operator’s manual power wave ac/dc 1000...

POWER WAVE ® AC/DC 1000 ® SD

Operator’s Manual

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10022-C | Issue D ate 12-Nov

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11592, 11881, 11918

Register your machine: www.lincolnelectric.com/register

Authorized Service and Distributor Locator: www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.comA Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA: Email: [email protected]

FOR ENGINEpowered equipment.

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

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

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

WARNING

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

iiSAFETYii

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

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

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

iiiSAFETYiii

Refer to http://www.lincolnelectric.com/safety for additional safety information.

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

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

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

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

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu 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” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

ivSAFETYiv

THIS SAMPLE DOCUMENT IS USED FOR “CE” MACHINES ONLY!

vv SAFETY

Electromagnetic Compatibility (EMC)

ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonizedstandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. WARNING: This equipment is not intended for use in residential locations where the electrical power is pro-vided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnet-ic compatibility in those locations, due to conducted as well as radiated disturbances.

Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons. Follow your local andnational standards for installation and use. Changing the earthing arrangements should onlybe authorized by a person who is competent to assess whether the changes will increase therisk of injury, e.g., by allowing parallel welding current return paths which may damage theearth circuits of other equipment.

Assessment of AreaBefore installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to thewelding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement;

g) the immunity of other equipment in the environment. The user shall ensure that other equipment beingused in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

THIS SAMPLE DOCUMENT IS USED FOR “CE” MACHINES ONLY!

vivi SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Public Supply SystemWelding equipment should be connected to the public supply system according to the manufacturer’s rec-ommendations. If interference occurs, it may be necessary to take additional precautions such as filtering ofthe public supply system. Consideration should be given to shielding the supply cable of permanentlyinstalled welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuousthroughout its length. The shielding should be connected to the welding power source so that good electricalcontact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according to the manufacturer’s recommendations.All access and service doors and covers should be closed and properly fastened when the welding equip-ment is in operation. The welding equipment should not be modified in any way except for those changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.

Equipotential BondingBonding of all metallic components in the welding installation and adjacent to it should be considered.However, metallic components bonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.

Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its sizeand position, e.g., ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.

Screening and ShieldingSelective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-lems of interference. Screening of the entire welding installation may be considered for special applica-

tions1.

_________________________

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

viivii

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 youhave 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 packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Support” and then “RegisterYour Product”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in ourpossession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect tosuch information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particularpurpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility forupdating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expandor 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 controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying 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.comfor any updated information.

viiiviii TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section ASpecifications .......................................................................................................................A-1Safety Precautions. ..............................................................................................................A-2

Location and Mounting..................................................................................................A-2Stacking ........................................................................................................................A-2Lifting.............................................................................................................................A-2Environmental Limitations .............................................................................................A-2Electromagnetic Compatibility .......................................................................................A-2Clearance Requirements ..............................................................................................A-3Input Voltage Selection and Ground Connections ........................................................A-4Connection Diagram .....................................................................................................A-4System Connection .......................................................................................................A-5Connection Diagrams and Check List ...........................................................A-6 thru A-16Electrode and Work Connection .................................................................................A-17Cable Inductance, Remote Sense Lead Connection.........................................A-18, A-19Multi-Arc Circumfirential Welds ...................................................................................A-20Control Cable Connections, Common Equipment Connections .................................A-21

________________________________________________________________________________Operation.........................................................................................................................Section B

Safety Precautions, Definition of Welding Modes, Graphic Symbols ...........................B-1, B-2Product Summary, Recommended Process, Process and Equipment Limitations..............B-3Common Equipment Packages and Recommended Equipment .........................................B-3Case Front Control Descriptions .........................................................................................,B-4Input Power Section .............................................................................................................B-4Case Back Components ...............................................................................................B-5, B-6Power-Up Sequence ............................................................................................................B-7Duty Cycle ............................................................................................................................B-7Common Welding Procedures .............................................................................................B-7Overview of the AC/DC Submerged Arc Process ................................................................B-7Multiple Arc System Considerations.....................................................................................B-8Basic Modes of Operation (CC / CV) ...................................................................................B-8Weld Sequence, Start Options, End Options, Re-Strike Timer ............................................B-9Weld Process Adjustment, Wave Balance, DC Offset, Frequency ....................................B-10Phase Adjustment for Multiple Arc Systems .....................................................................B-11

________________________________________________________________________________Accessories .....................................................................................................Section C

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

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Routine and Periodic Maintenance........................................................................D-1Calibration Specification ........................................................................................D-1

________________________________________________________________________Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1Using the Status LED to Troubleshoot System Problem.......................................E-2Error Codes....................................................................................................E-3, E-4Troubleshooting Guide ..........................................................................................E-5

________________________________________________________________________Wiring Diagrams and Dimension Print ..........................................................Section F

Wiring Diagram - Power Wave® AC/DC 1000® SD................................................F-1Wiring Diagram - AC Switch ................................................................................F-2Dimension Print .....................................................................................................F-3

________________________________________________________________________Parts List.................................................................................................................P-612

A-1INSTALLATION

POWER WAVE® AC/DC 1000® SD

A-1

TECHNICAL SPECIFICATIONS - Power Wave® AC/DC 1000® SD (K2803-1)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES1

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

3 PHASE50/60 Hz

380400460500575

OPENCIRCUIT

VOLTAGE

70V70VACpk.

3 PHASE INPUTVOLTAGE 50/60Hz

380400460500575

HEIGHT49.13 in

1248 mm

CONFORMITY MARKMODEL

K2803-1

WIDTH19.71 in501mm

DEPTH46.60 in

1184 mm

WEIGHT800 lbs.363 kg.

TIME-DELAY FUSEOR BREAKER2

AMPS10090908070

COPPER GROUNDINGCONDUCTOR

AWG (mm2)8 (10)8 (10)8 (10)8 (10)10 (6)

TYPE 90°CCOPPER WIRE3 IN

CONDUIT

AWG (mm2)3(25)3(25)4(25)4(25)6(16)

PROCESS CURRENT RANGES (AC or DC)

SAW-DC+ 100 amps @24 VoltsSAW-DC- 1000 Amps @44 VoltsSAW-AC (Actual range may be limited by process)

AUXILIARY POWER(CIRCUIT BREAKER

PROTECTED)

40 VDC AT10 AMPS

115 VAC AT10 AMPS

INPUTCURRENT AMPS

827969 6255

IDLEPOWERWATTS

225

POWER FACTOR@ RATED OUTPUT

.95

EFFICIENCY@ RATED OUTPUT

86%

OUTPUT CONDITIONS

[email protected]% Duty Cycle

OPERATING TEMPERATURE RANGE14°F to 104°F(-10°C to 40°C)

STORAGE TEMPERATURE RANGE-40°F to 185°F(-40°C to 85°C)

1 Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.2 Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the

magnitude of current increases.3 Fail to use proper type of copper wire will cause fire hazards.* An external filter will be required to meet CE and C-Tick conducted emission requirements. It will meet CE and C-Tick requirements with the

use of an optional external filter. (K2444-3 CE and C-Tick Filter Kit)

}

WELDING PROCESSESProcess

SAW

Electrode Diameter Range

5/64 – 7/32" (2 – 5.6 mm)

Output Range (Amperes)

100 - 1000

Wire Feed Speed Range

See Wire Drive Manual

Insulation Class: Class F(155°C)

EN 60974-1CSA C/US

*

LIFTING

Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto l i f t the Power Wave® AC/DC 1000® SD withaccessories attached to it.

ENVIRONMENTAL LIMITATIONS

The Power Wave® AC/DC 1000® SD can be used inan outdoor environment with an IP 23 rating. It shouldnot be subjected to falling water, nor should any partsof it be submerged in water. Doing so may causeimproper 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/DC1000® SD is Industrial, Scientific and Medical (ISM)group 2, class A. The Power Wave® AC/DC 1000® SDis for industrial use only.

