tabs, not the wiring harness.

4. Adjust the DIP switches as necessary (see infor-

mation below).

5. Replace the panel and screws, and restore power.

POWER WAVE® AC/DC 1000

Page 35

A-25

1 2 3 4 5 6 7 8

O N

{

OBJECT INSTANCE

(*DEFAULT SETTINGS SHOWN)

GROUP SELECT

AUTO MAP

WORK VOLTAGE SENSE ENABLE

1 2 3 4 5 6 7 8

O N

{

OBJECT INSTANCE

GROUP SELECT

LECTRODE

POLARITY

SPEED RANGE

(*DEFAULT SETTINGS SHOWN)

1 2 3 4 5 6 7 8

O N

{

OBJECT INSTANCE

GROUP SELECT

RESERVED

(*DEFAULT SETTINGS SHOWN)

1 2 3 4 5 6 7 8

O N

{

BAUD RATE (125K)

DEVICENET MAC ID (62)

(*DEFAULT SETTINGS SHOWN)

CONTROL BOARD DIP SWITCH (S1):

BANK S1

Switch Description

1 Object Instance LSB* (see table A.14) 2 Object Instance MSB** (see table A.14) 3 Equipment Group 1 Select (default OFF) 4 Equipment Group 2 Select (default OFF) 5 Equipment Group 3 Select (default OFF) 6 Equipment Group 4 Select (default OFF)

Arclink Object Auto mapping enabled (default)

off

7 8

*LSB - Least Significant Bit **MSB - Most Significant Bit

Arclink Object Auto mapping disabled

Work sense lead not connected

off

Work sense lead connected (default)

FEED HEAD BOARD DIP SWITCH (S1):

BANK S1

Switch Description

1 Object Instance LSB (see table A.14) 2 Object Instance MSB (see table A.14) 3 Equipment Group 1 Select (default OFF) 4 Equipment Group 2 Select (default OFF) 5 Equipment Group 3 Select (default OFF) 6 Equipment Group 4 Select (default OFF)

Electrode polarity positive (default)

off

Notes:

Electrode polarity negative

Low speed gear 142:1 (default)

off

High speed gear 95:1

High speed gear 57:1

off

Reserved (presently configured for 57:1)

1. No jumper installed on External I/O connector (pin 5 to pin 12).

2. Jumper installed on External I/O connector (pin 5 to pin 12).

INSTALLATION

TABLE A.10

Arclink configuration

Default setting Requires manual configuration Used for configuring work sense lead ( See section A )

TABLE A.11

ArcLink Configuration

Must be OFF for Power Wave AC/DC 1000 Gear ratio configuration.

These two options available in S25564-11 and later software.

}

A-25

Comments

ETHERNET BOARD DIP SWITCHES (S1, S2):

Bank S1 – ArcLink Set-up

Switch Description

Bank S2 – DeviceNet Set-up

Switch

1 2

DeviceNet Baud Rate see Table A.15

Description

3 4 5 6

DeviceNet Mac ID

see Table A.16 7 8

POWER WAVE® AC/DC 1000

TABLE A.12

Comments

Used for Arclink Configuration

TABLE A.13

Comments

Used for DeviceNet Configuration

Page 36

A-26

INSTALLATION

TABLE A.14

OBJECT INSTANCE

switch 2 switch 1 Instance

off off 0(default) off on 1 on off 2 on on 3

A-26

TABLE A.15

DeviceNet Baud Rate:

Switch 1 Switch 2 Baud Rate

off off 125K (default) on off 250K off on 500K on on Programmable value.

POWER WAVE® AC/DC 1000

Page 37

A-27

INSTALLATION

DEVICENET MAC ID

TABLE A.16

Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3

0 0 0 0 0 0 0 Software Selectable 1 000001 2000010 3000011 4000100 5000101 6000110 7000111 8001000 9001001 10 001010 11 001011 12 001100 13 001101 14 001110 15 001111 16 010000 17 010001 18 010010 19 010011 20 010100 21 010101 22 010110 23 010111 24 011000 25 011001 26 011010 27 011011 28 011100 29 011101 30 011110 31 011111 32 100000 33 100001 34 100010 35 100011 36 100100 37 100101 38 100110 39 100111 40 101000 41 101001 42 101010 43 101011 44 101100 45 101101 46 101110 47 101111 48 110000 49 110001 50 110010 51 110011 52 110100 53 110101 54 110110 55 110111 56 111000 57 111001 58 111010 59 111011 60 111100 61 111101 62 111110 Default Setting

A-27

POWER WAVE® AC/DC 1000

Page 38

A-28

1 2 3 4 5 6 7 8

O N

1 2 3 4 5 6 7 8

O N

1 2 3 4 5 6 7 8

O N

1 2 3 4 5 6 7 8

O N

1 2 3 4 5 6 7 8

O N

1 2 3 4 5 6 7 8

O N

INSTALLATION

ETHERNET BOARD DIP SWITCHES (S3, S4):

MASTER

Internal Synchronization Signal

(for systems without K2282-1 System Interface)

A-28

“BANK S4”

Master / Slave Config

MASTER

External Synchronization Signal

(for systems with K2282-1 System Interface)

“BANK S4”

Master / Slave Config

“BANK S3”

I / O Termination

(DEFAULT)

“BANK S3”

I / O Termination

“BANK S4”

Master / Slave Config

POWER WAVE® AC/DC 1000

SLAVE

“BANK S3”

I / O Termination

Page 39

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

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

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when feeding with gun trigger, the electrode and dr i ve me c h a n i sm ar e always electrically ene rgized and could remain energized several seconds after the welding ceases.

