POWER WAVE AC/DC 1000 SD - Lincoln Electric...May 16, 2018 · POWER WAVE ®AC/DC 1000 ... damaged in shipment must be made by the purchaser against the transportation company at

Operator’s Manual

POWER WAVE ®AC/DC 1000 ® SD

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IM10213-A | Issue D ate Oct-15

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

12385

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Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

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

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

FOR ENGINE POWEREDEQUIPMENT.

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

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

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich 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 and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

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

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.

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

In addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

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 It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the 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.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined 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 theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating 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 procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

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

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any 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 hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

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

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

ELECTROMAGNETICCOMPATIBILITY (EMC)

ConFormanCe

Products displaying the CE mark are in conformity with EuropeanCommunity Council Directive of 3 May 1989 on the approximation ofthe laws of the Member States relating to electromagnetic compat-ibility (89/336/EEC). It was manufactured in conformity with a nationalstandard that implements a harmonized standard: EN 60974-10Electromagnetic Compatibility (EMC) Product Standard for ArcWelding Equipment. It is for use with other Lincoln Electricequipment. It is designed for industrial and professional use.

introduCtion

All electrical equipment generates small amounts of electromagneticemission. Electrical emission may be transmitted through power linesor radiated through space, similar to a radio transmitter. Whenemissions are received by other equipment, electrical interferencemay result. Electrical emissions may affect many kinds of electricalequipment; other nearby welding equipment, radio and TV reception,numerical controlled machines, telephone systems, computers, etc.Be aware that interference may result and extra precautions may berequired when a welding power source is used in a domestic estab-lishment.

installation and use

The user is responsible for installing and using the welding equipmentaccording to the manufacturer’s instructions. If electromagneticdisturbances are detected then it shall be the responsibility of theuser of the welding equipment to resolve the situation with thetechnical assistance of the manufacturer. In some cases this remedialaction may be as simple as earthing (grounding) the welding circuit,see Note. In other cases it could involve construction of an electro-magnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbancesmust be reduced to the point where they are no longer troublesome.Note: The welding circuit may or may not be earthed for safety reasons according to

national codes. Changing the earthing arrangements should only be authorized by a per-son who is competent to access whether the changes will increase the risk of injury, e.g.,by allowing parallel welding current return paths which may damage the earth circuits ofother equipment.

assessment oF area

Before installing welding equipment the user shall make anassessment of potential electromagnetic problems in the surroundingarea. The following shall be taken into account:

a. other supply cables, control cables, signaling and telephone cables;above, below and adjacent to the welding 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 andhearing aids;

f. equipment used for calibration or measurement

g. the immunity of other equipment in the environment. The user shallensure that other equipment being used in the environment iscompatible. This may require additional protection measures;

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

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

methods oF reduCing emissions

Mains SupplyWelding equipment should be connected to the mains supplyaccording to the manufacturer’s recommendations. If interferenceoccurs, it may be necessary to take additional precautions such asfiltering of the mains supply. Consideration should be given toshielding the supply cable of permanently installed weldingequipment, in metallic conduit or equivalent. Shielding should beelectrically continuous throughout its length. The shielding should beconnected to the welding power source so that good electrical contactis maintained between the conduit and the welding power sourceenclosure.

Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according tothe manufacturer’s recommendations. All access and service doorsand covers should be closed and properly fastened when the weldingequipment is in operation. The welding equipment should not bemodified in any way except for those changes and adjustmentscovered in the manufacturers instructio ns. In particular, the sparkgaps of arc striking and stabilizing devices should be adjusted andmaintained according to the manufacturer’s recommendations.

Welding CablesThe welding cables should be kept as short as possible and should bepositioned close together, running at or close to floor level.

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

Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, notconnected to earth because of its size and position, e.g., ships hull orbuilding steelwork, a connection bonding the workpiece to earth mayreduce emissions in some, but not all instances. Care should be takento prevent the earthing of the work piece increasing the risk of injuryto users, or damage to other electrical equipment. Where necessary,the connection of the workpiece to earth should be made by a directconnection to the work piece, but in some countries where directconnection is not permitted, the bonding should be achieved bysuitable capacitance, selected according to national regulations.

Screening and ShieldingSelective screening and shielding of other cables and equipment inthe surrounding area may alleviate problems of interference.Screening of the entire welding installation may be considered forspecial applications. 1 Portions of the preceding text are contained in EN 60974-10: “ElectromagneticCompatibility (EMC) product standard for arc welding equipment.”

SAFETY

TABLE OF CONTENTS

7

Page

Definition of Welding Modes, Graphic Symbols.......................................................................................................8,9 Product Summary, Recommended Process, Process and Equipment Limitations.....................................................10 Common Equipment Packages and Recommended Equipment ...............................................................................10 Installation ................................................................................................................................................Section A Specifications ...............................................................................................................................................A-1 Safety Precautions. .......................................................................................................................................A-2 Location and Mounting .........................................................................................................................A-2 Stacking ...............................................................................................................................................A-2 Lifting...................................................................................................................................................A-2 Environmental Limitations.....................................................................................................................A-2 Electromagnetic Compatibility...............................................................................................................A-2 Clearance Requirements.......................................................................................................................A-3 Input Voltage Selection and Ground Connections...................................................................................A-4 Connection Diagram .............................................................................................................................A-4 System Connection...............................................................................................................................A-5 Connection Diagrams and Check List ....................................................................................A-6 thru A-16 Electrode and Work Connection ..........................................................................................................A-17 Cable Inductance, Remote Sense Lead Connection ...................................................................A-18, A-19 Multi-Arc Circumfirential Welds ..........................................................................................................A-20 Control Cable Connections, Common Equipment Connections.............................................................A-21_________________________________________________________________________________________ Operation Section B Safety Precautions ........................................................................................................................................B-1 Case Front Control Descriptions ....................................................................................................................B-2 Input Power Section ......................................................................................................................................B-2 Case Back Components.........................................................................................................................B-3, B-4 Power-Up Sequence .....................................................................................................................................B-5 Duty Cycle ....................................................................................................................................................B-5 Common Welding Procedures .......................................................................................................................B-5 Overview of the AC/DC Submerged Arc Process ............................................................................................B-5 Multiple Arc System Considerations ..............................................................................................................B-6 Basic Modes of Operation (CC / CV)...............................................................................................................B-6 Weld Sequence, Start Options, End Options, Re-Strike Timer ........................................................................B-7 Weld Process Adjustment, Wave Balance, DC Offset, Frequency ...................................................................B-8 Phase Adjustment for Multiple Arc Systems .................................................................................................B-9_________________________________________________________________________________________ Accessories .............................................................................................................................Section C Kits, Options and Accessories ......................................................................................................C-1 Software Tools.............................................................................................................................C-1________________________________________________________________________________ Maintenance............................................................................................................................Section D Safety Precautions.......................................................................................................................D-1 Routine and Periodic Maintenance ...............................................................................................D-1 Calibration Specification ..............................................................................................................D-1________________________________________________________________________________ Troubleshooting.......................................................................................................................Section E How to Use Troubleshooting Guide ...............................................................................................E-1 Using the Status LED to Troubleshoot System Problem.................................................................E-2 Error Codes ..........................................................................................................................E-3, E-4 Troubleshooting Guide .................................................................................................................E-5________________________________________________________________________________ Wiring Diagrams and Dimension Print ...................................................................................Section F Wiring Diagram - Power Wave® AC/DC 1000® SD........................................................................F-1 Wiring Diagram - AC Switch .......................................................................................................F-2 Dimension Print ...........................................................................................................................F-3________________________________________________________________________________ Parts List ........................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

