Lincoln Electric K2803 Operator's Manual
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Lincoln Electric K2803 Operator's Manual

Lincoln Electric K2803 Operator's Manual

Power wave ac/dc 1000 sd
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IM2064
04/2017
REV01
®

POWER WAVE

AC/DC 1000 SD CE
OPERATOR'S MANUAL
ENGLISH
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland Ohio 44117-1199 USA
www.lincolnelectric.eu

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  • Page 1: Power Wave

    IM2064 04/2017 REV01 ® POWER WAVE AC/DC 1000 SD CE OPERATOR’S MANUAL ENGLISH THE LINCOLN ELECTRIC COMPANY 22801 St. Clair Ave., Cleveland Ohio 44117-1199 USA www.lincolnelectric.eu...

  • Page 2: The Lincoln Electric Company

    Address: c/o Balmes, 89 - 8 08008 Barcelona SPAIN Hereby declare that equipment: K2803, Power Wave AC/DC 1000 SD K2444, CE Filter K2814, MAXsa 10 Controller K2626, MAXsa 19 Controller K2370, MAXsa 22 Feed Head K2312, MAXsa 29 Feed Head (Sales codes may contain suffixes and prefixes.)

  • Page 3: Table Of Contents

    12/05 THANKS! For having chosen the QUALITY of the Lincoln Electric products.  Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified immediately to the dealer.  For future reference record in the table below your equipment identification information. Model Name, Code &...

  • Page 4: Technical Specifications

    Technical Specifications ® POWER WAVE AC/DC 1000 SD CE (K2803-1*) INPUT AT RATED OUTPUT – THREE PHASE ONLY INPUT POWER FACTOR INPUT VOLTS 3 OUTPUT IDLE POWER EFFICIENCY @ CURRENT @ RATED PHASE 50/60Hz CONDITIONS WATTS RATED OUTPUT AMPS OUTPUT 1000A@44V.
  • Page 5 Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 6: Safety

    Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.

  • Page 7: Installation And Operator Instructions

    MAXsa™ 10 or MAXsa™ 19 Controllers may be used reconnection. It utilizes complex, high-speed waveform ® with a K2803-1 PowerWave AC/DC 1000 SD CE in a control to support a variety of constant current and Multi Arc system. Other Lincoln or non-Lincoln Wire constant voltage welding modes in each of its output Drives can only be used with custom interfaces.

  • Page 8: Duty Cycle

     Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas FILTER REMOVAL cylinder. FROM SIDE OF  Do not lift machine if lift bail is damaged. MACHINE  Do not operate machine while suspended from lift bail Lift the machine by the lift bail only.

  • Page 9: Input Connection

    Input Connection Input Supply Connection for K2803-1 WARNING WARNING ELECTRIC SHOCK can kill ELECTRIC SHOCK CAN KILL: Only a qualified electrician should connect the input  Do not operate with covers removed leads to the Power Wave. Connections should be made ...
  • Page 10 System Connection NOTE: The K2803-1 Power Wave® AC/DC 1000® SD is backwards compatible with the K2344-2 Power System Overview Wave® AC/DC 1000 in tandem or multi-arc systems. ® The Power Wave AC/DC 1000 SD CE power source is The K2803- 1 and K2344-2 machines cannot be designed to be a part of a modular welding system connected in parallel.
  • Page 11 Cruiser Connection Diagram English English...
  • Page 12 CRUISER™ SYSTEM CHECKLIST (See Cruiser Connection Diagram) ®  Place Power Wave AC/DC 1000 SD CE in 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 CE and the Cruiser™...
  • Page 13 Single Arc Connection Diagram English English...
  • Page 14 SINGLE ARC SYSTEM CHECKLIST (See Single Arc Connection Diagram) ®  Place Power Wave AC/DC 1000 SD CE in suitable operating location.  Mount MAXsa™ 10 Controller.  Install MAXsa™ 22 Wire Drive and other accessories in their operating location. ...
  • Page 15 Tandem Arc Connection Diagram English English...
  • Page 16 TANDEM ARC (2-ARC) SYSTEM CHECKLIST (See Tandem Arc Connection Diagram) ®  Place Power Wave AC/DC 1000 SD CE units in suitable operating location.  Mount MAXsa™ 10 Controllers.  Install MAXsa™ 22 Wire Drives and other accessories in their operating location. ...
  • Page 17 Paralleling Connection Diagram English English...
  • Page 18 PARALLEL CONNECTION CHECKLIST (See Parelleling Connection Diagram))  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 (5 pin) between Power Wave and MAXsa™...
  • Page 19 MAXsa™ 19 Connection Diagram English English...
  • Page 20 MAXsa™ 19 SYSTEM CHECKLIST ®  Place the Power Wave AC/DC 1000 SD CE in a suitable operating location.  DeviceNet PLC controlled systems: Mount DeviceNet PLC controller and User Interface.  Mount MAXsa™ 19 in it’s operating location. ® ...