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

• Insulate yourself from the work and ground.

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

single knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

COMMON WELDING ABBREVIATIONS

SAW

• Submerged Arc Welding

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from

breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held com-

bustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning of this manual.

POWER WAVE® AC/DC 1000

Page 40

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

B-2

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

OPEN CIRCUIT

VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

POWER WAVE® AC/DC 1000

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

Page 41

B-3

OPERATION

B-3

PRODUCT SUMMARY

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

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

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

RECOMMENDED PROCESSES

The Power Wave AC/DC 1000 is designed for submerged arc welding (SAW). Due to its modular design the Power Wave AC/DC can operate on either single arc or multiple arc applications. Each machine is factory preprogrammed with multiple welding procedures to support all types of submerged arc welding. The Power Wave AC/DC 1000 carries an output rating of 1000 amps, 44 volts (at 100% duty cycle). If higher currents are required machines can be easily paralleled.

PROCESS LIMITATIONS

The Power Wave AC/DC 1000 is suitable only for the processes listed.

Do not use Power Wave AC/DC 1000 for pipe thawing.

Only the ArcLink Power Feed 10S series wire feeders and Power Feed 10A controller may be used in a standard system. Other Lincoln or non-Lincoln wire feeders can only be used with custom interfaces. The Power Wave AC/DC will support a maximum average output current of 1000 Amps at 100% Duty Cycle.

COMMON EQUIPMENT PACKAGES

Basic Package

K2344-1 or Power Wave AC/DC 1000 K2344-2

K2370-1 Power Feed 10S Head Wire Feeder K2362-1 Power Feed 10A Controller / User

Interface

K1543-xx Control Cable (5 pin – 5 pin) - power

source to controller.

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

power source to wire feeder.

Optional kits

K2282-1 System Interface - for Synchronizing

multiple arc applications.

K1795-xx Control Cable (22 pin – 22 pin) - for

paralleling / multiple arc applications.

K2312-1 Power Feed 10SF wire feeder (for fix-

ture builders).

K2311-1

K2444-1 CE, C-Tick Filter Kit

Power Feed 10SM Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5 wire feeder gear boxes).

RECOMMENDED EQUIPMENT

(See Installation Section)

EQUIPMENT LIMITATIONS

The Power Wave AC/DC 1000 is not to be used in outdoor environments.

Operating Temperature Range is 32°F to 104°F(0°C to +40°C).

POWER WAVE® AC/DC 1000

Page 42

B-4

OPERATION

B-4

CASE FRONT CONTROL DESCRIPTIONS

(See Figure B.4)

1. Power Switch: Controls input power to the Power

Wave

2. Status Lights: A two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the

Troubleshooting Section.

NOTE: The robotic PowerWaves’ status light will

flash green, for up to 15 seconds when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

3. Thermal Fault Light : A yellow light that comes on

when an over temperature situation occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is enabled.

FIGURE B.4

(See Figure B.5)

4. 10 Amp Wire Feeder Circuit Breaker: Protects 40

volt DC wire feeder power supply.

5. 115 VAC Auxiliary Power Circuit Breaker:

Protects case front receptacle auxiliary supply. (10 amps)

6. 21 Work Sense Lead Connector(4-Pin)

7. Arclink Connector (5-Pin)

8. DeviceNet Connector (5-Pin)

9. Work Output Studs

10. Electrode Output Studs

11. Auxiliary Output

12. Ethernet Connector (RJ-45)

13. Wire Feeder Connection (14-Pin)-Connects the

control cable between the power source and wire feeder.

14. External Input Connector

15. Serial Communication (RS-232)

POWER WAVE® AC/DC 1000

Page 43

B-5

OPERATION

FIGURE B.5

B-5

POWER WAVE® AC/DC 1000

Page 44

B-6

OPERATION

B-6

CASE REAR COMPONENTS DESCRIPTION (See Figure B.6)

1. Input Contactor: Connection point for incoming 3

Phase power (see "Recommended Input Wire and Fuse Size" chart in this document).

2. Case Ground: The frame of the welder must be grounded to earth at this terminal. See your local and national electrical codes for proper grounding methods.

3. Auxiliary Reconnect: Select proper tap based on input voltage.

4. CB3: Primary side protection for auxiliary transformer (T2).

5. CB4: Primary side protection for auxiliary transformer (T1).

6. Impeller Fan Technology

cooling.