8

GENERAL DESCRIPTIONPRODUCT MODEL

DEFINITIONS OF WELDING MODES

NON-SYNERGIC WELDING MODES

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

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of single knobcontrol. The machine will select the correct voltage andamperage based on the wire feed speed (WFS) set by theoperator.

COMMON WELDING ABBREVIATIONS

SAW• Submerged Arc Welding

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

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

9

GENERAL DESCRIPTIONPOWER WAVE® AC/DC 1000® SD

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

PROTECTIVE GROUND

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

U0

U1

U2

I1

I2

10

GENERAL DESCRIPTIONPOWER WAVE® AC/DC 1000® SD

PRODUCT SUMMARY

The Power Wave® AC/DC 1000® SD is a high performance,digitally controlled inverter welding power source. It is capableof producing a variable frequency and amplitude AC output, DCpositive output, or DC negative output without the need forexternal reconnection. It utilizes complex, high-speed waveformcontrol to support a variety of constant current and constantvoltage welding modes in each of its output configurations.

The Power Wave® AC/DC 1000® SD power source is designed tobe a part of a modular welding system. Each welding arc may bedriven by a single machine, or by a number of machines inparallel. In multiple arc applications the phase angle andfrequency of different machines can be synchronized byinterconnecting the units with a control cable to improveperformance and reduce the effects of arc blow.

The Power Wave® AC/DC 1000® SD is primarily designed tointerface with compatible ArcLink equipment. However, it canalso communicate with other industrial machines and monitoringequipment via DeviceNet, or Ethernet. The result is a highlyintegrated and flexible welding cell.

RECOMMENDED PROCESSES

The Power Wave® AC/DC 1000® SD is designed for submergedarc welding (SAW). Due to its modular design the Power Wave®

AC/DC 1000® SD can operate on either single arc or in multi-arcapplications with up to six arcs. Each machine is factorypreprogrammed with multiple welding procedures to support alltypes of submerged arc welding. The Power Wave® AC/DC 1000®

SD carries an output rating of 1000 amps, 44 volts (at 100%duty cycle). If higher currents are required machines can beeasily paralleled for up to 3000 amps on each arc.

PROCESS LIMITATIONS

The Power Wave® AC/DC 1000® SD is suitable only for theSubmerged Arc Process (SAW).

EQUIPMENT LIMITATIONS

The Power Wave® AC/DC 1000® SD can be used in outdoorenvironments. The Operating Temperature Range is 14°F to104°F(-10°C to +40°C).

Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives and MAXsa™10 or MAXsa™ 19 Controllers may be used with a Power Wave®

AC/DC 1000® SD in a Multi Arc system. Other Lincoln or non-Lincoln Wire Drives can only be used with custom interfaces.

The Power Wave® AC/DC 1000® SD will support a maximumaverage output current of 1000 Amps at 100% Duty Cycle.

COMMON EQUIPMENT PACKAGES

BASIC PACKAGE

K2803-x Power Wave® AC/DC 1000® SD

K2370-x MAXsa™ 22 Wire Drive

K2814-x MAXsa™ 10 Controller / User Interface

K2683-xx Control Cable (5 pin – 5 pin) - power source tocontroller.

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

OPTIONAL KITS

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

K2312-x MAXsa™ 29 Wire Drive (for fixture builders).

K2311-1 Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5wire feeder gear boxes).

K2444-1 CE, C-Tick Filter Kit

K2626-x MAXsa™ 19 Controller (for fixture builders that do notrequire the MAXsa™ 10 Controller).

RECOMMENDED EQUIPMENT(See Installation Section)

A-1

INSTALLATIONPOWER WAVE® AC/DC 1000® SD

TECHNICAL SPECIFICATIONS - Power Wave® AC/DC 1000® SD (K2803-2*)

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES1

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS

3 PHASE 50/60 Hz380400460500575

OPENCIRCUITVOLTAGE

77V

3 PHASE INPUTVOLTAGE 50/60Hz

380400460500575

HEIGHT49.13 in1248 mm

WIDTH19.71 in501mm

DEPTH46.60 in1184 mm

WEIGHT800 lbs.363 kg.

TIME-DELAY FUSEOR BREAKER2

AMPS

10090908070

COPPER GROUNDINGCONDUCTORAWG (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 AMPS115 VAC AT10 AMPS

INPUTCURRENT AMPS

827969 6255

IDLEPOWER WATTS

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 externalfilter. (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 60974-1IP 23

A-2


LIFTING

Lift the machine by the lift bail only. The lift bail is designed to liftthe power source only. Do not attempt to lift the Power Wave®

AC/DC 1000® SD with accessories attached to it.

ENVIRONMENTAL LIMITATIONS

The Power Wave® AC/DC 1000® SD can be used in an outdoorenvironment with an IP 23 rating. It should not be subjected tofalling water, nor should any parts of it be submerged in water.Doing so may cause improper operation as well as pose a safetyhazard. The best practice is to keep the machine in a dry,sheltered area.