Locate the Power Wave® away from radio controlledmachinery.

The normal operation of the Power Wave® AC/DC1000® SD may adversely affect the operation of RFcontrolled equipment, which may result in bodilyinjury or damage to the equipment.

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

A-2INSTALLATION


A-2

SAFETY PRECAUTIONSRead this entire installation section before youstart installation.

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.• Turn the input power OFF at the

disconnect switch or fuse boxbefore working on this equipment.Turn off the input power to any otherequipment connected to the weldingsystem at the disconnect switch orfuse box before working on theequipment.

• 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

Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides and front. Dirt, dust, or any foreignmaterial that can be drawn into the welder should bekept at a minimum. Failure to observe theseprecautions can result in excessive operatingtemperatures and nuisance shutdowns. See theClearance Requirements and Figure A.1. in thissection.

STACKING

Power Wave® AC/DC 1000® SD machine cannot bestacked.

DO NOT MOUNT OVER COMBUSTIBLESURFACES.

Where there is a combustible surface directlyunder stationary or fixed electrical equipment, thesurface shall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not morethan 5.90”(150mm) beyond the equipment on allsides.-----------------------------------------------------------------------

CAUTION

• Lift only with equipment ofadequate lifting capacity.

• Be sure machine is stablewhen lifting.

• Do not lift this machine usinglift bail if it is equipped with aheavy accessory such astrailer 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.-----------------------------------------------------------------------

WARNING

CAUTION

WARNING

A-3INSTALLATION


A-3

CLEARANCE REQUIREMENTS

The maintenance requirements of the Power Wave®

AC/DC 1000® SD demand that enough clearancebehind the machine be maintained. This is especiallyimportant where more than one machine is to be usedor if the machines are going to be rack mounted.

The rear portion of the machine that contains the filterand the cooling fans slides out for easy access toclean the heat sink fins.

Removing the four(4) clips and pulling back on therear portion of the machine will provide access forcleaning the machine and checking the filter. The filteris removed from the right side of the machine.

Where machines are mounted side by side, themachine that is furthest to the right will need to havethe indicated clearance to the right side for filterremoval. See Figure A.1.

FIGURE A.1 - CLEARANCE REQUIREMENTS

61.30

22.6333.00

WIDTH NEEDED FOR FILTERMAINTENANCE ACCESS

FILTER REMOVALFROM SIDE OF MACHINE


INPUT AND GROUND CONNECTIONS

MACHINE GROUNDING

The frame of the welder must be grounded. A groundterminal marked with the symbol shown is locatedinside the reconnect / input access door for thispurpose. See your local and national electrical codesfor proper grounding methods.

A-4INSTALLATION A-4

INPUT FUSE AND SUPPLY WIRECONSIDERATIONS

Refer to Specifications page for recommended fuse andwire sizes. Fuse the input circuit with the recommendedsuper lag fuse or delay type breakers (also called "inversetime" or "thermal/magnetic" circuit breakers). Choose inputand grounding wire size according to local or nationalelectrical codes. Using fuses or circuit breakers smaller thanrecommended may result in "nuisance" shut-offs fromwelder inrush currents, even if the machine is not beingused at high currents.

INPUT VOLTAGE SELECTION

Welders are shipped connected for the highest input voltagelisted on the rating plate. To move this connection to adifferent input voltage, see the diagram located on the insideof the input access door, or the diagram shown below(Figure A.2). If the Auxiliary lead (indicated as ʻAʼ) is placedin the wrong position, there are two possible results.

a. If the lead is placed in a position higher than the appliedline voltage, the welder may not come on at all.

b. If the Auxiliary lead is placed in a position lower than theapplied line voltage, the welder may not come on, andfuse in the reconnect area may open. If this occurs, turnoff the input voltage, properly connect the auxiliarylead, replace the fuse, and try again.

INPUT CONNECTION

ELECTRIC SHOCK can kill.

• Only a qualified electrician shouldconnect the input leads to thePower Wave®. Connectionsshould be made in accordancewith all local and NationalElectrical Codes and theconnection diagram located onthe inside of the reconnect / inputaccess door of the machine.Failure to do so may result inbodily injury or death.

-----------------------------------------------------------------------Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe case back. Connect L1, L2, L3 and groundaccording to the Input Supply Connection Diagram.

FIGURE A.2 - INPUT SUPPLY CONNECTION FOR K2803-1 POWER WAVE® AC/DC 1000® SD

S2

60

47

TH

E L

INC

OLN

ELE

CT

RIC

CO

. C

LEV

ELA

ND

, OH

IO U

.S.A

.

VOLTAGE=440-460V

'A'

A

500V

U / L1

V / L2 CR1

W / L3INPUT SUPPLY CONNECTION DIAGRAM

550-575V

ELECTRICSHOCK

CAN KILL

WARNINGDo 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

WARNING


A-5INSTALLATION A-5

SYSTEM CONNECTION

System Overview

The Power Wave® AC/DC 1000® SD power source isdesigned to be a part of a modular welding systemtypically controlled by a MAXsa™ 10 Controller or acustomer supplied Programmable Logic Controller(PLC). Each welding arc may be driven by a singlepower source or by a number of power sourcesconnected in parallel. The actual number of powersources per arc will vary depending on the application.When only one power source is required for an arcgroup, it must be configured as a Master. Whenparallel machines are required, one is designated asthe Master and the rest as Slaves. The synchronizingconnectors for paralleled machines are on the back ofthe power source. The Master controls the ACswitching for the arc group, and the Slaves respondaccordingly. See Figure A.3.

When employed in a multi-arc AC system the arcsmust be synchronized to each other. The Master foreach arc can be configured to follow a dedicatedexternal synchronization signal to determine itsfrequency and balance. The SynchronizingConnectors on the back of the Power Wave® AC/DC1000® SD provide the means to synchronize the ACwave shapes of up to six different arcs to a commoncarrier frequency. (See Figure A.3). This frequencycan range from 20 hertz to 100 hertz. It can alsocontrol the phase angle between arcs to reduce theeffects of welding related issues such as "Arc Blow".

FIGURE A.3 - SYNCHRONIZING CONNECTORS

Input

OutputMulti-arc

Input

OutputParalleling

LINCOLN

ELECTR

IC

A-6INSTALLATION


A-6

The arc to arc phase relationship is determined by thetiming of each arcʼs "sync" signal relative to the "sync"signal of ARC 1. DIP Switches on the in each machinemust be set to identify it as a Master Lead, MasterTrail or Slave. See Figure A.4

In a typical multi-arc system, each arc is controlled byits own MAXsa™ 10 Controller. The basiccharacteristics of the individual arcs such as WFS,amplitude, and offset are set locally by each arcʼsdedicated controller. The frequency, balance, andphase shift parameters of each arc are controlled bythe MAXsa™ 10 Controller for ARC 1 (Master Lead).

NOTE: The K2803-1 Power Wave® AC/DC 1000® SDis backwards compatible with the K2344-2Power Wave® AC/DC 1000 in tandem or multi-arc systems. The K2803-1 and K2344-2machines cannot be connected in parallel.Paralleled machines must be of the sametype. A K1805-1 (14 to 22 pin adapter cable) isrequired to interface to the K2282-1 SystemsInterface in these setups

A PLC interface is an alternate method of control forlarger systems. The PLC is typically connected viaDeviceNet directly to the Master power source of eacharc group in the system. MAXsa™ 19 Controller isstill required to power the Wire Drive. Contact yourLocal Lincoln Electric Representative for more infor-mation.

The connection diagrams describe the layout of sever-al typical systems including Multi-Arc and Paralleledmachine set-ups. Each system also has a step bystep “Installation Checklist”.