7. Master/Slave Input (S12): Input connection for

paralleling machines, or multi-arc synchronization.

8. Master/Slave Output (S13): Output connection for paralleling machines.

provides superior

FIGURE B.6

9. AC Switch Assembly W/Impeller Fan

10. Optional CE Filter Assembly (not shown): CE

compliance filter connects in series with input connection. Available for K2344-2 only.

POWER-UP SEQUENCE

When power is applied to the Power Wave AC/DC 1000, the status lights will flash green, for up to 15 seconds. This is normal and indicates Power Wave AC/DC 1000 is performing a self test, and mapping (identifying) each component in the local ArcLink system. The status lights will also flash green as a result of a system reset or configuration change during operation. When the status lights become steady green the system is ready for normal operation.

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

POWER WAVE® AC/DC 1000

Page 45

B-7

Time

iti

Current

ega

ive

urr

Current

Output waveform variations made possible byWaveform Cont

rol T

echnology

Depending on the process, diffe

rent parts of

the output waveform and wi re feed

speed may be modulated at varying rates to achieve a smooth and sta

ble arc.

AC/DC Submerged Arc Process

requen

ulse

dth

Transi

tion

Rate

i/dT

OPERATION

B-7

DUTY CYCLE

The Power Wave AC/DC is capable of welding at a 100% duty cycle (continuous welding).

COMMON WELDING PROCEDURES

MAKING A WELD

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

OVERVIEW OF THE AC/DC SUBMERGED ARC PROCESS

The Power Wave AC/DC 1000 combines the advantages of AC and DC Submerged Arc Welding (SAW) into a single power source. The limiting factor of ACSAW welding has always been the time it takes to transition from positive to negative polarity. This lag through the zero crossing can cause arc instability, penetration, and deposition problems in certain applications. The Power Wave AC/DC 1000 utilizes the speed of an inverter based power source, and the flexibility of Waveform Control Technology™ to address this issue. By adjusting the Frequency, Wave Balance and Offset of the AC waveform the operator can now control the balance (relationship) between the penetration of DC positive and the deposition of DC negative while taking full advantage of the reduction in arc blow associated with AC.

FIGURE B.1

The steps for operating the Power Wave AC/DC 1000 will vary depending upon the user interface of the welding system. The flexibility of the Power Wave AC/DC 1000 lets the user customize operation for the best performance.

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

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

To make a weld, the Power Wave AC/DC 1000 needs to know the desired welding parameters. Waveform Control Technology ™ allows full customization of Strike, Run-in, Crater and other parameters for exacting performance.

POWER WAVE® AC/DC 1000

Page 46

B-8

USH

ULL

USH

ULL

USH

ULL

Lead Arc

Trail Arc

Positive Negative

Positive Positive

Negative Negative

Positive

Negative

Positive

Negative

Lead Arc

Trail Arc

PUSH

PULL

Extension Heating= Vir

Arc Length= Varc

Total Electrical Stick out V= Vir+Varc

MAINTAIN CONSTANT ARC LENGTH

AND

WIRE FEED SPEED VARIED

CURRENT HELD CONSTANT

AMPS

CONSTANT CURRENT (CC)

Extension Heating= Vir

Arc Length= Varc

Total Electrical Stick out V= Vir+Varc

MAINTAIN CONSTANT ARC LENGTH

AND

WIRE FEED SPEED HELD CONSTANT

CURRENT VARIED

AMPS

CONSTANT VOLTAGE (CV)

OPERATION

MULTIPLE ARC SYSTEM CONSIDERATIONS

Large scale SAW applications often employ multiple arcs to increase deposition rates. In multiple arc systems, magnetic forces created by like and opposing weld currents of adjacent arcs can result in arc interaction that can physically push or pull the arc columns together. To counteract this effect, the phase relationship between adjacent arcs can be adjusted to alternate and equalize the duration of magnetic push and pull forces. This is accomplished by the use of an optional K2282-1 Power Wave System Interface, which not only synchronizes the arcs, but also enables adjustment of the phase relationship between them. Ideally, the net result is a cancellation of the interacting forces.

FIGURE B.2

B-8

BASIC MODES OF OPERATION

CONSTANT CURRENT (CC)

• Operator presets Current and desired Voltage.

• The Power Source:

- Goal is to maintain a constant arc length.

- Drives a constant Current.

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

• Arc Length is proportional to Voltage.

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

CONSTANT VOLTAGE (CV)

• Operator presets Wire Feed Speed and desired Voltage

• The Power Source:

FIGURE B.3

- Goal is to maintain a constant arc length.

- Commands constant wire feed speed

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

• Arc Length is proportional to Voltage

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

CAUTION

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

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

POWER WAVE® AC/DC 1000

Page 47

B-9

Time

Output

eld Sequence adjustments made possible by

Waveform Control Technology

Weld sequence adjustments allow the operator to fine tune the start and finish

f each weld for superior performance.

