Lincoln Electric power wave ac/dc 1000 sd Operator's Manual
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Lincoln Electric power wave ac/dc 1000 sd Operator's Manual

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RETURN TO MAIN MENU
IM10022-C
P P OWER WAVE AC/DC 1000 SD
®
®
November, 2012
11592, 11881, 11918
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
IP 23
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A.
TEL: 1.216.481.8100
For Service in U.S. and Canada: Call 1.888.935.3877
FAX: 1.216.486.1751
WEB SITE: lincolnelectric.com
For Non-U.S. Service: Email globalservice@lincolnelectric.com

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  • Page 1 RETURN TO MAIN MENU IM10022-C P P OWER WAVE AC/DC 1000 SD ® ® November, 2012 11592, 11881, 11918 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.
  • 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 l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Public Supply System Welding equipment should be connected to the public supply system according to the manufacturer’s rec- ommendations.
  • 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS viii viii 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 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...

  • Page 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - Power Wave AC/DC 1000 SD (K2803-1) ® ® INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS INPUT OUTPUT POWER FACTOR IDLE EFFICIENCY 3 PHASE CURRENT AMPS CONDITIONS @ RATED OUTPUT POWER @ RATED OUTPUT 50/60 Hz WATTS 1000A@44V.

  • Page 11: Safety Precautions

    INSTALLATION LIFTING SAFETY PRECAUTIONS Read this entire installation section before you WARNING start installation. WARNING • Lift only with equipment of adequate lifting capacity. ELECTRIC SHOCK can kill. • Be sure machine is stable • Only qualified personnel should when lifting. perform this installation.

  • Page 12: Clearance Requirements

    INSTALLATION CLEARANCE REQUIREMENTS Removing the four(4) clips and pulling back on the The maintenance requirements of the Power Wave ® rear portion of the machine will provide access for AC/DC 1000 SD demand that enough clearance ® cleaning the machine and checking the filter. The filter behind the machine be maintained.

  • Page 13: Connection Diagram

    INSTALLATION INPUT AND GROUND CONNECTIONS INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS MACHINE GROUNDING Refer to Specifications page for recommended fuse and The frame of the welder must be grounded. A ground wire sizes. Fuse the input circuit with the recommended terminal marked with the symbol shown is located super lag fuse or delay type breakers (also called "inverse inside the reconnect / input access door for this...

  • Page 14: System Connection

    INSTALLATION SYSTEM CONNECTION System Overview When employed in a multi-arc AC system the arcs The Power Wave AC/DC 1000 SD power source is ® ® must be synchronized to each other. The Master for designed to be a part of a modular welding system each arc can be configured to follow a dedicated typically controlled by a MAXsa™...
  • Page 15 MAXsa™ 19 Controller is Trail or Slave. See Figure A.4 still required to power the Wire Drive. Contact your Local Lincoln Electric Representative for more infor- In a typical multi-arc system, each arc is controlled by mation.
  • Page 16 INSTALLATION FIGURE A.5 - CRUISER CONNECTION DIAGRAM POWER WAVE ® AC/DC 1000 ®...
  • Page 17 INSTALLATION CRUISER™ SYSTEM CHECKLIST (See Figure A.5) Place the Power Wave ® AC/DC 1000 ® SD in a suitable operating location. Place the Cruiser™ Tractor in itʼs operating location. Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave AC/DC 1000 SD and ®...
  • Page 18 INSTALLATION FIGURE A.6 - SINGLE ARC CONNECTION DIAGRAM POWER WAVE ® AC/DC 1000 ®...
  • Page 19 A-10 A-10 INSTALLATION SINGLE ARC SYSTEM CHECKLIST (See Figure A.6) Place the Power Wave ® AC/DC 1000 ® SD in a suitable operating location. 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™...
  • Page 20 A-11 A-11 INSTALLATION FIGURE A.7 - TANDEM ARC CONNECTION DIAGRAM POWER WAVE ® AC/DC 1000 ®...
  • Page 21 A-12 A-12 INSTALLATION 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).
  • Page 22 A-13 A-13 INSTALLATION FIGURE A.8 - PARALLELING CONNECTION DIAGRAM POWER WAVE ® AC/DC 1000 ®...
  • Page 23 A-14 A-14 INSTALLATION 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™...
  • Page 24 A-15 A-15 INSTALLATION FIGURE A.9 - MAXsa™ 19 CONNECTION DIAGRAM PLC Contro ller User Interface DeviceNet Cable Network K2683-XX Arclink Cable K2626-2 MAXsa™ 19 K1785-XX 14-Pin Cable K2803-1 K2312-2 MAXsa™ 29 Power Wave ® AC/DC 1000 67 Lead ® Electrode K231-XX Weld Cable Contact Nozzle...
  • Page 25 A-16 A-16 INSTALLATION MAXsa™ 19 SYSTEM CHECKLIST (See Figure A.9) Place the Power Wave ® AC/DC 1000 ® SD in a suitable operating location. DeviceNet PLC controlled systems: Mount DeviceNet PLC controller and User Interface. Mount MAXsa™ 19 in itʼs operating location. Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave ®...

  • Page 26: Electrode And Work Connection

    A-17 A-17 INSTALLATION ELECTRODE AND WORK Work Connections CONNECTIONS Connect cable(s) of sufficient size and length (Per Table A.1) between the "WORK" studs (located General Guidelines behind the cover on the lower left rear corner) and the work piece. Be sure the connection to the work makes The unique switching structure of the Power Wave ®...
  • Page 27 A-18 A-18 INSTALLATION CABLE INDUCTANCE, AND ITS EFFECTS Electrode Voltage Sensing ON WELDING The remote ELECTRODE sense lead (67) is built into the wire feeder control cable (K1785) and accessible Excessive cable inductance will cause the welding at the wire drive. It should always be connected to the performance to degrade.
  • Page 28 A-19 A-19 INSTALLATION VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS Special care must be taken when more than one arc • For longitudinal applications, connect all work is welding simultaneously on a single part. Remote leads at one end of the weldment, and all of the sensing is required in Multi-arc applications work voltage sense leads at the opposite end of the weldment.