FIGURE A.4 - DIP SWITCH SETTINGS

A-7INSTALLATION


A-7

Wo

rk

K2

68

3-X

X

Arc

link C

able

K2

60

7-1

Cru

ise

r

Wo

rk

We

ld C

able

Ele

ctr

ode

We

ld C

able

K18

11-X

X

Sen

se L

ead

K2803-1

Po

we

r W

ave

® A

C/D

C 1

00

0® S

D

FIGURE A.5 - CRUISER CONNECTION DIAGRAM

A-8INSTALLATION


A-8

CRUISER™ SYSTEM CHECKLIST (See Figure A.5)

Place the Power Wave® AC/DC 1000® SD in a suitable operating location.

Place the Cruiser™ Tractor in itʼs operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave® AC/DC 1000® SD andthe Cruiser™ Tractor

Install Work Voltage Sense Lead (21) from the Power Wave® AC/DC 1000® SD per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table A.1).

Open the Power Wave® AC/DC 1000® SD front panel and check the DIP switch settings per the decal on thepanel. Factory Setting is “Master-Lead”. (See Figure A.4).

Connect input power to Power Wave® AC/DC 1000® SD per recommended guidelines.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Turn on Power Wave® AC/DC 1000® SD, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

A-9INSTALLATION


A-9

K26

83-X

XA

rclin

k C

able

67 L

ead

K17

85-X

X14

-Pin

Cab

le

Wor

k

K23

1-X

X

Con

tact

Noz

zle

K28

03-1

Pow

er W

ave®

AC

/DC

100

0® S

D

K28

14-1

MA

Xsa

™ 1

0

K23

70-2

MA

Xsa

™ 2

2

K18

11-X

XS

ense

Lea

d

Ele

ctro

deW

eld

Cab

le

Wor

kW

eld

Cab

le

FIGURE A.6 - SINGLE ARC CONNECTION DIAGRAM

A-10INSTALLATION


A-10

SINGLE ARC SYSTEM CHECKLIST (See Figure A.6)


Mount MAXsa™ 10 Controller.

Install MAXsa™ 22 Wire Drive and other accessories in their operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave and MAXsa™ 10.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 and the MAXsa™ 22.

Install Electrode Sense Lead (67) at the feeder and the Work Sense Lead (21) from the Power Wave® AC/DC1000® SD per recommended guidelines.


Open the Power Wave® AC/DC 1000® SD front panels and check the DIP switch settings per the decal on thepanel. Factory Setting is “Master-Lead”. (See Figure A.4).





A-11INSTALLATION


A-11

67 L

eads

K17

85-X

X14

-Pin

Cab

le

Wor

kW

ork

Wel

d C

able

K23

1-X

X

Con

tact

Noz

zle

K28

14-1

MA

Xsa

™ 1

0

K23

70-2

MA

Xsa

™ 2

2

Ele

ctro

de W

eld

Cab

le

K26

83-X

XA

rclin

k C

able

K26

83-X

XA

rclin

k C

able

K17

85-X

X 1

4-P

in C

able

K28

03-1

Pow

er W

ave®

AC

/DC

100

0® S

DK

1785

-XX

14-P

in C

able

K18

11-X

XS

ense

Lea

d

Ele

ctro

deW

eld

Cab

le

K28

14-1

MA

Xsa

™ 1

0

K23

70-2

MA

Xsa

™ 2

2

K28

03-1

Pow

er W

ave®

AC

/DC

100

0® S

D

FIGURE A.7 - TANDEM ARC CONNECTION DIAGRAM

A-12INSTALLATION


A-12

TANDEM ARC (2-ARC) SYSTEM CHECKLIST (See Figure A-7)

Place the Power Wave® AC/DC 1000® SD units in a suitable operating location.

Mount MAXsa™ 10 Controllers.

Install MAXsa™ 22 Wire Drives and other accessories in their operating location.

Connect a K1785-xx Wire Feeder Control Cable (14 pin) between the two power sources (top connectors).

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave units and MAXsa™ 10controllers.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 controllers and theMAXsa™ 22 feeders.

Install Electrode Sense Lead (67) at each feeder and the Work Sense Lead (21) from the Lead Power Wave®

AC/DC 1000® SD Master per guidelines.


Open the Power Wave® AC/DC 1000® SD front panels and configure DIP switch settings per the decal on thepanel. (See Figure A.4).

Connect input power to Power Wave® AC/DC 1000® SD units per recommended guidelines.

Turn on Power Wave® AC/DC 1000® SD and verify all system Status Lights are solid green.


Run the subarc cell configurator from PC Tools (See Section C of this manual or go to www.powerwavesoft-ware.com).


A-13INSTALLATION


A-13

MA

Xsa

™ 1

0

MA

Xsa

™ 2

2

Pow

er W

ave ®

Pow

er W

ave®

Con

nect

ion

Di a

gra m

-P

ara l

lel M

a chi

nes

67 L

ead

Wor

kW

ork

Wel

d C

able

K28

14-1

K23

70-2

K26

83-X

XA

rclin

k C

able

K17

85-X

X 1

4-P

in C

able

K28

03-1

AC

/DC

100

0® S

D

K28

03-1

AC

/DC

100

0® S

DK

1785

-XX

14-P

in C

able

K18

11-X

XS

ense

Lea

d Ele

ctro

deW

eld

Cab

le

K23

1-X

XC

onta

ct N

ozzl

e

Ele

ctro

de W

eld

Cab

le

FIGURE A.8 - PARALLELING CONNECTION DIAGRAM

A-14INSTALLATION


A-14

PARALLEL CONNECTION CHECKLIST (See Figure A.8)

Place the Power Wave® AC/DC 1000® SD units in a suitable operating location.

Mount MAXsa™ 10 Controller.

Install MAXsa™ 22 Wire Drive and other accessories in their operating location.

The MAXsa™ Controller must be connected to the Master Power Source. Connect K2683-xx Heavy DutyArcLink Control Cable (5 pin) between Power Wave and MAXsa™ 10 controller.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 10 controller and the MAXsa™22 feeder.

Connect a K1785-xx Wire Feeder Control Cable (14 pin) between the two power sources (top connectors).

Install Electrode Sense Lead (67) at the feeder and the Work Sense Lead (21) from the Lead Power Wave®

AC/DC 1000® SD Master per guidelines.

Connect / Install welding cables to both the “master” and “slave” machine per recommended "Output CableGuidelines" (Table A.1).

Open the Power Wave® AC/DC 1000® SD front panels and configure DIP switch settings per the decal on thepanel. (See Figure A.4).

Connect input power to Power Wave® AC/DC 1000® SD units per recommended guidelines.



For tandem setups, run the subarc cell configurator from PC Tools (See Section C of this manual or go towww.powerwavesoftware.com).


A-15INSTALLATION


A-15

FIGURE A.9 - MAXsa™ 19 CONNECTION DIAGRAM

K2683-XXArclink Cable

67 Lead

K1785-XX14-Pin Cable

Work

K231-XX Contact Nozzle

K2803-1Power Wave® AC/DC 1000® SD

K2312-2MAXsa™ 29

K1811-XXSense Lead

ElectrodeWeld Cable

WorkWeld Cable

K2626-2MAXsa™ 19

DeviceNet Cable Network

PLC Controller

User Interface

A-16INSTALLATION


A-16

MAXsa™ 19 SYSTEM CHECKLIST (See Figure A.9)


DeviceNet PLC controlled systems: Mount DeviceNet PLC controller and User Interface.

Mount MAXsa™ 19 in itʼs operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave® AC/DC 1000® SD andMAXsa™ 19.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa™ 19 and the MAXsa™ 29.

DeviceNet PLC controlled systems: Connect each Arc Master power source to the PLC via the DeviceNetnetwork.

Install Work Voltage Sense Lead (21) from Power Wave® AC/DC 1000® SD per recomennded guidelines.


