Lincoln Electric POWER Wave AC/DC 1000 Operator's Manual
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Lincoln Electric POWER Wave AC/DC 1000 Operator's Manual

Lincoln Electric POWER Wave AC/DC 1000 Operator's Manual

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POWER WAVE AC/DC 1000
For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part.
DO
NOT
I NSTAL L ,
OPERATE OR REPAI R THI S
EQUI PM ENT W I THOUT READ-
I NG THI S M ANUAL AND THE
SAFETY PRECAUTI ONS CON-
TAI NED THROUGHOUT. And,
most importantly, think before you
act and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
®
11124, 11226
IEC 60974-1
OPERATOR' S M ANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM848-A
June, 2009

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Summary of Contents for Lincoln Electric POWER Wave AC/DC 1000

  • Page 1 June, 2009 11124, 11226 For use with machines having Code Numbers: This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 SAFETY...
  • Page 7 SAFETY...
  • Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 9: Table Of Contents

    viii viii TABLE OF CONTENTS Page Installation..........................Section A Specifications ........................A-1 Safety Precautions.......................A-2 Location and Mounting ....................A-2 Stacking ........................A-2 Lifting..........................A-2 Environmental Limitations .....................A-2 Electromagnetic Compatibility ..................A-2 Input Fuse and Supply Wire Considerations ..............A-3 Input Voltage Selection and Ground Connections ............A-3 Connection/Input Access Door, Connection Diagrams System ........A-3 System Connection .......................A-4 Recommended Equipment....................A-5...

  • Page 10: Table Of Contents

    TABLE OF CONTENTS Troubleshooting ....................Section E How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide................E-2 thru E-11 Using the Status LED to Troubleshoot System Problem ........E-12 Error Codes....................E-13, E-14 ________________________________________________________________________ Wiring Diagrams and Dimension Print ............Section F ________________________________________________________________________ Parts List.........................P-509 ________________________________________________________________________...
  • Page 11 SPECIFICATIONS TECHNICAL SPECIFICATIONS - POWER WAVE® AC/DC 1000 (K2344-1, K2344-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS INPUT OUTPUT POWER FACTOR IDLE EFFICIENCY 3 PHASE CURRENT AMPS CONDITIONS POWER @ RATED OUTPUT @ RATED OUTPUT 50/60 Hz K2344-1 K2344-2 WATTS 1000A@44V.

  • Page 12: Installation

    LOCATION AND MOUNTING ENVIRONMENTAL LIMITATIONS Place the welder where clean cooling air can freely Do not use the Power Wave AC/DC 1000 in an out- circulate in through the rear louvers and out through door environment. The Power Wave AC/DC 1000 the case sides and front.

  • Page 13: Input Fuse And Supply Wire Considerations

    Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install, use or service this equipment Reconnect Diagram for K2344-2 Power Wave AC/DC 1000 ("CE – ready") INPUT SUPPLY CONNECTION DIAGRAM W / L3 WARNING...

  • Page 14: System Connection

    System Overview DeviceNet directly to the Power Wave System Interface, and the Master power source of each arc The Power Wave AC/DC 1000 power source is group in the system. designed to be a part of a modular welding system...

  • Page 15: Recommended Equipment

    Description Single Arc Tandem Arc Triple Arc Identifier K2344-1 Power Source -or- Power Wave AC/DC 1000 Power Source K2344-2 Welding Power Cables Power Source to contact Nozzle, K2163-xx and Power Source to Work Refer to "Output Cable Guidelines" Weld Cables...