ELECTROMAGNETIC COMPATIBILITY (EMC)

The EMC classification ot the Power Wave® AC/DC 1000® SD isIndustrial, Scientific and Medical (ISM) group 2, class A. ThePower Wave® AC/DC 1000® SD is for industrial use only.

Locate the Power Wave® away from radio controlled machinery.

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

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

SAFETY PRECAUTIONSRead this entire installation section before you startinstallation.

ELECTRIC SHOCK can kill.• Only qualified personnel should performthis installation.

• Turn the input power OFF at the disconnectswitch or fuse box before working on thisequipment. Turn off the input power to anyother equipment connected to the weldingsystem at the disconnect switch or fusebox before working on the equipment.

• Do not touch electrically hot parts.• Always connect the Power Wave grounding lug (locatedinside the reconnect input access door) to a proper safety(Earth) ground.

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

LOCATION AND MOUNTING

Place the welder where clean cooling air can freely circulate inthrough the rear louvers and out through the case sides andfront. Dirt, dust, or any foreign material that can be drawn intothe welder should be kept at a minimum. Failure to observethese precautions can result in excessive operating temperaturesand nuisance shutdowns. See the Clearance Requirements andFigure A.1. in this section.

This equipment is for industrial use only and it is not intended foruse in residential locations where the electrical power is provid-ed by the public low-voltage supply system. There can be poten-tial difficulties in residential locations due to conducted as wellas radiated radio-frequency disturbances. The EMC or RF classi-fication of this equipment is Class A.

STACKING

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly understationary or fixed electrical equipment, the surface shall becovered with a steel plate at least .06”(1.6mm) thick, whichshall extend not more than 5.90”(150mm) beyond theequipment on all sides.--------------------------------------------------------------------

Power Wave® AC/DC 1000® SD machine cannot be stacked.

CAUTION

• Lift only with equipment of adequatelifting capacity.

• Be sure machine is stable whenlifting.

• Do not lift this machine using lift bailif it is equipped with a heavyaccessory such as trailer or gascylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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

CAUTION

WARNING

WARNING

A-3


CLEARANCE REQUIREMENTS

The maintenance requirements of the Power Wave® AC/DC1000® SD demand that enough clearance behind the machine bemaintained. This is especially important where more than onemachine is to be used or if the machines are going to be rackmounted.

The rear portion of the machine that contains the filter and thecooling fans slides out for easy access to clean the heat sinkfins.

Removing the four(4) clips and pulling back on the rear portion ofthe machine will provide access for cleaning the machine andchecking the filter. The filter is removed from the right side ofthe machine.

Where machines are mounted side by side, the machine that isfurthest to the right will need to have the indicated clearance tothe right side for filter removal. See Figure A.1.

FIGURE A.1 - CLEARANCE REQUIREMENTS

61.30

22.6333.00

WIDTH NEEDED FOR FILTERMAINTENANCE ACCESS

FILTER REMOVALFROM SIDE OF MACHINE

A-4


INPUT AND GROUND CONNECTIONS

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminalmarked with the symbol shown is located inside the reconnect /input access door for this purpose. See your local and nationalelectrical codes for proper grounding methods.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to Specifications page for recommended fuse and wire sizes. Fusethe input circuit with the recommended super lag fuse or delay typebreakers (also called "inverse time" or "thermal/magnetic" circuitbreakers). Choose input and grounding wire size according to local ornational electrical codes. Using fuses or circuit breakers smaller thanrecommended may result in "nuisance" shut-offs from welder inrushcurrents, even if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

Welders are shipped connected for the highest input voltage listed onthe rating plate. To move this connection to a different input voltage,see the diagram located on the inside of the input access door, or thediagram shown below (Figure A.2). If the Auxiliary lead (indicated as ‘A’)is placed in the wrong position, there are two possible results.

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

b. If the Auxiliary lead is placed in a position lower than the applied linevoltage, the welder may not come on, and fuse in the reconnectarea may open. If this occurs, turn off the input voltage, properlyconnect the auxiliary lead, replace the fuse, and try again.

INPUT CONNECTION

ELECTRIC SHOCK can kill.

• Only a qualified electrician shouldconnect the input leads to the PowerWave®. Connections should be made inaccordance with all local and NationalElectrical Codes and the connectiondiagram located on the inside of thereconnect / input access door of themachine. Failure to do so may result inbodily injury or death.

-------------------------------------------------------------------Use a three-phase supply line. A 1.75 inch (45 mm) diameteraccess hole for the input supply is located on the case back.Connect L1, L2, L3 and ground according to the Input SupplyConnection Diagram.

FIGURE A.2 - INPUT SUPPLY CONNECTION FOR 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-5


SYSTEM CONNECTION

System Overview

The Power Wave® AC/DC 1000® SD power source is designed tobe a part of a modular welding system typically controlled by aMAXsa™ 10 Controller or a customer supplied ProgrammableLogic Controller (PLC). Each welding arc may be driven by asingle power source or by a number of power sources connectedin parallel. The actual number of power sources per arc will varydepending on the application. When only one power source isrequired for an arc group, it must be configured as a Master.When parallel machines are required, one is designated as theMaster and the rest as Slaves. The synchronizing connectors forparalleled machines are on the back of the power source. TheMaster controls the AC switching for the arc group, and theSlaves respond accordingly. See Figure A.3.

When employed in a multi-arc AC system the arcs must besynchronized to each other. The Master for each arc can beconfigured to follow a dedicated external synchronization signalto determine its frequency and balance. The SynchronizingConnectors on the back of the Power Wave® AC/DC 1000® SDprovide the means to synchronize the AC wave shapes of up tosix different arcs to a common carrier frequency. (See FigureA.3). This frequency can range from 20 hertz to 100 hertz. Itcan also control the phase angle between arcs to reduce theeffects of welding related issues such as "Arc Blow".

FIGURE A.3 - SYNCHRONIZING CONNECTORS

InputOutput

Multi-arc

InputOutput

Paralleling

LINCOLN

ELECTR

IC

A-6


The arc to arc phase relationship is determined by the timing ofeach arc’s "sync" signal relative to the "sync" signal of ARC 1.DIP Switches on the in each machine must be set to identify it asa Master Lead, Master Trail or Slave. See Figure A.4

In a typical multi-arc system, each arc is controlled by its ownMAXsa™ 10 Controller. The basic characteristics of theindividual arcs such as WFS, amplitude, and offset are set locallyby each arc’s dedicated controller. The frequency, balance, andphase shift parameters of each arc are controlled by theMAXsa™ 10 Controller for ARC 1 (Master Lead).