Open the Power Wave® AC/DC 1000® SD front panels and configure DIP switch settings per the decal on thepanel. Factory setting is “Master-Lead”.(See Figure A.4).


Turn on Power Wave® AC/DC 1000® SD and verify all system Status Lights are solid green.

DeviceNet PLC controlled systems: Run Weld Manager. For each Arc Master connect to the power source.Under Network Settings -> DeviceNet-> Configuration, configure the DeviceNet MAC address and baud rate.

Run Weld Manager. For each Arc Master connect to the power source. Under Feeder Settings -> WireFeeder, verify the appropriate Feeder and gear ratio are selected.



A-17INSTALLATION


A-17

ELECTRODE AND WORKCONNECTIONS

General Guidelines

The unique switching structure of the Power Wave®

AC/DC 1000® SD allows it to produce DC positive, DCnegative or AC output waveforms without reposition-ing the work and electrode leads. Additionally, no DIPswitch changes are required to switch between the dif-ferent polarities. All of this is controlled internally bythe Power Wave® AC/DC 1000 SD, and based exclu-sively on the weld mode selection.

The following recommendations apply to all outputpolarities and weld modes:

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

Note: Excessive heat in the weld circuit indicatesundersized cables and/or bad connections.

• Route all cables directly to the work and wirefeeder, avoid excessive lengths and do not coilexcess cable. Route the electrode and work cablesin close proximity to one another to minimize theloop area and therefore the inductance of the weldcircuit.

• Always weld in a direction away from the work(ground) connection.

TABLE A.1 - Output Cable Guidelines

Electrode Connections

Connect cable(s) of sufficient size and length (PerTable A.1) to the "ELECTRODE" studs on the powersource (located behind the cover plate on the lowerright rear corner). Connect the other end of the elec-trode cable(s) to the tab of the contact nozzle. Be surethe connection to the nozzle makes tight metal-to-metal electrical contact.

Work Connections

Connect cable(s) of sufficient size and length (PerTable A.1) between the "WORK" studs (locatedbehind the cover on the lower left rear corner) and thework piece. Be sure the connection to the work makestight metal-to-metal electrical contact.

NOTE: For parallel and/or multiple arc applicationswith excessive ground path lengths, a com-mon work connection bus should be used. Thecommon work connection serves to minimizevoltage drops associated with resistive lossesin the ground paths. It should be made out ofcopper, and located as close as possible tothe power sources (See Figure A.10).

Total Cable Lengthft (m)

Electrode and WorkCombined

0 (0) to 250 (76.2)

0 (0) to 250 (76.2)

Duty Cycle

80%

100%

Number ofParallel Cables

2

3

Cable SizeCopper

4/0 (120 mm2)

3/0 (95 mm2)

WORK PIECE

COMMON CONNECTION(LOCAT ED CLOSE TO

POWER SOURCES)

FIGURE A.10

A-18INSTALLATION


A-18

CABLE INDUCTANCE, AND ITS EFFECTSON WELDING

Excessive cable inductance will cause the weldingperformance to degrade. There are several factorsthat contribute to the overall inductance of the cablingsystem including cable size, and loop area. The looparea is defined by the separation distance betweenthe electrode and work cables, and the overall weldingloop length. The welding loop length is defined as thetotal of length of the electrode cable (A) + work cable(B) + work path (C) (see Figure A.11). To minimizeinductance always use the appropriate size cables,and whenever possible, run the electrode and workcables in close proximity to one another to minimizethe loop area. Since the most significant factor incable inductance is the welding loop length, avoidexcessive lengths and do not coil excess cable. Forlong work piece lengths, a sliding ground should beconsidered to keep the total welding loop length asshort as possible.

REMOTE SENSE LEAD CONNECTIONS

Voltage Sensing Overview

The best arc performance occurs when the PowerWave® AC/DC 1000® SD has accurate data about thearc conditions. Depending upon the process, induc-tance within the electrode and work cables can influ-ence the voltage apparent at the studs of the welder,and have a dramatic effect on performance. To coun-teract this negative effect, remote voltage sense leadsare used to improve the accuracy of the arc voltageinformation supplied to the control pc board.

There are several different sense lead configurationsthat can be used depending on the application. Inextremely sensitive applications it may be necessaryto route cables that contain the sense leads awayfrom the electrode and work welding cables.

If the remote voltage sensing is enabled but thesense leads are missing, improperly connectedextremely high welding outputs may occur.

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

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built intothe wire feeder control cable (K1785) and accessibleat the wire drive. It should always be connected to theContact Assembly where the Weld Cable is connect-ed. Enabling or disabling electrode voltage sensing isapplication specific, and automatically configuredthrough software.

Work Voltage Sensing

The use of a remote work voltage sense lead isalways required. The Power Wave® AC/DC 1000® SDis shipped from the factory with the remote work volt-age sense lead enabled. It must be attached to thework as close to the weld as practical, but out of theweld current path. For more information regarding theplacement of remote work voltage sense leads, seethe section entitled "Voltage Sensing Considerationsfor Multiple Arc Systems." The remote WORK senselead (21) can be accessed at the four-pin WORKsense lead connector located on the back panel of thePower Wave AC/DC 1000 SD.

NOTE: All of the machines of a given arc group(Master and Slaves) will relate to theVoltage Sense Lead of the Master machine.

Never connect the WORK sense lead at two differ-ent locations.


• Do not touch electrically live parts orelectrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.------------------------------------------------------------------------

FIGURE A.11

B

A

C

POWERWAVE

WORK

CAUTION

CAUTION

WARNING

A-19INSTALLATION


A-19

VOLTAGE SENSING CONSIDERATIONS FORMULTIPLE ARC SYSTEMS

Special care must be taken when more than one arcis welding simultaneously on a single part. Remotesensing is required in Multi-arc applications

• Avoid common current paths. Current from adja-cent arcs can induce voltage into each others cur-rent paths that can be misinterpreted by the powersources, and result in arc interference.

• Position the sense leads out of the path of theweld current. Especially any current paths commonto adjacent arcs. Current from adjacent arcs caninduce voltage into each others current paths thatcan be misinterpreted by the power sources, andresult in arc interference.

• For longitudinal applications, connect all workleads at one end of the weldment, and all of thework voltage sense leads at the opposite end of theweldment. Perform welding in the direction awayfrom the work leads and toward the sense leads.See Figure A.12.

• For circumferential applications, connect all workleads on one side of the weld joint, and all of thework voltage sense leads on the opposite side, suchthat they are out of the current path. See FigureA.13

FIGURE A.12 MULTI-ARC LONGITUDINAL WELDS

DIRECTION

OF TRAVEL

CONNECT ALLWORK LEADS AT THE BEGINNINGOF THE WELD.

CONNECT ALL WORK SENSELEADS AT THE ENDOF THE WELD.

A-20INSTALLATION


A-20

FIGURE A.13 MULTI-ARC CIRCUMFIRENTIAL WELDS

POWERSOURCE #2

POWERSOURCE #1

POWERSOURCE #1

POWERSOURCE #2

POWERSOURCE #2

POWERSOURCE #1

A-21INSTALLATION


A-21

CONTROL CABLE CONNECTIONS

GENERAL GUIDELINES

These guidelines apply to all communicationcables including optional DeviceNet and Ethernetconnections.

• Genuine Lincoln control cables should be usedat all times (except as noted otherwise). Lincolncables are specifically designed forthe communica-tion and power needs of the Power Wave®/MAXsa™ systems. Most are designed to be con-nected end to endfor ease of operation.

• Always use the shortest cable lengths possi-ble. DO NOT coil excess cable. It is recommend-ed that the total length of control cable does notexceed 100ʼ (30.5M). The use of non-standardcables in excess of 25ʼ (7.5M) can lead to commu-nication problems (system shutdowns), poor motoracceleration (poor arc starting), and low wire dri-ving force (wire feeding problems).