Weld Sequence

Start (Strike)

Upslope

Weld

Crater (Burnback)

Downslope

OPERATION

B-9

WELD SEQUENCE:

The weld sequence defines the weld procedure from beginning to end. The Power Wave AC/DC 1000 not only provides adjustment of basic welding parameters, but also allows the operator to fine tune the start and finish of each weld for superior performance.

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

END OPTIONS

The Downslope, Crater, and Burnback parameters are used to define the end of the weld sequence.

• Downslope determines the amount of time it takes to ramp from the Weld parameters to the Crater parameters. The transition is linear and may be up or down depending on the relationship between the Weld and Crater settings.

• Crater parameters are typically used to fill the crater at the end of the weld, and include both time and output settings.

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

START OPTIONS

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

• Strike settings are valid from the beginning of the sequence (Trigger) until the arc is established. They control Run-in (speed at which the wire approaches the workpiece), and provide the power to establish the arc.

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

• Start values allow the arc to become stabilized once it is established.

- Extended Start times or improperly set parameters can result poor starting

RE-STRIKE TIMER

If the arc goes out for any reason (short circuit or open circuit), the Power Wave AC/DC 1000 will enter a Restrike state. During this state the system will automatically manipulate the WFS and output in an attempt to re-establish the arc. The Re-strike timer determines how long the system will attempt to re-establish the arc before it shuts down.

• Used to protect the welding system and/or work piece being welded.

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

• Upslope determines the amount of time it takes to ramp from the Start parameters to the Weld parameters. The transition is linear and may be up or down depending on the relationship between the Start and Weld settings.

POWER WAVE® AC/DC 1000

Page 48

B-10

-500

-1000

1000

Nominal Balance

Increased Balance

ore Penetration

ess Deposition

Decreased Balance

Less Penetration

More Deposition

Wave Balance

500

-500

-1000

1000

Use Frequency to fin e tune stability of

imbalanced waveform s and multipl e arc systems

Frequency

Increase

Decrease

500

-1000

000

Nominal Offset

Positive Offset

More Penetration

ess Deposition

Negative Offset

ess Penetration

More Deposition

DC Offse t

OPERATION

B-10

WELD PROCESS ADJUSTMENTS

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

AC ADJUSTMENTS

In addition to the basic weld parameters, there are a number of unique adjustments related to the AC waveform of the Power Wave AC/DC 1000. These adjustments enable the operator to balance the relationship between penetration and deposition to tailor the output for specific applications.

WAVE BALANCE

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

DC OFFSET

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

• Use Offset to control the penetration and deposition of a given process.

• Use Wave Balance to control the penetration and deposition of a given process.

FREQUENCY

• POWER WAVE AC/DC 1000 can produce Output Frequencies from 10 - 100Hz

• Use Frequency to fine tune stability

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

POWER WAVE® AC/DC 1000

Page 49

B-11

Phase Relations

hip

500

-500

Use Phase Relationship to minimize arc blow

in multip le arc systems.

(Balanced two arc system shown)

0°

(PULL)

90°

(PUSH/PULL)

180°

(PUSH)

BAD GOOD

BAD

ARC 1 ARC 2

Best results obtained by alternating and equalizing the duration of

magnetic forces between adjacent arcs.

OPERATION

MULTIPLE ARC AC ADJUSTMENTS FOR SYSTEMS EQUIPPED WITH K2282-1 SYSTEM INTERFACE

Phase

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

Recommendations:

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

ARC 1 ARC2 ARC3 ARC 4 2 Arc System 0° 90° XX 3 Arc System 0° 90° 180° X 4 Arc System 0° 90° 180° 270°

B-11

• For unbalanced waveforms: – Avoid switching at same time – Break up long periods of unchanged polarity

relative to adjacent arcs

POWER WAVE® AC/DC 1000

Page 50

C-1

ACCESSORIES

KITS, OPTIONS AND ACCESSORIES

OPTIONAL KITS AND ACCESSORIES

K2282-1 Power Wave System Interface

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 relationship between arcs to reduce the effects of welding related issues such as "Arc Blow".

K2444-1 CE – C-Tick Filter Kit

This external filter kit is available for the K2344-2 Power Wave AC/DC 1000, and mounts directly to the reconnect area on the rear of the machine. The filter is necessary to meet CE conducted emission requirements.

C-1

SOFTWARE TOOLS

The Power Wave AC/DC 1000 is shipped with a CD including software tools and other documents related to the integration, configuration, and operation of the system. The Power Wave Submerged Arc Utilities CD includes the following items and all of the documentation to support them.

Name Purpose

Weld Manager Setup Ethernet address information, and apply security settings. Command Center AC/DC system tool to observe and log welding operation, verify

DeviceNet welding configuration, and facilitate quality analysis.

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

source (more than one Power Wave per arc) systems.