NOTE: The Power Wave® AC/DC 1000® SD is backwardscompatible with the K2344-2 Power Wave® AC/DC 1000in tandem or multi-arc systems. The Power Wave® AC/DC1000® SD and K2344-2 machines cannot be connected inparallel. Paralleled machines must be of the same type. AK1805-1 (14 to 22 pin adapter cable) is required to inter-face to the K2282-1 Systems Interface in these setups APLC interface is an alternate method of control for largersystems. The PLC is typically connected via DeviceNetdirectly to the Master power source of each arc group inthe system. MAXsa™ 19 Controller is still required topower the Wire Drive. Contact your Local Lincoln ElectricRepresentative for more information.

The connection diagrams describe the layout of several typicalsystems including Multi-Arc and Paralleled machine set-ups.Each system also has a step by step “Installation Checklist”.

FIGURE A.4 - DIP SWITCH SETTINGS

A-7


Wor

k

K26

83-X

XAr

clin

k C

able

K26

07-X

Cru

ise r

Wo r

kW

eld

Cab

le

Ele

ctro

deW

eld

Cab

le

K1 8

11-X

XS

ense

Lea

d

Pow

er W

ave®

AC

/ DC

100

0® S

D

FIGURE A.5 - CRUISER CONNECTION DIAGRAM

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 it’s operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave® AC/DC 1000® SD and the 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 the panel. Factory Settingis “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-9


K26 8

3-XX

Arcli

nk C

able

67 L

ead

K178

5-XX

14-P

in Ca

ble

Wor

k

K231

-XX

Cont

act N

ozzle

Powe

r Wa v

e® A

C/DC

100

0® S

D

K281

4-X

MAX

sa™

10

K237

0 -X

MAX

sa™

22

K181

1 -XX

Sens

e L e

ad

Elec

trod e

We ld

Cab

le

Wor

kW

eld C

able

FIGURE A.6 - SINGLE ARC CONNECTION DIAGRAM

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/DC 1000® SD per recom-mended guidelines.


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





A-11


67 L

eads

K178

5-XX

14- P

in Ca

ble

Wor

kW

ork W

e ld C

able

K 231

- XX

Con t

act N

ozzle

K28 1

4 -X

MAX

sa™

10

K237

0-X

MAX

sa™

22

Elec

trode

Weld

Cab

le

K268

3-XX

Arcl i

n k C

able

K26 8

3-XX

Arcli

nk C

able

K 178

5-XX

14-

Pin

Cab le

Powe

r Wav

e®AC

/DC

1000

® SD

K178

5-XX

14-P

in Ca

bl e

K181

1-XX

Sens

e Le

ad

Elec

trode

Wel d

Cab

le

K281

4-X

MAX

sa™

10

K237

0-X

MAX

sa™

22

Powe

r Wav

e®AC

/DC

1000

® SD

FIGURE A.7 - TANDEM ARC CONNECTION DIAGRAM

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™ 10 controllers.

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

Install Electrode Sense Lead (67) at each feeder and the Work Sense Lead (21) from the Lead Power Wave® AC/DC 1000® SDMaster per guidelines.


Open the Power Wave® AC/DC 1000® SD front panels and configure DIP switch settings per the decal on the panel. (See FigureA.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.powerwavesoftware.com).


A-13


MAX

sa™

10

MAX

sa™

22

Powe

r Wav

e®Po

wer W

ave®

Con

nect

ion

Di a

gra m

-P

ara l

lel M

a chi

nes

67 L

ead

Wor

kW

ork W

eld C

a bl e

K281

4-X

K237

0-X

K268

3-XX

Arcli

nk C

able

K 178

5-XX

14-

Pin

Cable

AC/D

C 10

00® S

DA C

/DC

1000

® SD

K178

5-XX

14-P

in Ca

ble

K181

1-XX

Sens

e Le

ad E le c

trode

We ld

Ca b

le

K23 1

-XX

Cont

act N

ozzle

Ele c

tr ode

Weld

Cab

le

FIGURE A.8 - PARALLELING CONNECTION DIAGRAM

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 Duty ArcLink Control Cable (5pin) 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 Masterper guidelines.

Connect / Install welding cables to both the “master” and “slave” machine per recommended "Output Cable Guidelines" (TableA.1).

Open the Power Wave® AC/DC 1000® SD front panels and configure DIP switch settings per the decal on the panel. (See FigureA.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 to www.powerwavesoft-ware.com).


A-15


FIGURE A.9 - MAXsa™ 19 CONNECTION DIAGRAM

K2683-XXArclink Cable

67 Lead

K1785-XX14-Pin Cable

Work

K231-XX Contact Nozzle

Power Wave® AC/DC 1000® SD

K2312-XMAXsa™ 29

K1811-XXSense Lead

ElectrodeWeld Cable

WorkWeld Cable

K2626-XMAXsa™ 19

DeviceNet Cable Network

PLC Controller

User Interface

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 it’s operating location.

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

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 the panel. Factory settingis “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 -> Wire Feeder, verify the appropri-ate Feeder and gear ratio are selected.



A-17


ELECTRODE AND WORK CONNECTIONS

General Guidelines

The unique switching structure of the Power Wave® AC/DC1000® SD allows it to produce DC positive, DC negative or ACoutput waveforms without repositioning the work and electrodeleads. Additionally, no DIP switch changes are required to switchbetween the different polarities. All of this is controlled internallyby the Power Wave® AC/DC 1000 SD, and based exclusively onthe weld mode selection.

The following recommendations apply to all output polarities andweld modes:

• Select the appropriate size cables per the "Output CableGuidelines" below. Excessive voltage drops caused byundersized welding cables and poor connections often resultin unsatisfactory welding performance. Always use the largestwelding cables (electrode and work) that are practical, and besure all connections are clean and tight.

Note: Excessive heat in the weld circuit indicates undersizedcables and/or bad connections.

• Route all cables directly to the work and wire feeder,avoid excessive lengths and do not coil excess cable.Route the electrode and work cables in close proximity to oneanother to minimize the loop area and therefore the induc-tance of the weld circuit.