• Best results will be obtained when the controlcables are routed separate from the weldcables. This minimizes the possibility of interfer-ence between the high currents flowing throughthe weld cables and the low level signals in thecontrol cables.

COMMON EQUIPMENT CONNECTIONS

Connection Between MAXsa™ Controller andMAXsa™ series Wire Drive (K1785-xx)

The 14 pin Wire Drive Control Cable (K1785-xx) con-nects the Controller (MAXsa™ 10 or MAXsa™ 19) tothe Wire Drive (MAXsa™ 22 or MAXsa™ 29). Thiscable should be kept as short as possible.

Connection Between Power Source and theMAXsa™ Controller (K2683-xx - ArcLink ControlCable).

Single and tandem arc systems are typically con-trolled by a MAXsa™ 10 Controller. In a tandem, ormulti-arc system, each arc requires its own dedicatedcontroller.

The 5-pin ArcLink control cable connects the powersource to the MAXsa™ 10. If there is more than onepower source per arc, it connects from the MAXsa™10 to the power source designated as the Master forthat arc. The control cable consists of two powerleads, one twisted pair for digital communication, andone lead for voltage sensing (67).

NOTE

Connections Between Power Source and OptionalDeviceNet Programmable Logic Controller(PLC).

It is sometimes more practical and cost effective touse a custom PLC interface to control a multi-arc sys-tem (refer to the "DeviceNet Configuration" section forinterface information). The Power Wave® AC/DC1000® SD is equipped with a 5-pin DeviceNet ministyle receptacle for this purpose. The receptacle islocated on the rear panel of the machine See FigureB.3 The DeviceNet cable is keyed and polarized toprevent improper connection.

NOTE: DeviceNet cables should not be routedwith weld cables, wire drive control cables,or any other current carrying device thatcan create a fluctuating magnetic field.

In a typical system, a DeviceNet connection is madebetween the master power source of each arc, andthe PLC interface. DeviceNet cables must be sourcedlocally by the customer. For additional guidelines referto the "DeviceNet Cable Planning and InstallationManual" (Allen Bradley publication DN-6.7.2).

Connections Between Parallel Power Sources(K1785-xx - Control Cable).

To increase the output capacity for a given arc, theoutput studs of multiple Power Wave® AC/DC 1000®

SD machines can be connected in parallel. The paral-lel machines utilize a master/slave control scheme todistribute the load evenly and to coordinate ACswitching. K1785-xx cables connect the paralleledmachines via the synchronizing connectors on theback of the machine. The system is currently limited toa maximum of 2 slaves per master, or a total of 3machines per arc.

Connections Between Power Sources in Multi-ArcApplications (K1785-xx - Control Cable).

Synchronizing Connectors are available on the rearpanel of the machine for Multi-Arc applications usingthe K1875-xx control cables. The system is currentlylimited to six(6) arcs, or a “Lead” and five “Trail” arcs.

B-1OPERATION


B-1

SAFETY PRECAUTIONSRead this entire section of operating instructions

before operating the machine.


• Unless using cold feed feature, whenfeeding with gun trigger, theelectrode and drive mechanism arealways electrically energized andcould remain energized severalseconds after the welding ceases.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can bedangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can causefire or explosion.

• Keep flammable material away.

• Do not weld on containers that haveheld combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in thebeginning of this manual.

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all weldingprocess variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity ofsingle knob control. The machine will select thecorrect voltage and amperage based on the wirefeed speed (WFS) set by the operator.

COMMON WELDING ABBREVIATIONS

SAW• Submerged Arc Welding

GRAPHIC SYMBOLS THATAPPEAR ON

THIS MACHINE OR IN THISMANUAL

WARNING

WORK SENSE LEADCONNECTOR

MULTI-ARCCONNECTOR

PARALLEL ARCCONNECTOR

ETHERNETCONNECTOR

ARC LINKCONNECTOR

DEVICENETCONNECTOR

115VACRECEPTACLE

Device

COMMUNICATIONS PROTOCOL

NEUTRAL BONDED TO FRAMENEUTRE RACCORDE AU BATINEUTRO CONECTADO AL CHASIS

L15129-4

15V 10A

B-2OPERATIONB-2


INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVEGROUND

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

B-3OPERATIONB-3

PRODUCT SUMMARY

The Power Wave® AC/DC 1000® SD is a highperformance, digitally controlled inverter weldingpower source. It is capable of producing a variablefrequency and amplitude AC output, DC positiveoutput, or DC negative output without the need forexternal reconnection. It utilizes complex, high-speedwaveform control to support a variety of constantcurrent and constant voltage welding modes in eachof its output configurations.

The Power Wave® AC/DC 1000® SD power source isdesigned 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 arcapplications the phase angle and frequency ofdifferent machines can be synchronized byinterconnecting the units with a control cable toimprove performance and reduce the effects of arcblow.

The Power Wave® AC/DC 1000® SD is primarilydesigned to interface with compatible ArcLinkequipment. However, it can also communicate withother industrial machines and monitoring equipmentvia DeviceNet, or Ethernet. The result is a highlyintegrated and flexible welding cell.

RECOMMENDED PROCESSES

The Power Wave® AC/DC 1000® SD is designed forsubmerged arc welding (SAW). Due to its modulardesign the Power Wave® AC/DC 1000® SD canoperate on either single arc or in multi-arc applicationswith up to six arcs. Each machine is factorypreprogrammed with multiple welding procedures tosupport all types of submerged arc welding. ThePower Wave® AC/DC 1000® SD carries an outputrating of 1000 amps, 44 volts (at 100% duty cycle). Ifhigher currents are required machines can be easilyparalleled for up to 3000 amps on each arc.

PROCESS LIMITATIONS

The Power Wave® AC/DC 1000® SD is suitable onlyfor the Submerged Arc Process (SAW).

EQUIPMENT LIMITATIONS

The Power Wave® AC/DC 1000® SD can be used inoutdoor environments. The Operating TemperatureRange is 14°F to 104°F(-10°C to +40°C).

Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives andMAXsa™ 10 or MAXsa™ 19 Controllers may be usedwith a K2803-1 Power Wave® AC/DC 1000® SD in aMulti Arc system. Other Lincoln or non-Lincoln WireDrives can only be used with custom interfaces.

The Power Wave® AC/DC 1000® SD will support amaximum average output current of 1000 Amps at100% Duty Cycle.

COMMON EQUIPMENT PACKAGES

BASIC PACKAGE

K2803-1 Power Wave® AC/DC 1000® SD

K2370-2 MAXsa™ 22 Wire Drive

K2814-1 MAXsa™ 10 Controller / UserInterface

K2683-xx Control Cable (5 pin – 5 pin) - powersource to controller.

K1785-xx Control Cable (14 pin – 14 pin) -Controller to Wire Drive.

OPTIONAL KITS

K1785-xx Control Cable (14 pin – 14 pin) - forparalleling / multiple arc applications.

K2312-2 MAXsa™ 29 Wire Drive (for fixturebuilders).

K2311-1 Motor Conversion Kit (to convertexisting NA-3/NA-4/NA-5 wire feedergear boxes).

K2444-1 CE, C-Tick Filter Kit

K2626-2 MAXsa™ 19 Controller (for fixturebuilders that do not require theMAXsa™ 10 Controller).

RECOMMENDED EQUIPMENT(See Installation Section)


B-4OPERATIONB-4

CASE FRONT CONTROLS

1. Power Switch: Controls input power to the PowerWave® AC/DC 1000® SD and any auxil iaryequipment that may be connected to it.

2. Status Light: A two color LED that indicatessystem errors. Normal operation is steady green.Flashing green or red/green indicates a systemerror. See the Troubleshooting Section.

NOTE: The Power Wave® Status Light will flashgreen for up to 60 seconds at power up asthe machine runs through a self testroutine, and then go to steady green.