Production Monitoring Allows user to setup Production Monitoring options on the Power Wave

including Email notification, Shift Timers, Wire Package Tracking. Also provides means to retrieve statistical welding data, generate machine reports, and update the Power Wave Firmware and Welding Software.

Diagnostics Utility Utility to diagnose Power Wave problems, read system information, cali-

brate output voltage and current, test sense leads, and diagnose feed head issues. Can also setup and verify DeviceNet operation.

Weld Manager Palm based utility used to configure, backup and restore various Power

(Palm Application)

Feed 10A Controller settings (can be used to copy settings from one PF-10A to another). Also provides means to retrieve version information and setup Ethernet address of the local Power Wave system (only those components directly connected to the PF-10A via ArcLink).

POWER WAVE® AC/DC 1000

Page 51

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only Qualified personnel should perform this maintenance.

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

• Do not touch electrically hot parts.

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

ROUTINE MAINTENANCE

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

D-1

PERIODIC MAINTENANCE

Calibration of the Power Wave AC/DC 1000 is critical to its operation. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and Current should be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the factory. Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a problem, use the calibration section of the Diagnostics Utility to make the appropriate adjustments.

The calibration procedure itself requires the use of a grid (Resistive Load Bank), and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. The Diagnostics Utility includes detailed instructions, and is available on the Power Wave Submerged

Arc Utilities and Service Navigator CD’s.

POWER WAVE® AC/DC 1000

Page 52

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

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

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 53

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

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

Input fuses keep blowing.

Machine will not power up (no lights)

POSSIBLE

CAUSE

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

1. Improperly sized input fuses.

2. Improper Weld Procedure

requiring output levels in excess of machine rating.

3. Major physical or electrical

damage is evident when the sheet metal covers are removed.

1. No Input Power.

RECOMMENDED

COURSE OF ACTION

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

1. Make sure fuses are properly

sized. See Installation section of this manual for recommended sizes.

2. Reduce output current, duty

cycle, or both.

3. Contact an authorized Lincoln

Electric Service facility.

1. Make sure input supply dis-

connect has been turned ON. Check input fuses. Make certain that the Power Switch (SW1) on the power source is in the "ON" position.

2. Circuit breaker CB4 (in reconnect area) may have tripped. Power Down and Reset CB4.

3. Input voltage selection made improperly.

2. Power Down and Reset CB4.

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

(Qualified person should perform this operation)

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 54

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Machine won’t weld, can’t get any

output. (CR1 will not pull in.)

This problem will normally be accompanied by an error code. Error codes are displayed as a series of red and green flashes by the status light(s). See "Status Light" section of this document for additional information.

POSSIBLE

CAUSE

1. Input voltage is too low or too high.

2. Thermal Error.

3. Primary current limit has been exceeded. (CR1 drops out when output is initiated).

4. Inverter Fault - switch pc board, contactor problem, etc.

RECOMMENDED

COURSE OF ACTION

1. Make certain that input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. See "Thermal LED is ON" section.

3. Possible short in output circuit. Turn machine off. Remove all loads from the output of the machine. Turn back on, and activate output. If condition persists, turn power off, and contact an authorized Lincoln Electric Field Service facility.

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

Thermal LED is on.

1. Improper fan operation.

2. Switch Board or AC Output Chopper board thermostat.

3. DC Bus PC board thermostat

4. Open thermostat circuit.

1. Check for proper fan operation. (Fans should run whenever output power is on.) Check for material blocking intake or exhaust louvers, or for excessive dirt clogging cooing channels in machine.

2. After machine has cooled, reduce load, duty cycle, or both. Check for material blocking intake or exhaust louvers.

3. Check for excessive load on 40VDC supply.

4. Check for broken wires, open connections or faulty thermostats DC Bus, Switch, and AC Chopper PC Board heat sinks.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 55

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Auxiliary receptacle is “dead”.

WELD AND ARC QUALITY PROBLEMS

General degradation of weld performance

POSSIBLE

CAUSE

1. Circuit breaker CB2 (on case front) may have tripped.

2. Circuit breaker CB3 or CB4 (in reconnect area) may have tripped.

1. Wire feed problem.

2. Cabling problems.

RECOMMENDED

COURSE OF ACTION

1. Power down and reset CB2.

2. Power down and reset CB3 or CB4.

1. Check for feeding problems. Make sure proper gear ratio has been selected.

2. Check for bad connections, excessive loops in cable, etc.

NOTE: The presence of heat in

the external welding circuit indicates poor connections or undersized cables.

Wire burns back to tip when the arc is initiated.

Wire burns back to tip at the end of the weld.

3. Verify weld mode is correct for process.

4. Machine calibration.

1. Voltage sense lead problem.

2. Wire feed problem.

1. Burnback Time

3. Select the correct weld mode for the application.

4. The power source may require calibration. (current, voltage, WFS).

1. Check sense lead connections. Check DIP switch settings for sense lead configuration and arc polarity. Make sure Electrode and Work connections are not reversed.