• 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 (Per Table A.1) tothe "ELECTRODE" studs on the power source (located behind thecover plate on the lower right rear corner). Connect the other endof the electrode cable(s) to the tab of the contact nozzle. Be surethe connection to the nozzle makes tight metal-to-metal electri-cal contact.

Work Connections

Connect cable(s) of sufficient size and length (Per Table A.1)between the "WORK" studs (located behind the cover on thelower left rear corner) and the work piece. Be sure the connec-tion to the work makes tight metal-to-metal electrical contact.

NOTE: For parallel and/or multiple arc applications with exces-sive ground path lengths, a common work connection busshould be used. The common work connection serves tominimize voltage drops associated with resistive losses inthe ground paths. It should be made out of copper, andlocated as close as possible to the power sources (SeeFigure A.10).

Total Cable Length ft(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-18


CABLE INDUCTANCE, AND ITS EFFECTS ON WELD-ING

Excessive cable inductance will cause the welding performanceto degrade. There are several factors that contribute to the over-all inductance of the cabling system including cable size, andloop area. The loop area is defined by the separation distancebetween the electrode and work cables, and the overall weldingloop length. The welding loop length is defined as the total oflength of the electrode cable (A) + work cable (B) + work path(C) (see Figure A.11). To minimize inductance always use theappropriate size cables, and whenever possible, run the elec-trode and work cables in close proximity to one another to mini-mize the loop area. Since the most significant factor in cableinductance is the welding loop length, avoid excessive lengthsand do not coil excess cable. For long work piece lengths, asliding ground should be considered to keep the total weldingloop length as short as possible.

REMOTE SENSE LEAD CONNECTIONS

Voltage Sensing Overview

The best arc performance occurs when the Power Wave® AC/DC1000® SD has accurate data about the arc conditions. Dependingupon the process, inductance within the electrode and workcables can influence the voltage apparent at the studs of thewelder, and have a dramatic effect on performance. To counter-act this negative effect, remote voltage sense leads are used toimprove the accuracy of the arc voltage information supplied tothe control pc board.

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

If the remote voltage sensing is enabled but the sense leadsare missing, improperly connected extremely high weldingoutputs may occur.

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

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the wirefeeder control cable (K1785) and accessible at the wire drive. Itshould always be connected to the Contact Assembly where theWeld Cable is connected. Enabling or disabling electrode voltagesensing is application specific, and automatically configuredthrough software.

Work Voltage Sensing

The use of a remote work voltage sense lead is always required.The Power Wave® AC/DC 1000® SD is shipped from the factorywith the remote work voltage sense lead enabled. It must beattached to the work as close to the weld as practical, but out ofthe weld current path. For more information regarding the place-ment of remote work voltage sense leads, see the section enti-tled "Voltage Sensing Considerations for Multiple Arc Systems."The remote WORK sense lead (21) can be accessed at the four-pin WORK sense 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 andSlaves) will relate to the Voltage Sense Lead of theMaster machine.

Never connect the WORK sense lead at two different loca-tions.


• do not touch electrically live parts or

electrodes with your skin or wet

clothing.

• insulate yourself from the work and

ground.

• always wear dry insulating gloves.

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

FIGURE A.11

B

A

C

POWERWAVE

WORK CAUTION

CAUTION

WARNING

A-19


VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARCSYSTEMS

Special care must be taken when more than one arc is weldingsimultaneously on a single part. Remote sensing is required inMulti-arc applications

• Avoid common current paths. Current from adjacent arcscan induce voltage into each others current paths that can bemisinterpreted by the power sources, and result in arc inter-ference.

• Position the sense leads out of the path of the weld cur-rent. Especially any current paths common to adjacent arcs.Current from adjacent arcs can induce voltage into each oth-ers current paths that can be misinterpreted by the powersources, and result in arc interference.

• For longitudinal applications, connect all work leads at oneend of the weldment, and all of the work voltage sense leadsat the opposite end of the weldment. Perform welding in thedirection away from the work leads and toward the senseleads. See Figure A.12.

• For circumferential applications, connect all work leads onone side of the weld joint, and all of the work voltage senseleads on the opposite side, such that they are out of the cur-rent path. See Figure A.13

FIGURE A.12 MULTI-ARC LONGITUDINAL WELDS

DIRECTIONOF TRAVEL

CONNECT ALLWORK LEADS AT THE BEGINNINGOF THE WELD.

CONNECT ALL WORK SENSELEADS AT THE ENDOF THE WELD.

A-20


FIGURE A.13 MULTI-ARC CIRCUMFIRENTIAL WELDS

POWERSOURCE #2

POWERSOURCE #1

POWERSOURCE #1

POWERSOURCE #2

POWERSOURCE #2

POWERSOURCE #1

A-21


CONTROL CABLE CONNECTIONS

GENERAL GUIDELINES

These guidelines apply to all communication cables includ-ing optional DeviceNet and Ethernet connections.

• Genuine Lincoln control cables should be used at alltimes (except as noted otherwise). Lincoln cables arespecifically designed forthe communication and power needsof the Power Wave®/ MAXsa™ systems. Most are designedto be connected end to endfor ease of operation.

• Always use the shortest cable lengths possible. DO NOTcoil excess cable. It is recommended that the total length ofcontrol cable does not exceed 100’ (30.5M). The use of non-standard cables in excess of 25’ (7.5M) can lead to commu-nication problems (system shutdowns), poor motor accelera-tion (poor arc starting), and low wire driving force (wire feed-ing problems).

• Best results will be obtained when the control cables arerouted separate from the weld cables. This minimizes thepossibility of interference between the high currents flowingthrough the weld cables and the low level signals in the con-trol cables.

COMMON EQUIPMENT CONNECTIONS

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

The 14 pin Wire Drive Control Cable (K1785-xx) connects theController (MAXsa™ 10 or MAXsa™ 19) to the Wire Drive(MAXsa™ 22 or MAXsa™ 29). This cable should be kept asshort as possible.

Connection Between Power Source and the MAXsa™Controller (K2683-xx - ArcLink Control Cable).

Single and tandem arc systems are typically controlled by aMAXsa™ 10 Controller. In a tandem, or multi-arc system, eacharc requires its own dedicated controller.

The 5-pin ArcLink control cable connects the power source tothe MAXsa™ 10. If there is more than one power source per arc,it connects from the MAXsa™ 10 to the power source designat-ed as the Master for that arc. The control cable consists of twopower leads, one twisted pair for digital communication, and onelead for voltage sensing (67).