  • Page 16: Optional Equipment

    INSTALLATION OPTIONAL EQUIPMENT System Identifier Part No. Description Ethernet Network Customer Ethernet Switch, Cables, etc. required for arcs > 1000A, or for use of Power Wave Equipment Supplied Submerged Arc Utilities software package. Personal Customer IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater) Computer Supplied required for use with Power Wave Submerged Arc Utilities software package.
  • Page 17 INSTALLATION Connection Diagram- Typical Single Arc System (Power Feed 10A Controller) Arclink (5 Pin) Work Studs Wire Feeder (14 Pin) E lectrode Studs Travel Carriage Connection Flux Hopper Connection K1543-XX Arclink Connection Arclink Control Cable K 2362-1 K1785-XX Wire Feeder Control Cable * Work Cable(s) * Electrode Cable(s)
  • Page 18 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST SINGLE ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE) (as shown in the Connection Diagram "Typical Single Arc System") Place Power Wave in suitable operating location. Mount PF10A Controller. Install PF10S Wire Drive and other accessories in their operating location. Connect K1785-xx Wire Feeder Control Cable (14 pin) between the Power Wave and Wire Drive.
  • Page 19 INSTALLATION Connection Diagram- Typical Tandem Arc System ( Power Feed 10A Controller) Wire Feeder (14 Pin) Arc link (5 Pin) Master Input (S12) Connects to System Interface Work Studs K1795-XX Cabl es Electrode Studs Wir e Reel and Mountings Arclink Input Arclink Output K2282-1 K1785-XX...
  • Page 20 A-10 A-10 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST TANDEM ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE PER ARC) (as shown in the Connection Diagram "Typical Tandem Arc System”) Place Power Waves in suitable operating location. Mount PF10A Controllers. Install PF10S Wire Drives and other accessories in their operating location.
  • Page 21 A-11 A-11 INSTALLATION POWER WAVE® AC/DC 1000...
  • Page 22 A-12 A-12 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST TRIPLE ARC SYSTEM CHECKLIST – (DEVICENET PLC CONTROLLED, 1 POWER SOURCE PER ARC) (as shown in the Connection Diagram "Typical Triple Arc System”) Place Power Waves in suitable operating location. Mount DeviceNet PLC Controller and User Interface. Install PF10S Wire Drives and other accessories in their operating location.
  • Page 23 A-13 A-13 INSTALLATION Connection Diagram - Parallel Machines (Example depicts a single arc grouping, and may be repeated for each arc in the system) Front view o f machines Ethernet * Electrode Cables * Work Cables Work Common bus connections Connect to optional recommended for K2282-1 System Interface...
  • Page 24 A-14 A-14 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST EXTRA CAPACITY PARALLEL CONNECTION (as shown in the Connection Diagram "Parallel Machines”) Follow all steps of Single, Tandem, or Triple Arc checklists. Be sure input power is disconnected prior to following the remaining steps. Control Cable Connections: PF-10S Connections: Each PF-10S must be connected to the Master power source of its associated arc.

  • Page 25: Electrode And Work Connection

    All of this is controlled internally by Connect a work lead of sufficient size and length (Per the Power Wave AC/DC 1000, and based exclusively Table 1) between the "work" stud (located beneath the on the weld mode selection.

  • Page 26: Cable Inductance, And Its Effects On Welding

    A-16 A-16 INSTALLATION Electrode Voltage Sensing CABLE INDUCTANCE, AND ITS EFFECTS The remote ELECTRODE sense lead (67) is built into ON WELDING the wire feeder control cable (K1785) and accessible at the wire drive. It should always connected to the Excessive cable inductance will cause the welding wire drive feed plate when a wire feeder is present.
  • Page 27 A-17 A-17 INSTALLATION c. Locate the 8-position DIP switch on the control VOLTAGE SENSING CONSIDERATIONS FOR board and look for switch 8 of the DIP switch. MULTIPLE ARC SYSTEMS d. Using a pencil or other small object, slide the Special care must be taken when more than one arc switch to the OFF position if the work sense lead is welding simultaneously on a single part.
  • Page 28 A-18 A-18 INSTALLATION • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work volt- age sense leads on the opposite side, such that they are out of the current path. POWER SOURCE POWER...
  • Page 29 The ArcLink connection on the cables are specifically designed for the communica- Power Wave AC/DC 1000 is located under the spring tion and power needs of the Power Wave / Power loaded output cover on the case front. The control Feed systems.
  • Page 30 Run in Parallel (K1795 - Control Cable). To increase tional information. the output capacity for a given arc, the output studs of multiple Power Wave AC/DC 1000 machines can be Connections Between a Power Source and connected in parallel. The parallel machines utilize a System Interface (K1795 - Control Cable).

  • Page 31: External I/O Connector

    INSTALLATION EXTERNAL I/O CONNECTOR RECEPTACLE SPECIFICATION The Power Wave AC/DC 1000 is equipped with a ter- Table A.2 Output Arclink Receptacle S1 (5 pin – MS style) minal strip for making simple input signal connections. (See Figure A.2a) The terminal strip is located under-...
  • Page 32 A-22 A-22 INSTALLATION Table A.7 External I/O S7 (12 pin – terminal block) Lead # Function +15vdc for Trigger group Trigger input Dual procedure input 4 step input (Disabled as of S25564-19) +15vdc for cold inch group (Disabled as of S25564-19) cold inch forward cold inch reverse gas purge input...
  • Page 33 (Feed Head PCB - Bank S1) (Pin 5 to Pin 12) change in the wire drive, and a configuration change 142:1 at the power source. The Power Wave AC/DC 1000 95:1 can be configured to support up to 4 unique gear 57:1* ratios.