2. Check for feeding problems. Make sure proper gear ratio has been selected.

1. Reduce burnback time and/or work point.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 56

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

WELD AND ARC QUALITY PROBLEMS

E-5

RECOMMENDED

COURSE OF ACTION

Cannot weld AC.

Machine output shuts down during a weld.

1. Improper Ethernet I/O Configuration.

2. AC Switch Problem.

1. Secondary current limit has been exceeded, and the machine shuts down to protect itself.

2. Single phase input (loss of L2).

3. Re-strike Time exceeded.

1. Verify Ethernet board DIP Switch settings.

2. If major physical or electrical damage is evident when the sheet metal cover is removed from the AC Switch (lower section of the machine).Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. Adjust procedure or reduce load to lower current draw from the machine.

2. Single phase input (loss of L2). A single phase input (loss of L2) will reduce the secondary current limit and cause secondary over current shutdown at lower output levels. Check the input fuses and supply lines.

3. Adjust the process parameters to avoid excessive arc loss time or increase the re-strike time.

Machine won’t produce full output.

Excessively long and erratic arc.

1. Input voltage may be too low, limiting output capability of the power source.

2. Machine calibration.

1. Voltage sensing problem.

2. Machine calibration.

1. Make certain that the input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. Calibrate secondary current and voltage.

1. Check for proper configuration and implementation of voltage sensing circuits.

2. Calibrate secondary current and voltage.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 57

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-6

Device does not go on Line.

1. 24v bus power.

2. Baud rate.

3. MAC ID.

4. Termination.

5. Wiring.

1. Verify that LED 2 is on when the DeviceNet network is powered. This can be done with the Power Wave turned on or off.

2. Verify the baud rate setting is the same as the DeviceNet Master. The baud rate is set via dip switch on the Ethernet PC Board. The current value of the baud rate setting can be viewed on the DeviceNet tab of the Diagnostics Utility.

3. Verify the DeviceNet MAC ID is correct. The Mac ID is set via dip switch on the Ethernet PC Board. The current value of the MAC ID can be viewed on the DeviceNet tab of the Diagnostics Utility.

4. Verify that the DeviceNet bus is ter-

minated correctly.

5. Verify the wiring of all multi-port taps

and field attachable ends.

6. (Electronic Data Sheet Files) Verify

that the correct EDS files are being used if they are needed. The DeviceNet tab of the Diagnostics Utility displays the current Product Code and Vendor Revision of the Power Wave.

1. Verify that DeviceNet cables are not

running next to (in close proximity with) current carrying conductors. This includes the welding cables, input cables, etc.

2. Verify that the DeviceNet bus is ter-

minated correctly.

3. Verify that the cable shielding is cor-

rectly grounded at the bus power supply. The shield should be tied into the bus ground at only one point.

Device goes off line during welding

6. EDS Files.

1. Interference / Noise.

2. Termination.

3. Shielding.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 58

E-7

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-7

Output will not come on.

4. Power Supply.

5. Expected Packet Rate.

1. DeviceNet trigger not asserted.

2. Touch Sense command.

3. Passive Mode.

4. Verify that the DeviceNet bus power supply can supply sufficient current for the devices on the network.

5. Verify that 1000/(Expected Packet Rate)  (scans per second). The DeviceNet tab of the Diagnostics Utility displays these values.

1. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the "Produced Assembly" that "Trigger" is highlighted.

2. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the "Produced Assembly" that "Touch Sense" is NOT highlighted.

3. The DeviceNet tab of the Diagnostics Utility displays the Power Wave’s passive mode status. If the status needs to be changed, select Configure, and make the necessary modification.

4. Welding Cables.

5. Output Disabled.

6. Other modules faulted.

4. Verify that welding cables are connected properly.

5. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the "Produced Assembly" that "Disable Output" is NOT highlighted.

6. Verify no other modules are faulted (all system Status Lights should be steady green). Use Diagnostics Utility to display any current faults in the system.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 59

E-8

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-8

Bad Weld Starting 1. Wire Feed problem.

2. Strike Wire Feed Speed.

3. Incorrect Weld Schedule.

4. Voltage Sense Leads.

5. Analog Scans Between Updates.

1. Verify Feeders drive roll tension

is not too low allowing the wire to slip in the rolls. Verify wire can be pulled easily through the wire conduit. Verify Contact tip is not blocked.

2. Verify the Strike Wire Feed

Speed set correctly.

3. Verify the correct weld schedule

is selected.

4. Verify voltage sense leads are

properly connected and configured as described in the instruction manual.

5. The DeviceNet tab of the

Diagnostics Utility displays the Power Wave’s "Analog Scans Between Updates" and "I/O Scans/Sec." Verify that "Analog Scans Between Updates" is 1/4 of "I/O Scans/Sec" value.

6. Analog Hysteresis.

7. Limit Error.

8. Fan Out.

9. Gas.

6. From the DeviceNet tab of the

Diagnostics Utility, select Configure. Verify in "Analog Input Channels" that the Hysteresis settings are all 0.