  • Page 29: Multi-Arc Circumfirential Welds

    A-20 A-20 INSTALLATION FIGURE A.13 MULTI-ARC CIRCUMFIRENTIAL WELDS POWER SOURCE POWER SOURCE POWER POWER SOURCE SOURCE POWER SOURCE POWER SOURCE POWER WAVE ® AC/DC 1000 ®...
  • Page 30 A-21 A-21 INSTALLATION CONTROL CABLE CONNECTIONS NOTE Connections Between Power Source and Optional GENERAL GUIDELINES DeviceNet Programmable Logic Controller(PLC). These guidelines apply to all communication It is sometimes more practical and cost effective to cables including optional DeviceNet and Ethernet use a custom PLC interface to control a multi-arc sys- connections.
  • Page 31 OPERATION SAFETY PRECAUTIONS SYNERGIC WELDING MODES Read this entire section of operating instructions • A Synergic welding mode offers the simplicity of before operating the machine. single knob control. The machine will select the correct voltage and amperage based on the wire feed speed (WFS) set by the operator.

  • Page 32: Graphic Symbols That Appear On This Machine Or In This Manual

    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 33: Recommended Processes

    OPERATION PRODUCT SUMMARY Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives and MAXsa™ 10 or MAXsa™ 19 Controllers may be used The Power Wave ® AC/DC 1000 ® SD is a high with a K2803-1 Power Wave AC/DC 1000 SD in a ®...

  • Page 34: Operation

    OPERATION CASE FRONT CONTROLS FIGURE B.1 - CASE FRONT 1. Power Switch: Controls input power to the Power Wave AC/DC 1000 SD and any auxiliary ® ® equipment that may be connected to it. 2. Status Light: A two color LED that indicates system errors.

  • Page 35: Case Back Components

    OPERATION 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.
  • Page 36 OPERATION FIGURE B.3 - CASE BACK COMPONENTS 115V AC 10 A 4 0V 10 A Device COMMUNICATIONS PROTOCOL L15129-1 Stud Cover Doors Removed for Clarity POWER WAVE ® AC/DC 1000 ®...

  • Page 37: Power-Up Sequence

    If a consult the troubleshooting section of this manual for special welding program is desired, contact the local further instruction. Lincoln Electric sales representative. DUTY CYCLE To make a weld, the Power Wave AC/DC 1000 ®...

  • Page 38: Multiple Arc System Considerations

    OPERATION MULTIPLE ARC SYSTEM BASIC MODES OF OPERATION 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 - Goal is to maintain a constant arc length. systems, magnetic forces created by like and - Drives a constant Current.
  • Page 39 OPERATION WELD SEQUENCE END OPTIONS The weld sequence defines the weld procedure from The Downslope, Crater, Burnback and Restrike beginning to end. The Power Wave ® AC/DC 1000 ® Timer parameters are used to define the end of the not only provides adjustment of basic welding weld sequence.
  • Page 40 B-10 B-10 OPERATION WELD PROCESS ADJUSTMENTS DC OFFSET Depending on the weld mode, there are a number of • Refers to +/- shift of the current waveform with adjustments that can be made, including but not respect to the zero crossing. limited to Current, Voltage and WFS.

  • Page 41: Phase Adjustment For Multiple Arc Systems

    B-11 B-11 OPERATION PHASE ADJUSTMENT FOR MULTIPLE ARC SYSTEMS Phase • The phase relationship between the arcs helps to minimize the magnetic interaction between adjacent arcs. It is essentially a time offset between the waveforms of different arcs, and is set in terms of an angle from 0 to 360°, representing no offset to a full period offset.

  • Page 42: Accessories

    ACCESSORIES OPTIONS AND ACCESSORIES available at www.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 ʻEnterʼ on the keyboard). 3. On the Results page, scroll down to the Equipment list and click on E9.181.

  • Page 43: Maintenance

    MAINTENANCE CALIBRATION SPECIFICATION SAFETY PRECAUTIONS WARNING Output Voltage and Current are calibrated at the factory. Generally speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check ELECTRIC SHOCK can kill. reveals a problem, use the calibration section of the Weld Manager Utility to make the appropriate •...

  • Page 44: Troubleshooting

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

  • Page 45: Using The Status Led To Troubleshoot System Problem

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave ® AC/DC 1000 ® SD is equipped with one externally mounted status light. If a problem occurs it is important to note the condition of the status lights.
  • Page 46 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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 Service Manual for this machine. POWER SOURCE–––WELD CONTROLLER LECO Error Code #...
  • Page 47 BASIC MACHINE PROBLEMS Major physical or electrical damage None Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service covers are removed. facility for technical assis- tance. Input fuses keep blowing Make sure fuses are properly Improperly sized input fuses.
  • Page 48 DIAGRAMS POWER WAVE ® AC/DC 1000 ®...
  • Page 49 Enhanced Diagrams DIAGRAMS POWER WAVE ® AC/DC 1000 ®...

  • Page 50: Dimension Print

    DIMENSION PRINT POWER WAVE ® AC/DC 1000 ®...
  • Page 51 NOTES POWER WAVE ® AC/DC 1000 ®...
  • Page 52 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 53 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 54 Need Help? Lincoln Electric “Rapid Response” Service! Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 A.M. to 6:00 P.M. (ET) Mon. thru Fri. After hours? Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you by the next business day.

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