3. Thermal Light: A yellow light that comes ON whenan over temperature situation occurs. The machineoutput is disabled until the machine cools downand the thermal light goes OFF.NOTE: The Thermal Light may also indicate a

problem with the AC Switch portion of thepower source. See the TroubleshootingSection.

INPUT POWER SECTION

1. Input Contactor: Connection point for incoming 3phase power. See the Installation Section forinput wiring and fusing information.

2. Case Ground: Used to provide an “earth ground”for the frame of the welder. Consult your local andnational electrical codes for proper groundinginformation.

3. Auxiliary Reconnect: Select the proper tap basedon the supply voltage.

4. Fuse (F1): Protection for the primary side of theauxiliary transformer

5. Cord Connector: Input power cord strain relief.


FIGURE B.1 - CASE FRONT

2

3

1

FIGURE B.2 - INPUT SECTION (LEFT SIDE)

5

1 3

2 4

L15129-2

380-415V 440-

460V

500V 550-575V

B-5OPERATIONB-5

CASE BACK COMPONENTS (See Figure B.3)

1. 10 Amp Circuit Breaker (CB1): Protects the 40VDC wire feeder power supply.

2. 10 amp Circuit Breaker (CB-2): Protects the 115VAC Auxiliary Power Receptacle.

3. Work Sense Lead Connector(4 Pin): Connection point for the #21 lead.

4. Arclink Connector (5 Pin): Provides power and communication to the controller.

5. Devicenet Connector: Provides Devicenet communication to remote equipment.

6. Output Studs (2) (WORK): Connection point for welding cable(s) to the work piece.

7. Output Studs (2) (ELECTRODE): Connection point for welding cables to the Wire Drive.

8. Auxiliary Output Receptacle: Provides 10 amps of 115VAC power.

9. Ethernet Connector (RJ-45): Provides Ethernet communication to remote equipment.

10. Master Input: From Lead or previous trail arc in a Multi-arc system

11. Master Output: To subsequent trail arc in a Multi-arc system.

12. Parallel Input: From Master or previous Slave in a parallel machine set up.

13. Parallel Output: To Slave in a parallel machine set up


FIGURE B.3 - CASE BACK COMPONENTS

123

4

9

5

6

7

810

11

12

13

Stud Cover Doors Removedfor Clarity

COMMUNICATIONS PROTOCOL

115V AC

10 A

10 A 40V

L15129-1

-

-Device

123

4 5 8

910 11

12 13

B-6OPERATIONB-6


B-7OPERATIONB-7


POWER-UP SEQUENCE

When power is applied to the Power Wave® AC/DC1000® SD, the status lights will flash green for up to 60seconds. During this time the Power Wave® AC/DC1000® SD is performing a self test, and mapping(identifying) each component in the local ArcLinksystem. The status lights will also flash green as aresult of a system reset or configuration changeduring operation. When the status lights becomesteady green the system is ready for use

If the status lights do not become steady greenconsult the troubleshooting section of this manual forfurther instruction.

DUTY CYCLE

The Power Wave® AC/DC 1000® SD is capable ofwelding 1000Amps, @ 44 Volts, at a 100% duty cycle.

COMMON WELDING PROCEDURES

MAKING A WELD

The serviceability of a product or structureutilizing the welding programs is and must be thesole responsibility of the builder/user. Manyvariables beyond the control of The LincolnElectric Company affect the results obtained inapplying these programs. These variablesinclude, but are not limited to, welding procedure,plate chemistry and temperature, weldmentdesign, fabrication methods and servicerequirements. The available range of a weldingprogram may not be suitable for all applications,and the build/user is and must be solelyresponsible for welding program selection.

The steps for operating the Power Wave® AC/DC1000® SD will vary depending upon the user interfaceof the welding system. The flexibility of the system letsthe user customize operation for the bestperformance.

Consult the User Interface documentation for moredetailed set up information. (MAXsa™ 10, CommandCenter, PLC, Robot etc..)

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

Second, find the program in the welding software thatbest matches the desired welding process. Thestandard software shipped with the Power Wave®

AC/DC 1000® SD encompasses a wide range ofcommon processes and will meet most needs. If aspecial welding program is desired, contact the localLincoln Electric sales representative.

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

OVERVIEW OF THE AC/DC SUBMERGEDARC PROCESS

The Power Wave® AC/DC 1000® SD combines theadvantages of AC and DC Submerged Arc Welding(SAW) into a single power source. The limiting factorof AC-SAW welding has traditionally been the time ittakes to transition from positive to negative polarity.This lag through the zero crossing can cause arcinstability, penetration, and deposition problems incertain applications. The Power Wave® AC/DC 1000®

SD utilizes the speed of an inverter based powersource, and the flexibility of Waveform ControlTechnology™ to address this issue.

By adjusting the Frequency, Wave Balance and Offsetof the AC waveform the operator can now control thebalance (relationship) between the penetration of DCpositive and the deposition of DC negative whiletaking full advantage of the reduction in arc blowassociated with AC.

FIGURE B.4 - AC/DC SUBMERGED ARC PROCESS

TimePositive

Current

NegativeCurrent

Cur

rent

Output waveform variations made possible by Waveform Control Technology

Depending on the process, different parts of the output waveform and wire feed speed may be modulat ed at varying rates to achieve a smooth and stable arc.

TM

Frequency

Pulse Width

Transition Ratedi/dT

B-8OPERATIONB-8


MULTIPLE ARC SYSTEMCONSIDERATIONS

Large scale SAW applications often employ multiplearcs to increase deposition rates. In multiple arcsystems, magnetic forces created by l ike andopposing weld currents of adjacent arcs can result inarc interaction that can physically push or pull the arccolumns together. See Figure B.5. To counteract thiseffect, the phase relationship between adjacent arcscan be set to alternate and equalize the duration ofmagnetic push and pull forces. This is accomplishedthrough the synchronizing cables (K1785-xx). Ideally,the net result is a cancellation of the interactingforces. See Figure B.6.

Never simultaneously touch electrically "hot"parts in the electrode circuits of two differentwelders. The electrode to electrode no loadvoltage of multiple arc systems with oppositepolarities can be double the no load voltage ofeach arc. Consult the Safety information locatedat the front of the Instruction Manual for additionalinformation.------------------------------------------------------------------------

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:

- 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.

FIG. B.5 - ARC INTERFERENCE

+ -- +

PUSH

+ +- -

PULL

+ -- ++ -

+

PUSH

+ +- -

PULLPUSH

+ +- -+ +-+ +- -

PULL

FIG. B.6 SYNCHRONIZED ARCS

Lead Arc

Trai l Arc

Pos

itive

Neg

ativ

e

Pos

itive

Pos

itive

Neg

ativ

eN

egat

ive

Pos

itive

N

egat

ive

Pos

itive

Neg

ativ

e

Lead Arc

Trai l Arc

PU

SH

PU

SH

PU

SH

PU

LL

PU

LL

CAUTION

ExtensionHeating= Vir

Arc Length= Varc

Total ElectricalStick outV= Vir+Varc

TO

MAINTAIN CONSTANT ARC LENGTH

AND

WIRE FEED SPEED VARIED

CURRENT HELDCONSTANT

AMPS

WIRE FEED SPEED

ExtensionHeating= Vir

Arc Length= Varc

Total ElectricalStick outV= Vir+Varc

TO

MAINTAIN CONSTANTARC LENGTH

AND

WIRE FEED SPEEDHELD CONSTANT

CURRENT VARIED

AMPS

WIRE FEED SPEED

FIGURE B.7 - CONSTANT CURRENT

FIGURE B.8

B-9OPERATIONB-9


WELD SEQUENCE

The weld sequence defines the weld procedure frombeginning to end. The Power Wave® AC/DC 1000® SDnot only provides adjustment of basic weldingparameters, but also allows the operator to fine tunethe start and finish of each weld for superiorperformance.