7. Verify all analog input values are

within limits.

8. From the DeviceNet tab of the

Diagnostics Utility, select Monitor. Verify under "Analog Input Fan Out" that Burnback is present for all analogs in.

9. Verify Gas is being turned on

before the output.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 60

E-9

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-9

Analog Inputs don’t respond or don’t respond quickly.

1. Analog Scans Between Updates.

2. Analog In Active Selections.

3. Analog Hysteresis.

4. Passive Mode.

1. The DeviceNet tab of the

Diagnostics Utility displays the Power Wave’s "Analog Scans Between Updates" and "I/O Scans/Sec." Verify that "Analog Scans Between Updates" is 1/4 of "I/O Scans/Sec" value.

2. From the DeviceNet tab of the

Diagnostics Utility, select Configure. Verify in "Analog Input Channels" that the required channels are set active.

3. From the DeviceNet tab of the

Diagnostics Utility, select Configure. Verify in "Analog Input Channels" that the Hysteresis settings are all 0.

4. The DeviceNet tab of the

Diagnostics Utility displays the Power Wave’s passive mode status. If the status needs to be changed, select Configure, and make the necessary modification.

Gas purge not working.

1. Out of gas.

2. Gas Purge not asserted.

3. Passive Mode.

4. Gas Lines.

1. Verify there is gas available at

the input of the gas solenoid.

2. From the DeviceNet tab of the

Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the "Produced Assembly" that "Gas Purge" is highlighted.

3. The DeviceNet tab of the

Diagnostics Utility displays the Power Wave’s passive mode status. If the status needs to be changed, select Configure, and make the necessary modification.

4. Verify nothing is obstructing the

flow of gas.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 61

E-10

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-10

Bad Weld Ending

1. Burnback Disabled.

2. Burnback Time.

3. Analog Scans Between Updates.

4. Limit Error reported at the end of a weld.

5. Fan Out.

1. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the "State Enabled" that "Burnback" is present.

2. Using Command Center verify that Burnback Time for the active schedule in the main window has a value other than 0.

3. The DeviceNet tab of the Diagnostics Utility displays the Power Wave’s "Analog Scans Between Updates" and "I/O Scans/Sec." Verify that "Analog Scans Between Updates" is 1/4 of "I/O Scans/Sec" value.

4. Verify all welding settings for Burnback and Crater states.

5. From the DeviceNet tab of the Diagnostics Utility, select Monitor. Verify under "Analog Input Fan Out" that Burnback is present for all analogs in.

Bad Welding

6. Welding set points.

7. Analog Hysteresis.

8. Gas.

1. Analog Scans Between Updates.

2. Voltage Sense Leads.

6. Verify Burnback set points for work point, trim, and wave values.

7. From the DeviceNet tab of the Diagnostics Utility, select Configure. Verify in "Analog Input Channels" that the Hysteresis settings are all 0.

8. Verify Gas is turned on.

1. The DeviceNet tab of the Diagnostics Utility displays the Power Wave’s "Analog Scans Between Updates" and "I/O Scans/Sec." Verify that "Analog Scans Between Updates" is 1/4 of "I/O Scans/Sec" value.

2. Verify voltage sense leads are properly connected and configured as described in the instruction manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 62

E-11

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

DEVICENET-PLC CONTROLLED SYSTEM

RECOMMENDED

COURSE OF ACTION

E-11

Cannot Connect.

3. Analog Hysteresis.

4. Limit Errors.

5. Gas.

6. Welding set points.

ETHERNET

1. Physical connection.

3. From the DeviceNet tab of the

Diagnostics Utility, select Configure. Verify in "Analog Input Channels" that the Hysteresis settings are all 0.

4. Verify all welding set point values are

within limits.

5. Verify Gas remains on until after the

weld is complete.

6. Verify welding set points for work

point, trim, and wave values.

1. Verify that the correct patch cable or

cross over cable is being used (refer to local IT department for assistance).

• Verify the cables are fully inserted

into the bulk head connector.

• LED 10 will be lit when the board is

connected to another network device.

Connection Drops while welding.

2. IP address information.

3. Ethernet Speed.

1. Cable Location.

2. User

• Verify that the PC has the correct IP

• Verify that another device on the net-

3. Verify that the network device con-

1. Verify Network cable is not located

Weld Manager

correct IP address information has been entered.

address information entered.

work is not already using the IP address entered into the

Manager

nected to the Power Wave is either a 10-baseT device or a 10/100-baseT device.

next to current carrying conductors. This would include input power cables and welding output cables.

utility.

to verify the

Weld

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 63

E-12

TROUBLESHOOTING

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave AC/DC 1000 is equipped with three externally mounted status lights, one for the power source, and each module contained in the power source. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to

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

Troubleshooting the Power Wave AC/DC 1000 Using the External Status LED’s

E-12

Included in this section is information about the power source, Wire Drive Module, and Communication Module Status LED’s, and some basic troubleshooting charts for both machine and weld performance.