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

It is sometimes more practical and cost effective to use a customPLC interface to control a multi-arc system (refer to the"DeviceNet Configuration" section for interface information). ThePower Wave® AC/DC 1000® SD is equipped with a 5-pinDeviceNet mini style receptacle for this purpose. The receptacleis located on the rear panel of the machine See Figure B.3 TheDeviceNet cable is keyed and polarized to prevent improper con-nection.

NOTE: DeviceNet cables should not be routed with weldcables, wire drive control cables, or any other currentcarrying device that can create a fluctuating magnet-ic field.

In a typical system, a DeviceNet connection is made between themaster power source of each arc, and the PLC interface.DeviceNet cables must be sourced locally by the customer. Foradditional guidelines refer to the "DeviceNet Cable Planning andInstallation Manual" (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, the output studsof multiple Power Wave® AC/DC 1000® SD machines can be con-nected in parallel. The parallel machines utilize a master/slavecontrol scheme to distribute the load evenly and to coordinate ACswitching. K1785-xx cables connect the paralleled machines viathe synchronizing connectors on the back of the machine. Thesystem is currently limited to a maximum of 2 slaves per master,or a total of 3 machines per arc.

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

Synchronizing Connectors are available on the rear panel of themachine for Multi-Arc applications using the K1875-xx controlcables. The system is currently limited to six(6) arcs, or a“Lead” and five “Trail” arcs.

B-1

OPERATIONPOWER WAVE® AC/DC 1000® SD

SAFETY PRECAUTIONSRead this entire section of operating instructions before

operating the machine.


• Unless using cold feed feature, whenfeeding with gun trigger, the electrode anddrive mechanism are always electricallyenergized and could remain energizedseveral seconds after the welding ceases.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumesfrom breathing zone.

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

WELDING SPARKS can cause fire orexplosion.

• Keep flammable material away.

• Do not weld on containers that have heldcombustibles.

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

ARC RAYS can burn.

• Wear eye, ear, and body protection.

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

Observe additional guidelines detailed in the beginning ofthis manual.

WARNING

CASE FRONT CONTROLS

1. Power Switch: Controls input power to the Power Wave®

AC/DC 1000® SD and any auxiliary equipment that may beconnected to it.

2. Status Light: A two color LED that indicates system errors.Normal operation is steady green. Flashing green orred/green indicates a system error. See theTroubleshooting Section.

NOTE: The Power Wave® Status Light will flash green for upto 60 seconds at power up as the machine runsthrough a self test routine, and then go to steadygreen.

3. Thermal Light: A yellow light that comes ON when an overtemperature situation occurs. The machine output is disableduntil the machine cools down and the thermal light goes OFF.

NOTE: The Thermal Light may also indicate a problem withthe AC Switch portion of the power source. See theTroubleshooting Section.

INPUT POWER SECTION

1. Input Contactor: Connection point for incoming 3 phasepower. See the Installation Section for input wiring andfusing information.

2. Case Ground: Used to provide an “earth ground” for theframe of the welder. Consult your local and national electricalcodes for proper grounding information.

3. Auxiliary Reconnect: Select the proper tap based on the sup-ply voltage.

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

5. Cord Connector: Input power cord strain relief.

B-2


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-3


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

B-4


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-5


POWER-UP SEQUENCE

When power is applied to the Power Wave® AC/DC 1000® SD, thestatus lights will flash green for up to 60 seconds. During thistime the Power Wave® AC/DC 1000® SD is performing a self test,and mapping (identifying) each component in the local ArcLinksystem. The status lights will also flash green as a result of asystem reset or configuration change during operation. When thestatus lights become steady green the system is ready for use

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

DUTY CYCLE

The Power Wave® AC/DC 1000® SD is capable of welding1000Amps, @ 44 Volts, at a 100% duty cycle.

COMMON WELDING PROCEDURES

MAKING A WELD

The serviceability of a product or structure utilizing thewelding programs is and must be the sole responsibility ofthe builder/user. Many variables beyond the control of TheLincoln Electric Company affect the results obtained inapplying these programs. These variables include, but arenot limited to, welding procedure, plate chemistry andtemperature, weldment design, fabrication methods andservice requirements. The available range of a weldingprogram may not be suitable for all applications, and thebuild/user is and must be solely responsible for weldingprogram selection.

The steps for operating the Power Wave® AC/DC 1000® SD willvary depending upon the user interface of the welding system.The flexibility of the system lets the user customize operation forthe best performance.Consult the User Interface documentation for more detailed setup information. (MAXsa™ 10, Command Center, PLC, Robotetc..)

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

Second, find the program in the welding software that bestmatches the desired welding process. The standard softwareshipped with the Power Wave® AC/DC 1000® SD encompasses awide range of common processes and will meet most needs. Ifa special welding program is desired, contact the local LincolnElectric sales representative.

To make a weld, the Power Wave® AC/DC 1000® SD needs toknow the desired welding parameters. Waveform ControlTechnology™ allows full customization of Strike, Run-in, Craterand other parameters for exacting performance.

OVERVIEW OF THE AC/DC SUBMERGED ARCPROCESS

The Power Wave® AC/DC 1000® SD combines the advantages ofAC and DC Submerged Arc Welding (SAW) into a single powersource. The limiting factor of AC-SAW welding has traditionallybeen the time it takes to transition from positive to negativepolarity. This lag through the zero crossing can cause arcinstability, penetration, and deposition problems in certainapplications. The Power Wave® AC/DC 1000® SD utilizes thespeed of an inverter based power source, and the flexibility ofWaveform Control Technology™ to address this issue.

By adjusting the Frequency, Wave Balance and Offset of the ACwaveform the operator can now control the balance (relationship)between the penetration of DC positive and the deposition of DCnegative while taking full advantage of the reduction in arc blowassociated with AC.

FIGURE B.4 - AC/DC SUBMERGED ARC PROCESS

TimePositive

Current

NegativeCurrent

Cu

rren

t

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-6


MULTIPLE ARC SYSTEM CONSIDERATIONS

Large scale SAW applications often employ multiple arcs toincrease deposition rates. In multiple arc systems, magneticforces created by like and opposing weld currents of adjacentarcs can result in arc interaction that can physically push or pullthe arc columns together. See Figure B.5. To counteract thiseffect, the phase relationship between adjacent arcs can be setto alternate and equalize the duration of magnetic push and pullforces. This is accomplished through the synchronizing cables(K1785-xx). Ideally, the net result is a cancellation of theinteracting forces. See Figure B.6.