All adjustments are made through the user interface.Because of the different configuration options, yoursystem may not have all of the following adjustments.Regardless of availability, all controls are describedbelow.

START OPTIONS

The Delay, Strike, Start, and Upslope parameters areused at the beginning of the weld sequence toestablish a stable arc and provide a smooth transitionto the welding parameters.

• ARC DELAY inhibits the wire feed for up to 5 sec-onds to provide an accurate weld start point.Typically used in multi-arc systems.

• Strike settings are valid from the beginning of thesequence (Start Button Pressed) until the arc isestablished. They control Run-in (speed at whichthe wire approaches the workpiece), and providethe power to establish the arc.Typically output levels are increased and WFS isreduced during the Strike portion of the weldsequence

• Start values allow the arc to become stabilized onceit is established.Extended Start times or improperly set parameterscan result poor starting

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

END OPTIONS

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

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

• Crater parameters are typically used to fill the craterat the end of the weld, and include both time andoutput settings.

• Burnback defines the amount of time the outputremains on after the wire has stopped. This featureis used to prevent the wire from sticking in the weldpuddle, and condition the end of the wire for thenext weld. A Burnback time of 0.4 sec is sufficient inmost applications. The output level for Burnback isthe same level as the last active weld sequencestate (either Weld or Crater).

• Restrike Timer is used to protect the weldingsystem and/or work piece being welded. If the arcgoes out for any reason (short circuit or opencircuit), the Power Wave® AC/DC 1000® SD willenter a Re-strike state and automatically manipulatethe WFS and output in an attempt to re-establish thearc. The Re-strike timer determines how long thesystem will attempt to re-establish the arc before itshuts down. • A Re-strike time of 1 to 2 sec is sufficient in most

applications.• A Re-Strike setting of “OFF” allows for infinite

restriking attempts until a shutdown occurs.

FIGURE B.9 WELD SEQUENCE

Out

put

Strike Upslope Weld Downslope

Time

Arc Start Delay Start Crater Burnback

Sta

rtB

utto

nP

ress

ed

Wire

Beg

ins

toF

eed

Wire

Tou

ches

Pla

te

End

ofS

tart

Tim

er

End

ofU

pslo

pe

Sto

pB

utto

nP

ress

ed

End

ofD

owns

lope

End

ofC

rate

rT

imer

End

ofB

urnb

ack

B-10OPERATIONB-10


WELD PROCESS ADJUSTMENTS

Depending on the weld mode, there are a number ofadjustments that can be made, including but notl imited to Current, Voltage and WFS. Theseadjustments apply to either AC or DC processes, andcontrol the basic parameters of the weld.

AC ADJUSTMENTS

In addition to the basic weld parameters, there are anumber of unique adjustments related to the ACwaveform of the Power Wave® AC/DC 1000® SD.These adjustments enable the operator to balance therelationship between penetration and deposition totailor the output for specific applications.

WAVE BALANCE

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

• Use Wave Balance to control the penetration anddeposition of a given process. See Figure B.10.

DC OFFSET

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

• Use Offset to control the penetration and depositionof a given process. See Figure B.11.

FREQUENCY

• Power Wave® AC/DC 1000® SD can produce OutputFrequencies from 20 - 100Hz

• Use Frequency to help provide stability.

• Higher frequencies in multiple arc setups can helpreduce arc interaction.

• Lower frequencies will help overcome output limita-tions due to inductance in the Weld Circuit. SeeFigure B.12.

FIGURE B.10 - WAVE BALANCE

500

-500

0

-1000

1000

Nominal BalanceIncreased Balance

More PenetrationLess Deposition Decreased Balance

Less PenetrationMore Deposition

FIGURE B.11 - DC OFFSET

500

-500

0

-1000

1000

Nominal Offset

Positive OffsetMore PenetrationLess Deposition

Negative OffsetLess PenetrationMore Deposition

FIGURE B.12 - FREQUENCY

500

-500

0

-1000

1000 Use Frequency to fin e tune stability ofimbalanced waveform s and multipl e arc syst ems

IncreaseDecrease

B-11OPERATIONB-11


PHASE ADJUSTMENT FOR MULTIPLEARC SYSTEMS

Phase• The phase relationship between the arcs helps to

minimize the magnetic interaction between adjacentarcs. It is essentially a time offset between thewaveforms of different arcs, and is set in terms of anangle from 0 to 360°, representing no offset to a fullperiod offset. The offset of each arc is setindependently with respect to the lead arc of thesystem (ARC 1).

Recommendations:

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

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

relative to adjacent arcs.

500

-500

0

Use Phase Relation ship to minimize arc blowin 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 ofmagnetic forces between adjacent arcs.

PHASE RELATIONSHIP

TABLE B.1 - PHASE RELATIONSHIP

ARC 1Lead

ARC 2Trail

ARC 3Trail

ARC 4Trail

ARC 5Trail

ARC 6Trail

2 ArcSystem 0° 90° X X X X

3 ArcSystem 0° 90° 180° X X X

4 ArcSystem 0° 90° 180° 270° X X

5 ArcSystem 0° 90° 180° 270° 0° X

6 ArcSystem 0° 90° 180° 270° 0° 90°

C-1ACCESSORIESC-1


OPTIONS AND ACCESSORIES areavailable at www.lincolnelectric.com

Follow these steps:

1. Go to www.lincolnelectric.com

2. In the Search field type E9.181 and click on theSearch icon (or hit ʻEnterʼ on the keyboard).

3. On the Results page, scroll down to theEquipment list and click on E9.181.

All of the information for the Power Wave® Systemaccessories can be found in this document.

SOFTWARE TOOLS

Power Wave® AC/DC 1000® SD software tools and other documents related to the integration, configuration, andoperation of the system is available at www.powerwavesoftware.com. Power Wave® Submerged Arc Utilitiesincludes the following items and all of the documentation to support them.

Name Purpose

Weld Manager Setup Ethernet address information, and apply security settings.Utility to diagnose Power Wave® problems, read system information,calibrate output voltage and current, test sense leads, and diagnosefeed head issues. Can also setup and verify DeviceNet operation.

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 powersource (more than one Power Wave® per arc) systems.• Multi Arc setup• Generators Command Center connection file• Setup Verification-output cables (cables crossed)-software versions (Master to slave and Arc to Arc)-I/O verification (Master to Master and Master to slave)-sense lead-inductance test

• Gear Box / Feeder Selection• Memory Lables• DeviceNet setup and Verification• UI setup (Lockout and Limits)• Ethernet setup and Verification • Diagnostic

-snapshot-weldview-error lookup-inductance test-sense lead test

• Calibration (I,V,WFS)• Cable Test

-inductance-sense leads

D-1MAINTENANCED-1


SAFETY PRECAUTIONS


• Only Qualified personnel shouldperform this maintenance.

• Turn the input power OFF at the disconnectswitch or fuse box before working on thisequipment.

• Do not touch electrically hot parts.

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowingout the machine, using a low-pressure airstream, toremove accumulated dust and dirt from the intake andoutlet louvers, and the cooling channels in themachine.

The rear portion of the machine that contains the filterand the cooling fans slides out for easy access.Removing the four(4) clips and pulling back on therear portion of the machine will provide access forcleaning the machine and checking the filter. The filtermay be removed from the right side of the machine.See Figure A.1.

PERIODIC MAINTENANCE

Calibration of the Power Wave® AC/DC 1000® SD iscritical to its operation. Generally speaking thecalibration will not need adjustment. However,neglected or improperly calibrated machines may notyield satisfactory weld performance. To ensureoptimal performance, the calibration of output Voltageand Current should be checked yearly.

WARNING

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at thefactory. Generally speaking the machine calibrationwill not need adjustment. However, if the weldperformance changes, or the yearly calibration checkreveals a problem, use the calibration section of theWeld Manager Utility to make the appropriateadjustments.