  • Page 21: Electrode And Work Connections

    Electrode and Work Connections Electrode Connections Connect cable(s) of sufficient size and length (Per Table General Guidelines 1: Output Cable Guidelines) to the "ELECTRODE" studs ® The unique switching structure of the Power Wave on the power source (located behind the cover plate on AC/DC 1000 SD CE allows it to produce DC positive, DC the lower right rear corner).
  • Page 22 Work Voltage Sensing For most applications the use of a remote work volt-age ® sense lead is recommended. The Power Wave AC/DC 1000 SD CE is shipped from the factory with the remote work voltage sense lead enabled. It must be attached to the work as close to the weld as practical, but out of the weld current path.

  • Page 23: Control Cable Connections

     Both Sense# leads are out of the current paths.  Both Sense# leads detect arc voltage accurately.  No voltage drop between Arc# and Sense# leads.  Best start, best arcs, most reliable results. Figure #8 Control Cable Connections General Guidelines These Guidelines apply to all commumication cables including optional DeviceNet and Ethernet...
  • Page 24 NOTE: DeviceNet cables should not be routed with weld cables, wire drive control cables, or any other DEVICENET CONNECTOR current carrying device that can create a fluctuating magnetic field. In a typical system, a DeviceNet connection is made between the master power source of each arc, and the 115VAC RECEPTABLE PLC interface.

  • Page 25: Case Front Controls

    Cord Connector: Input power cord strain relief. WARNING or CAUTION EXPLOSION DANGEROUS VOLTAGE SHOCK HAZARD Case Front Controls Power Switch: Controls input power to the Power ® Wave AC/DC 1000 SD CE and any auxiliary equipment that may be connected to it. Status Light: A two color LED that indicates system errors.

  • Page 26: Common Welding Procedures

    Power Wave AC/DC 1000 SD CE encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales representative. ® To make a weld, the Power Wave AC/DC 1000 SD CE needs to know the desired welding parameters.

  • Page 27: Weld Sequence

    is a cancellation of the interacting forces. See Figure below. CONSTANT VOLTAGE (CV)  Operator presets Wire Feed Speed and desired Voltage.  The Power Source: Goal is to maintain a constant arc length. Commands constant wire feed speed. Synergically Controls Current to Maintain Voltage at the desired Set point.
  • Page 28 End Options Wave Balance The Downslope, Crater, Burnback and Restrike  Refers to amount of time the waveform spends in Timer parameters are used to define the end of the weld DC+ portion of the cycle. sequence.  Use Wave Balance to control the penetration and deposition of a given process.
  • Page 29 Phase Relationship Use Phase relation ship to minimize arc blow in multiple arc systems. (Balanced two arc system shown) Figure: Frequency Phase Adjustment for Multiple Arc Systems Best results obtained by alternating and equalizing the Phase  duration of magnetic forces between adjacebt arcs. The phase relationship between the arcs helps to minimize the magnetic interaction between adjacent arcs.
  • Page 30 We respond to our customers will null and void the manufacturers warranty. based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or WARNING guarantee such advice, and assumes no liability, with Do not open this machine and do not introduce anything respect to such information or advice.

  • Page 31: Weee

    WEEE 07/06 Do not dispose of electrical equipment together with normal waste! In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE) and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility.

  • Page 32: Electrical Schematic

    Electrical Schematic ® WIRING DIAGRAM – POWER WAVE AC/DC 1000 (380/400/460/500/575) POWER SOURCE NOTE: this diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a partiuclar code is pasted inside the machine on one of the enclosure panels. If the diagram is ellegible, write to the Service Department for a raplacement.
  • Page 33 ® WIRING DIAGRAM – POWER WAVE AC/DC 1000 (380/400/460/500/575) AC SWITCH NOTE: this diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a partiuclar code is pasted inside the machine on one of the enclosure panels. If the diagram is ellegible, write to the Service Department for a raplacement.

  • Page 34: Suggested Accessories

    Suggested Accessories BASIC PACKAGE Item number Description K2803-1 Power Wave AC/DC 1000 SD CE K2370-2 MAXsa 22 Wire Drive K2814-1 MAXsa 10 Controller/User interface K2683-XX Control Cable (5 pin- 5pin) – power source to controller K1785-xx Control Cable (14 pin- 14pin) – Controller to Wire Drive...

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