Never simultaneously touch electrically "hot" parts in theelectrode circuits of two different welders. The electrode toelectrode no load voltage of multiple arc systems withopposite polarities can be double the no load voltage ofeach arc. Consult the Safety information located at the frontof the Instruction Manual for additional information.-------------------------------------------------------------------

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 thedesired Set point.

• Arc Length is proportional to Voltage.• Traditionally used for larger diameter wires and slower travelspeeds.

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 thedesired Set point

• Arc Length is proportional to Voltage• Traditionally used for smaller diameter wires and faster travelspeeds.

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

it ive

Pos

itive

Neg

a tiv

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

L L

PU

LL

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

CAUTION

B-7


WELD SEQUENCE

The weld sequence defines the weld procedure from beginningto end. The Power Wave® AC/DC 1000® SD not only providesadjustment of basic welding parameters, but also allows theoperator to fine tune the start and finish of each weld forsuperior performance.

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

START OPTIONS

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

• ARC DELAY inhibits the wire feed for up to 5 seconds to pro-vide an accurate weld start point. Typically used in multi-arcsystems.

• Strike settings are valid from the beginning of the sequence(Start Button Pressed) until the arc is established. They controlRun-in (speed at which the wire approaches the workpiece),and provide the power to establish the arc.Typically output levels are increased and WFS is reducedduring the Strike portion of the weld sequence

• Start values allow the arc to become stabilized once it isestablished.Extended Start times or improperly set parameters can resultpoor starting

• Upslope determines the amount of time it takes to ramp fromthe Start parameters to the Weld parameters. The transition islinear and may be up or down depending on the relationshipbetween the Start and Weld settings.

END OPTIONS

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

• Downslope determines the amount of time it takes to rampfrom the Weld parameters to the Crater parameters. Thetransition is linear and may be up or down depending on therelationship between the Weld and Crater settings.

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

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

• Restrike Timer is used to protect the welding system and/orwork piece being welded. If the arc goes out for any reason(short circuit or open circuit), the Power Wave® AC/DC 1000®

SD will enter a Re-strike state and automatically manipulatethe WFS and output in an attempt to re-establish the arc. TheRe-strike timer determines how long the system will attemptto re-establish the arc before it shuts down. • A Re-strike time of 1 to 2 sec is sufficient in mostapplications.

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

Wi re

To u

che s

Pl a

t e

En d

ofS

tart

Tim

er

End

ofU

pslo

pe

St o

pB

u tto

nP

r ess

e d

End

ofD

owns

lope

End

ofC

rate

rT

ime r

En d

ofB

urn b

ack

B-8


WELD PROCESS ADJUSTMENTS

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

AC ADJUSTMENTS

In addition to the basic weld parameters, there are a number ofunique adjustments related to the AC waveform of the PowerWave® AC/DC 1000® SD. These adjustments enable the operatorto balance the relationship between penetration and depositionto tailor the output for specific applications.

WAVE BALANCE

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

• Use Wave Balance to control the penetration and deposition ofa given process. See Figure B.10.

DC OFFSET

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

• Use Offset to control the penetration and deposition of a givenprocess. 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 help reduce arcinteraction.

• Lower frequencies will help overcome output limitations dueto inductance in the Weld Circuit. See Figure 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-9


PHASE ADJUSTMENT FOR MULTIPLE ARC SYS-TEMS

Phase• The phase relationship between the arcs helps to minimizethe magnetic interaction between adjacent arcs. It isessentially a time offset between the waveforms of differentarcs, and is set in terms of an angle from 0 to 360°,representing no offset to a full period offset. The offset of eacharc is set independently with respect to the lead arc of thesystem (ARC 1).

Recommendations:

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

• For unbalanced waveforms:– Avoid switching at same time.– Break up long periods of unchanged polarity relativeto 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-1

ACCESSORIESPOWER WAVE® AC/DC 1000® SD

OPTIONS AND ACCESSORIES are available atwww.lincolnelectric.com

Follow these steps:

1. Go to www.lincolnelectric.com

2. In the Search field type E9.181 and click on the Search icon(or hit ‘Enter’ on the keyboard).

3. On the Results page, scroll down to the Equipment list andclick on E9.181.

All of the information for the Power Wave® System accessoriescan be found in this document.

SOFTWARE TOOLS

Power Wave® AC/DC 1000® SD software tools and other documents related to the integration, configuration, and operation of thesystem is available at www.powerwavesoftware.com. Power Wave® Submerged Arc Utilities includes the following items and all ofthe 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 outputvoltage and current, test sense leads, and diagnose feed head issues. Can also setupand 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 power source (morethan 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-1

MAINTENANCEPOWER WAVE® AC/DC 1000® SD

SAFETY PRECAUTIONS


• Only Qualified personnel should performthis maintenance.

• Turn the input power OFF at thedisconnect switch or fuse box beforeworking on this equipment.

• Do not touch electrically hot parts.

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

ROUTINE MAINTENANCE

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

The rear portion of the machine that contains the filter and thecooling fans slides out for easy access. Removing the four(4)clips and pulling back on the rear portion of the machine willprovide access for cleaning the machine and checking the filter.The filter may be removed from the right side of the machine.See Figure A.1.

PERIODIC MAINTENANCE

Calibration of the Power Wave® AC/DC 1000® SD is critical to itsoperation. Generally speaking the calibration will not needadjustment. However, neglected or improperly calibratedmachines may not yield satisfactory weld performance. Toensure optimal performance, the calibration of output Voltageand Current should be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the factory.Generally speaking the machine calibration will not needadjustment. However, if the weld performance changes, or theyearly calibration check reveals a problem, use the calibrationsection of the Weld Manager Utility to make the appropriateadjustments.

The calibration procedure itself requires the use of a grid(Resistive Load Bank), and certified actual meters for voltage andcurrent. The accuracy of the calibration will be directly affectedby the accuracy of the measuring equipment you use. The WeldManager Utility includes detailed instructions, and is availableon the internet at powerwavesoftware.com under PowerWave® Submerged Arc Utilities.