The STATUS LIGHTS are dual-color LED’s that indicate system errors. Normal operation for each is steady green. Error conditions are indicated in the following chart.

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

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

Occurs during power up or a system reset, and indicates the Power Wave AC/DC 1000 is mapping (identifying) each component in the system. Normal for first 110 seconds after power is turned on, or if the system configuration is changed during operation.

Indicates Auto-mapping has failed

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

is turned off. Error Code interpretation through the Status light is

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

Error codes can also be retrieved with the Diagnostics

Utility (included on the Power Wave Submerged Arc Utilities and Service Navigator CD’s). This is the pre-

ferred method, since it can access historical information contained in the error logs.

To clear the active error(s), turn power source off, and

back on to reset. Steady Red Blinking Red

Not applicable.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 64

E-13

Observe all Safety Guidelines detailed throughout this manual

ERROR CODES

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

TROUBLESHOOTING

E-13

POWER SOURCE- WELD CONTROLLER

Error Code #

31 Primary (Input) overcurrent error.

32 Capacitor "A" under voltage (Left

side facing machine)

33 Capacitor "B" under voltage (Right

side facing machine)

34 Capacitor "A" over voltage (Left

side facing machine)

35 Capacitor "B" over voltage (Right

side facing machine)

36 Thermal error

37 Soft start error 41 Secondary (Output) overcurrent error

Indication

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

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

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

43)

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

Capacitor pre-charge failed. Usually accompanied by codes 32-35. The long term average secondary (weld) current limit has been exceeded.

This error will cause the machine output to phase back to 100 amps, typically resulting in a condition referred to as “noodle welding”.

NOTE: The long term average secondary current limit is 1050 amps.

43 Capacitor delta error

46 Secondary (Output) overcurrent error

49 Single phase error

54 Secondary (Output) overcurrent error

Other

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

Absolute maximum output level has been exceeded. Usually associated with excessive short circuit currents and/or specific weld mode issues. This is a short term average designed to protect the inverter switching circuitry.

Indicates machine is running on single phase input power. Usually caused by the loss of the middle leg of the input power (L2).

The long term average secondary (weld) current limit has been exceeded.

This error will immediately turn off the machine output.

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 65

E-14

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

WIRE DRIVE MODULE

E-14

Error Code #

81 Motor Overload

82 Motor Overcurrent

83 Shutdown #1

84 Shutdown #2

Error Code #

118 DeviceNet connection error 119 DeviceNet de-allocation error

Indication

Long term average motor current limit has been exceeded. Typically indicates mechanical overload of system. If problem continues consider higher gear ratio.

Absolute maximum motor current level has been exceeded. This is a short term average to protect drive circuitry.

The normally closed circuit of Shutdown #1 has been interrupted. Check the connection between pins 9 and 10 on the External I/O connector (S7).

The normally closed circuit of Shutdown #2 has been interrupted. Check the connection between pins 9 and 11 on the External I/O connector (S7).

COMMUNICATION MODULE

Indication

Lost Connection with DeviceNet Master The DeviceNet Master de-allocated the connection

133 Write ArcLink action failure

145 Duplicate MAC ID error 146 DeviceNet Bus off 147 DeviceNet polled I/O error 149 DeviceNet I/O data error 169 Ethernet Connection Time out

171 Ethernet Socket Time out 172 Ethernet Watch Dog Time out

194 Ethernet Send Problem 195 Ethernet Problem 197 Ethernet Problem

198 Ethernet Client Time out 216 Ethernet Problem 224 Ethernet Problem

May be caused by activating Cold Inch while welding through DeviceNet

Check MAC ID assignments on DeviceNet Setup Dip switch Bank (S2) Check condition of on board DeviceNet Status indicators Problem changing attribute over polled I/O Received DeviceNet I/O data with wrong number of bytes Loss of communication with PC Application.

Communication problem between Master and Slave machines.

Master lost communications with Slave Machine. Communication problem between Master and Slave machines. Master had problem connecting to a Slave machine.

226 Ethernet Problem

Communication problem between Master and Slave machines.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000

Page 66

F-1

DIAGRAMS

F-1

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

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

POWER WAVE® AC/DC 1000

Page 67

F-2

DIAGRAMS

F-2

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

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

POWER WAVE® AC/DC 1000

Page 68

F-3

AC SWITCH WIRING DIAGRAM

F-3

POWER WAVE® AC/DC 1000

Page 69

F-4

AC SWITCH WIRING DIAGRAM

F-4

POWER WAVE® AC/DC 1000

Page 70

F-5

L12302

A.01

19.70

19.16

9.56

18.84

40.94

43.44

33.00

34.34

14.62

DIMENSION PRINT

F-5

POWER WAVE® AC/DC 1000

Page 71

NOTES

POWER WAVE® AC/DC 1000

Page 72

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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

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

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

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

Page 73

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

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

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

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

Page 74

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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