  • Page 34: Internal Controls

    Power Wave AC/DC 1000 with a DeviceNet PLC is provided in the DeviceNet Interface Specification (part • Insulate yourself from the work and ground. of the Power Wave Submerged Arc Utilities software package available on CD from the Lincoln Electric •...
  • Page 35 Equipment Group 4 Select (default OFF) Electrode polarity positive (default) Must be OFF for SPEED RANGE OBJECT INSTANCE ELECTRODE Electrode polarity negative Power Wave AC/DC 1000 POLARITY Low speed gear 142:1 (default) Gear ratio configuration. GROUP SELECT High speed gear 95:1 High speed gear 57:1 These two options available in S25564-11 and later software.
  • Page 36 A-26 A-26 INSTALLATION TABLE A.14 OBJECT INSTANCE switch 2 switch 1 Instance 0(default) TABLE A.15 DeviceNet Baud Rate: Switch 1 Switch 2 Baud Rate 125K (default) 250K 500K Programmable value. POWER WAVE® AC/DC 1000...
  • Page 37 A-27 A-27 INSTALLATION DEVICENET MAC ID TABLE A.16 Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3 Software Selectable Default Setting POWER WAVE® AC/DC 1000...
  • Page 38 A-28 A-28 INSTALLATION ETHERNET BOARD DIP SWITCHES (S3, S4): MASTER Internal Synchronization Signal (for systems without K2282-1 System Interface) “BANK S3” “BANK S4” I / O Termination Master / Slave Config 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 (DEFAULT) MASTER External Synchronization Signal...

  • Page 39: Operation

    OPERATION SAFETY PRECAUTIONS DEFINITIONS OF WELDING MODES Read this entire section of operating instructions NON-SYNERGIC WELDING MODES before operating the machine. • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES WARNING • A Synergic welding mode offers the simplicity of single knob control.

  • Page 40: Graphic Symbols

    OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE HIGH TEMPERATURE INPUT CURRENT MACHINE STATUS OUTPUT CURRENT CIRCUIT BREAKER PROTECTIVE WIRE FEEDER GROUND POSITIVE OUTPUT WARNING or CAUTION NEGATIVE OUTPUT 3 PHASE INVERTER Explosion...
  • Page 41 (See Installation Section) Do not use Power Wave AC/DC 1000 for pipe thaw- ing. EQUIPMENT LIMITATIONS The Power Wave AC/DC 1000 is not to be used in outdoor environments. Operating Temperature Range is 32°F to 104°F(0°C to +40°C). POWER WAVE® AC/DC 1000...

  • Page 42: Case Front Control Descriptions

    OPERATION CASE FRONT CONTROL DESCRIPTIONS (See Figure B.5) 4. 10 Amp Wire Feeder Circuit Breaker: Protects 40 (See Figure B.4) volt DC wire feeder power supply. 1. Power Switch: Controls input power to the Power 5. 115 VAC Auxiliary Power Circuit Breaker: Wave Protects case front receptacle auxiliary supply.
  • Page 43 OPERATION FIGURE B.5 POWER WAVE® AC/DC 1000...

  • Page 44: Case Rear Components

    OPERATION CASE REAR COMPONENTS 9. AC Switch Assembly W/Impeller Fan DESCRIPTION (See Figure B.6) 10. Optional CE Filter Assembly (not shown): CE compliance filter connects in series with input con- 1. Input Contactor: Connection point for incoming 3 Phase power (see "Recommended Input Wire and nection.

  • Page 45: Duty Cycle

    If a special welding pro- gram is desired, contact the local Lincoln Electric sales representative. To make a weld, the Power Wave AC/DC 1000 needs to know the desired welding parameters. Waveform Control Technology ™ allows full customization of Strike, Run-in, Crater and other parameters for exact- ing performance.

  • Page 46: Multiple Arc System Considerations

    OPERATION BASIC MODES OF OPERATION MULTIPLE ARC SYSTEM CONSIDERATIONS CONSTANT CURRENT (CC) • Operator presets Current and desired Voltage. Large scale SAW applications often employ multiple • The Power Source: arcs to increase deposition rates. In multiple arc sys- - Goal is to maintain a constant arc length. tems, magnetic forces created by like and opposing - Drives a constant Current.

  • Page 47: Weld Sequence

    Weld sequence adjustments allow the operator to fine tune the start and finish of each weld for superior performance. If the arc goes out for any reason (short circuit or open circuit), the Power Wave AC/DC 1000 will enter a Re- START OPTIONS strike state. During this state the system will automati-...
  • Page 48 Nominal Offset Negative Offset number of unique adjustments related to the AC Less Penetration waveform of the Power Wave AC/DC 1000. These More Deposition adjustments enable the operator to balance the rela- tionship between penetration and deposition to tailor the output for specific applications.