WARNING

E-1

TROUBLE SHOOTING

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

POWER WAVE® AC/DC 1000® SD

CAUTION

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

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

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” lists the obviousexternal possibilities that may contribute to the machinesymptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for the Possible Cause,generally it states to contact your local Lincoln Authorized FieldService Facility.

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

HOW TO USE TROUBLESHOOTING GUIDE

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

__________________________________________________________________________

WARNING

E-2

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual


CAUTIONIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln AuthorizedField Service Facility for technical troubleshooting assistance before you proceed.

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROB-LEMS

The Power Wave® AC/DC 1000® SD is equipped with one externally mounted statuslight. If a problem occurs it is important to note the condition of the status lights.Therefore, prior to cycling power to the system, check the power source sta-tus light for error sequences as noted below.

Included in this section is information about the power source Status LED and somebasic troubleshooting charts for both machine and weld performance.

The STATUS LIGHT is a dual-color LED that indicates system errors. Normal opera-tion is steady green. Error conditions are indicated in the following 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 healthy peripheral equip-ment 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 1-10 seconds after power isturned on, or if the system configuration is changed during operation.

Under normal conditions indicates Auto-mapping has failed. Also used by Weld Manager andSubmerged Arc Cell Setup (available at www.powerwavesoftware.com) to identify theselected machine when connecting to a specific IP address.

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

Error Code interpretation through the Status light is detailed in the Service Manual. Individualcode digits are flashed in red with a long pause between digits. If more than one code is pre-sent, the codes will be separated by a green light. Only active error conditions will be acces-sible through the Status Light.

Error codes can also be retrieved with Weld Manager under System Status (available atwww.powerwavesoftware.com). This is the preferred method, since it can access historicalinformation 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

E-3

TROUBLE SHOOTING




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 listing consult the ServiceManual 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 a switch boardor output rectifier failure.

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

Excess voltage on the main capacitors. May be caused by improperinput configuration, excessive line voltage, or improper capacitor bal-ance (see Error 43)

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cycle limitof the machine. Also acts with a malfunction.

Capacitor precharge failed. Usually accompanied by codes 32 and 33.

Unknown glitch has occurred on the fault interrupt circuitry.Sometimes caused by primary over current fault, or intermittent con-nections in the thermostat circuit.

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

A complete list of error codes is available in Weld Manager underTools -> Lookup Error (available at www.powerwavesoftware.com).

Error codes that contain three or four digits are defined as fatal errors.These codes generally indicate internal errors on the Power SourceControl Board. If cycling the input power on the machine does notclear the error, contact the Service Department

E-4

TROUBLE SHOOTING




PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

BASIC MACHINE PROBLEMS

Major physical or electrical damage is evi-dent when the sheet metal covers areremoved.

Input fuses keep blowing

Machine will not power up (no lights)

None

1. Improperly sized input fuses.

2. Improper Weld Procedure requiringoutput levels in excess of machinerating.

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

1. No Input Power.

2. Fuse F1 (in reconnect area) mayhave blown.

3. Circuit breaker CB1 (on the controlpanel) may have tripped.

4. Improper input voltage selection(multiple input voltage machinesonly).

1. Contact your local authorizedLincoln Electric Field Service facilityfor technical assistance.

1. Make sure fuses are properly sized.See installation section of this man-ual for recommended sizes.

2. Reduce output current, duty cycle,or both.

3. Contact your local authorizedLincoln Electric Field Service facilityfor technical assistance.

1. Make sure input supply disconnecthas been turned ON. Check inputfuses. Make certain that the PowerSwitch (SW1) on the power sourceis in the “ON” position.

2. Power Down and replace the fuse.

3. Power Down and reset CB1.

4. Power down, check input voltagereconnect according to diagram onreconnect cover.

F-1

WIRING DIAGRAMSPOWER WAVE® AC/DC 1000® SD

NOTE: This diagram

is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram

for a particular code is pasted inside the machine on one of the enclosure panels.

If the diagram is illegible, write to the Service Departm

ent for a replacem

ent. Give the equipm

ent code number.

TO A

UX

#2

606

3 4 5

S1

AR

CLI

NK

RE

CEP

TAC

LE

TO A

SY

STE

MG

RO

UN

D P

ER

NAT

ION

AL

ELE

CTR

ICAL

CO

DE

F1

705

704

706

1J2

2J2

3J2

4J2

1J2

2J2

3J2

4J2

5J2

6J2

11J1

7J1

8J1

9J1

10J1

5J1

6J1

12J1

3J1

4J1

1J1

2J1

+

TO J6

5

202

320

286

285

282

281

206

GN

D

WO

RK

SEN

SE

TO STA

US

LE

D

11

TO A

C S

WIT

CH

(DR

IVE

SIG

NA

LS)

CO

NTA

INS

GA

TE, T

HE

RM

AL

&V

OLT

AG

E S

EN

SE

P91

AU

XIL

IAR

Y T

RA

NS

FOR

MER

#1

(380

-415

)

(440

-460

)H

2

(500

)H

3

H5

(550

-575

)

238

604

240

328

505

231

1W 1B281

282

286

778

232777

774

607

611

776

615

8

L2 L3

C3

C4+

+

C1

C2+

+

CT

#2N

.C.

30 O

HM

/ 30

0 W

ATT

(2 P

LAC

ES)

CT

#1N

.C.

N.D

.

3W

DC

BU

S

PO

WE

R B

DR

EC

TIFI

ER

AC

212

213

216

TO J41

J4

J47

1 2 3 4

+

C3

AUX

. #1

TO

J7J5

4 5 6

NE

GTO

SO

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F-2

WIRING DIAGRAMSPOWER WAVE® AC/DC 1000® SD

NOTE: This diagram

is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram

for a particular code is pasted inside the machine on one of the enclosure panels.

If the diagram is illegible, write to the Service Departm

ent for a replacem

ent. Give the equipm

ent code number.

F-3

DIMENSION PRINTPOWER WAVE® AC/DC 1000® SD

L15

150A

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

F-4

NOTES

Customer assistanCe PoliCy

The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

TABLE OF CONTENTSINSTALLATIONOPERATIONACCESSORIESMAINTENANCETROUBLE SHOOTINGWIRING DIAGRAMS

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POWER WAVE AC/DC 1000 SD - Lincoln Electric...May 16, 2018 · POWER WAVE ®AC/DC 1000 ... damaged in shipment must be made by the purchaser against the transportation company at