The calibration procedure itself requires the use of agrid (Resistive Load Bank), and certified actual metersfor voltage and current. The accuracy of thecalibration will be directly affected by the accuracy ofthe measuring equipment you use. The WeldManager Utility includes detailed instructions, and isavailable on the internet at powerwavesoftware.comunder Power Wave® Submerged Arc Utilities.

E-1TROUBLESHOOTINGE-1


If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

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

Step 1. LOCATE PROBLEM (SYMPTOM).This column describes possible symptoms that themachine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING



Observe all Safety Guidelines detailed throughout this manual


CAUTION

USING THE STATUS LED TO TROUBLESHOOTSYSTEM PROBLEMS

The Power Wave® AC/DC 1000® SD is equipped with one externallymounted status light. If a problem occurs it is important to note thecondition of the status lights. Therefore, prior to cycling power tothe system, check the power source status light for errorsequences as noted below.

Included in this section is information about the power source StatusLED and some basic troubleshooting charts for both machine andweld performance.

The STATUS LIGHT is a dual-color LED that indicates system errors.Normal operation is steady green. Error conditions are indicated in thefollowing Table E.1.

LightCondition

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

Meaning

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

Occurs during power up or a system reset, and indicates the POWER WAVE®

is mapping (identifying) each component in the system. Normal for first 1-10seconds after power is turned on, or if the system configuration is changedduring operation.

Under normal conditions indicates Auto-mapping has failed. Also used byWeld Manager and Submerged Arc Cell Setup (available at www.power-wavesoftware.com) to identify the selected machine when connecting to aspecific IP address.

Non-recoverable system fault. If the Status lights are flashing any combinationof red and green, errors are present. Read the error code(s) before themachine is turned off.

Error Code interpretation through the Status light is detailed in the ServiceManual. Individual code digits are flashed in red with a long pause betweendigits. If more than one code is present, the codes will be separated by agreen light. Only active error conditions will be accessible through the StatusLight.

Error codes can also be retrieved with Weld Manager under System Status(available at www.powerwavesoftware.com). This is the preferred method,since it can access historical information contained in the error log.

To clear the active error(s), turn power source off, and back on to reset.

Not applicable.

Not applicable.

TABLE E.1





CAUTION

LECO(FANUC#)

49

50

51

52

53

54

55

57

67

see complete

listing

POWER SOURCE–––WELD CONTROLLER

ERROR CODES FOR THE POWER WAVE®

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

Error Code #

31 Primary (Input) overcurrent error.

32 Capacitor “A” under voltage (right side facing the Switch PC Board)

33 Capacitor bank "B" under voltage(left side facing the Switch PC Board)

34 Capacitor "A" over voltage (right side facing the Switch PC Board)

35 Capacitor "B" over voltage(left side facing the Switch PC Board)

36 Thermal error

37 Softstart (pre-charge) error

39 Misc. hardware fault

43 Capacitor delta error

Other

Indication

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

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

Excess voltage on the main capacitors. May be caused byimproper input configuration, excessive line voltage, orimproper capacitor balance (see Error 43)

Indicates over temperature. Usually accompanied byThermal LED. Check fan operation. Be sure process doesnot exceed duty cycle limit of the machine. Also acts witha malfunction.

Capacitor precharge failed. Usually accompanied bycodes 32 and 33.

Unknown glitch has occurred on the fault interrupt circuit-ry. Sometimes caused by primary over current fault, orintermittent connections in the thermostat circuit.

The maximum voltage difference between the main capac-itors has been exceeded. May be accompanied by errors32-35. May be caused by an open or short in the primaryor secondary circuit(s).

A complete list of error codes is available in WeldManager under Tools -> Lookup Error (available atwww.powerwavesoftware.com).

Error codes that contain three or four digits are defined asfatal errors. These codes generally indicate internal errorson the Power Source Control Board. If cycling the inputpower on the machine does not clear the error, contact theService Department





CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

BASIC MACHINE PROBLEMS

Major physical or electrical damageis evident when the sheet metalcovers are removed.

Input fuses keep blowing

Machine will not power up (nolights)

None

1. Improperly sized input fuses.

2. Improper Weld Procedurerequiring output levels inexcess of machine rating.

3. Major physical or electricaldamage is evident when thesheet metal covers areremoved.

1. No Input Power.

2. Fuse F1 (in reconnect area)may have blown.

3. Circuit breaker CB1 (on thecontrol panel) may havetripped.

4. Improper input voltage selec-tion (multiple input voltagemachines only).

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assis-tance.

1. Make sure fuses are properlysized. See installation sectionof this manual for recom-mended sizes.

2. Reduce output current, dutycycle, or both.

3. Contact your local authorizedLincoln Electric Field Servicefacility for technical assis-tance.

1. Make sure input supply dis-connect has been turned ON.Check input fuses. Make cer-tain that the Power Switch(SW1) on the power source isin the “ON” position.

2. Power Down and replace thefuse.

3. Power Down and reset CB1.

4. Power down, check input volt-age reconnect according todiagram on reconnect cover.

F-1DIAGRAMSF-1


NO

TE

: T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-2DIAGRAMSF-2


NO

TE

: T

his

diag

ram

is fo

r re

fere

nce

only

. It

may

not

be

accu

rate

for

all m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a

part

icul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pane

ls.

If th

e di

agra

m is

ille

gibl

e, w

rite

to th

e S

ervi

ce D

epar

tmen

t for

a r

epla

cem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-3DIMENSION PRINTF-3


L151

50A

19.1

2

19.7

1

9.56

9.56

46.6

0

19.4

77.

94

45.7

549

.13

61.3

0

22.6

3

33.0

0

WID

TH

NE

ED

ED

FO

R F

ILT

ER

MA

INT

EN

AN

CE

AC

CE

SS

FIL

TE

R R

EM

OV

AL

FR

OM

SID

E O

F M

AC

HIN

E

NOTES


WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

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

Do not touch electrically live parts orelectrode with skin or wet clothing.Insulate yourself from work andground.

No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.Aislese del trabajo y de la tierra.

Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.Isolez-vous du travail et de la terre.

Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!Isolieren Sie sich von denElektroden und dem Erdboden!

Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.Isole-se da peça e terra.

Keep flammable materials away.

Mantenga el material combustiblefuera del área de trabajo.

Gardez à l’écart de tout matérielinflammable.

Entfernen Sie brennbarres Material!

Mantenha inflamáveis bem guarda-dos.

Wear eye, ear and body protection.

Protéjase los ojos, los oídos y elcuerpo.

Protégez vos yeux, vos oreilles etvotre corps.

Tragen Sie Augen-, Ohren- und Kör-perschutz!

Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

Keep your head out of fumes.Use ventilation or exhaust toremove fumes from breathing zone.

Los humos fuera de la zona de res-piración.Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

Gardez la tête à l’écart des fumées.Utilisez un ventilateur ou un aspira-teur pour ôter les fumées des zonesde travail.

Vermeiden Sie das Einatmen vonSchweibrauch!Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

Mantenha seu rosto da fumaça.Use ventilação e exhaustão pararemover fumo da zona respiratória.

Turn power off before servicing.

Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

Débranchez le courant avant l’entre-tien.

Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

Não opere com as tampas removidas.Desligue a corrente antes de fazerserviço.Não toque as partes elétricas nuas.

Do not operate with panel open orguards off.

No operar con panel abierto oguardas quitadas.

N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

Mantenha-se afastado das partesmoventes.Não opere com os paineis abertosou guardas removidas.

Need Help?

Lincoln Electric “Rapid Response” Service!

Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 A.M. to 6:00 P.M. (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you by the next business day.

• For Non-U.S. Service: Email [email protected]

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [email protected]

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Copyright © Lincoln Global Inc.

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