  • Page 49: Multiple Arc Ac Adjustments For Systems Equipped With K2282-1 System Interface

    B-11 B-11 OPERATION MULTIPLE ARC AC ADJUSTMENTS FOR SYSTEMS EQUIPPED WITH K2282-1 SYSTEM INTERFACE Phase The phase relationship between the arcs helps to minimize the magnetic interaction between adjacent arcs. It is essentially a time offset between the wave- forms of different arcs, and is set in terms of an angle from 0 to 360°, representing no offset to a full period offset.

  • Page 50: Accessories

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

  • Page 51: Maintenance

    PERIODIC MAINTENANCE Calibration of the Power Wave AC/DC 1000 is critical to its operation. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance.

  • Page 52: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 53 OUTPUT PROBLEMS Major physical or electrical damage Contact your local authorized Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service Lincoln Electric Field Service covers are removed. facility for technical assistance. facility for technical assistance.
  • Page 54 Turn back on, and acti- vate output. If condition persists, turn power off, and contact an authorized Lincoln Electric Field Service facility. 4. Inverter Fault - switch pc board, 4. Contact your local authorized Lincoln Electric Field Service contactor problem, etc.
  • Page 55 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Auxiliary receptacle is “dead”. Circuit breaker CB2 (on case Power down and reset CB2. front) may have tripped. Circuit breaker CB3 or CB4 (in Power down and reset CB3 or reconnect area) may have CB4.
  • Page 56 AC Switch (lower sec- tion of the machine).Contact your local authorized Lincoln Electric Field Service facility for technical assistance. Machine output shuts down during a 1. Secondary current limit has been 1.
  • Page 57 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM Device does not go on Line. 1. 24v bus power. 1. Verify that LED 2 is on when the DeviceNet network is powered. This can be done with the Power Wave turned on or off.
  • Page 58 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM 4. Power Supply. 4. Verify that the DeviceNet bus power supply can supply sufficient current for the devices on the network. 5.
  • Page 59 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM Bad Weld Starting 1. Wire Feed problem. 1. Verify Feeders drive roll tension is not too low allowing the wire to slip in the rolls.
  • Page 60 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM Analog Inputs donʼt respond or donʼt 1. Analog Scans Between Updates. 1. The DeviceNet tab of the Diagnostics Utility displays the respond quickly.
  • Page 61 E-10 E-10 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM Bad Weld Ending 1. Burnback Disabled. 1. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed.
  • Page 62 E-11 E-11 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION DEVICENET-PLC CONTROLLED SYSTEM 3. From the DeviceNet tab of the 3. Analog Hysteresis. Diagnostics Utility, select Configure. Verify in "Analog Input Channels"...

  • Page 63: Using The Status Led To Troubleshoot System Problem

    Troubleshooting the Power Wave AC/DC 1000 Using the External Status LEDʼs Steady Green System OK. Power source is operational, and is com- municating normally with all healthy peripheral equip- ment connected to its ArcLink network.
  • Page 64 Observe all Safety Guidelines detailed throughout this manual ERROR CODES The following is a partial list of possible error codes for the Power Wave AC/DC 1000. For a complete listing con- sult the Service Manual for this machine. POWER SOURCE- WELD CONTROLLER...
  • Page 65 E-14 E-14 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual WIRE DRIVE MODULE Error Code # Indication Long term average motor current limit has been exceeded. Typically Motor Overload indicates mechanical overload of system. If problem continues consider higher gear ratio. Motor Overcurrent Absolute maximum motor current level has been exceeded.
  • Page 66 DIAGRAMS POWER WAVE® AC/DC 1000...
  • Page 67 DIAGRAMS POWER WAVE® AC/DC 1000...
  • Page 68 AC SWITCH WIRING DIAGRAM POWER WAVE® AC/DC 1000...
  • Page 69 AC SWITCH WIRING DIAGRAM POWER WAVE® AC/DC 1000...
  • Page 70 DIMENSION PRINT POWER WAVE® AC/DC 1000...
  • Page 71 NOTES POWER WAVE® AC/DC 1000...
  • Page 72 • Keep flammable materials away. • • Do not touch electrically live parts or Wear eye, ear and body pro- WARNING electrode with skin or wet clothing. tection. • Insulate yourself from work and ground. Spanish • Mantenga el material combustible •...
  • Page 73 • Turn power off before servicing. • Keep your head out of fumes. • Do not operate with panel open or • Use ventilation or exhaust to WARNING guards off. remove fumes from breathing zone. • Desconectar el cable de ali- Spanish •...
  • Page 74 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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