ADVANCED PROCESS WELDERS Power Wave Advanced Module Processes GMAW-STT®, SMAW, GMAW, GMAW-P, GTAW Product Number K2912-1 Advanced Module K4192-1 Advanced Module Aluminum See back for complete specs Input Power 40V DC Weight/Dimensions (H x W x D) 70.5 lbs. (32.0 kg) Rated Output Capacity(1) 100% Duty Cycle: 300A@32V 40% Duty Cycle: 350A@34V Peak (Max.): 600A 11.5 x 14 x 25 in. 292.1 x 355.6 x 635 mm (1) Host welding power source will be limited to these outputs. Expand Your Welding Capabilities K4192-1 The Power Wave® Advanced Module increases flexibility by expanding your welding capabilities. The module has alternating current (AC) welding capability to run aluminum processes. With the module, you’ll have the ability to perform several welding processes with AC advanced waveform control - shielded metal arc, metal inert gas (MIG), pulsed MIG, tungsten electrode inert gas (TIG) and Surface Tension Transfer® (STT). K2912-1 FEATURES APPLICATIONS Automotive Pipe Fabrication Heavy Equipment Pressure Vessels Shipbuilding Trailer Manufacturing IN CO LN ELECT RI WHAT’S INCLUDED Power Source Output Pigtail Adapter Cable (Tweco-style) 25 ft. (7.6 m) Remote Voltage Sense Lead ArcLink Output Receptacle Differential Input and Output (Sync Tandem Output) Shielding Gas Input THE LINCOLN ELECTRIC COMPANY Publication E5.191 | Issue Date 05/15 © Lincoln Global, Inc. All Rights Reserved. CE C-Tick CCC CSA L OUTPUT INPUT C The Power Wave Advanced Module – Provides multi-process reverse polarity (DC+), straight polarity (DC-), AC, high frequency TIG and STT functionality. Integrated Control Cables – Provides easy connection to compatible Power Wave models. Quick Lock Mounting System – Provides a way to safely secure the module to the power source. Ingress Protection (IP23) Safety – Provides use in outdoor applications. - Protects against the entry of mediumsized foreign bodies greater than 12 millimeters in diameter, along with spray water from any direction up to 60 degrees from the vertical. ArcLink® Digital Communications – Trades status and identification information while receiving high-speed, synchronized switching command from the power source. Intelligent Protection – Prevents potential damage caused by misconnection and voltage transients. Fan – Synchronizes operation with the host power source. 22801 St. Clair Avenue • Cleveland, OH • 44117-1199 • U.S.A. PH: +1.216-481-8100 • www.lincolnelectric.com Two Year Extended Warranty Available In the U.S.A. and Canada IP23S KEY CONTROLS CASE FRONT DESCRIPTIONS 1. Status light-emitting diode (LED) provides ArcLink status of module. 2. Connects to workpiece, regardless of process. 3. Connects to feeder for MIG welding, regardless of process. 4. Power source mounting bracket. 5. Negative input and positive input. 6. Sense lead input provides voltage feedback to the power source from the module. 7. Sense lead output provides voltage feedback. 8. TIG electrode connects internally to MIG electrode, and provides high frequency capability for TIG starting. 4. 1. 2. 3. 5. 6. 7. 8. CASE BACK DESCRIPTIONS 1. Differential input and output pigtail connects to the differential input and output receptacle on the rear of the power source. 2. Differential input and output (sync tandem) output supports synchronized MIG welding with compatible power sources. 3. ArcLink pigtail connects to the ArcLink output receptacle on the rear of the power source. 1. 4. ArcLink (output) provides a pass through connection for all compatible wire feeders. 2. 3. 5. Gas input provides a solenoid controlled gas feed to TIG on case front. 4. 5. 6. Removable cover; a channel for cable management. NOTE: For operation with the K2823-3 Power Wave S350 power source or K2862-3 Power Wave S350 Ready-Pak® models with code numbers prior to 11600, the S28481 retrofit kit is required. Contact the customer service team in Cleveland, Ohio to order a kit at no charge to assure proper connection to the Advanced Module. THREE REASONS TO BUY The Advanced Module adds three important capabilities to Lincoln Electric’s mid-sized modular, multi-process S-Series Power Wave power sources, which include the following: 1 2 3 AC polarity welding capability for aluminum MIG and TIG welding. High frequency starting use when necessary to aid arc initiation. STT welding is great for root pass welding on pipe or thin sheet metal applications. [ 2 ] | Power Wave Advanced Module 6. AC Aluminum Pulse for superior quality welding*. Increases travel speed up to 40% Increases deposition up to 75% ADVANCED MODULE burnthrough CAPABILITIES Decreases Improves gap bridging 1 PULSE 10.1” AC ALUMINUM PULSE 14.1” AC POLARITY WELDING CAPABILITY Adding the Advanced Module to your Power Wave augments the inverter-based DC welding AC Aluminum Pulse (GMAW) brings that be realized with standard architecture of the Power Wave withfeatures AC welding. Usecannot AC for cleaning action on aluminum when DC pulse MIG welding. The AC pulse process reduces heat or input thetoenergy away the base plate and switching the polarity of the arc. MIG or TIGthe welding, use itby forfocusing stick welding help combat arcfrom blow problems. Productivity increases with improved deposition rates using AC Aluminum Pulse (GMAW) waveform technology are Benefits: available exclusively on the Power Wave® Advanced Module. This is possible because the negative polarity arc redirects the heat away from the workpiece, reducing the chance of burnthrough. The UltimArc™ and synergic precision controls Increases wire feed speed give the user full control over heat input, penetration while improving cleaning action, and allowing for faster travel speeds Reduces burn-through with improved heat control on thin material. Increases cleaning With this technology, it is now easier to weld thin aluminum and bridge gaps. Precise control of the heat input is achieved with the UltimArc™ control using AC Aluminum Pulse (GMAW). UltimArc™ adjusts the amount of DC negative time during the background to allow less heat to be transferred to the workpiece. FEATURES Compares to conventional pulse processes LOW TRAVEL SPEED HIGH AC Aluminum Pulse vs. Pulse AC ALUMINUM PULSE PULSE THIN MATERIAL THICKNESS THICK E AC ALUMINUM LS MAX PU DEPOSITION HE AT INP UT MIN Burnthrough AC ALUMINUM PULSE LOW HEAT INPUT WIRE FEED WFSSPEED HIGH MIN AC ALUMINUM MAX PULSE *Based on a side by side comparison of AC Aluminum Pulse and Pulse using a Power Wave® S350 with SuperGlaze® 4043 3/64” wire on a 1.5mm lap. AC Aluminum Pulse parameters: Mode 393, WFS 215 in/min, Travel Speed 40 in/min, 0.75 Trim and -5 WC. Pulse parameters:Mode72, WFS 130 in/min, Travel Speed 30 in/min, 0.8Trim and 0 WC. 2 HIGH FREQUENCY STARTING When welding in DC- on steel or AC polarity mode on aluminum, it’s helpful to have a high TE12.009frequency current to improve arc starting performance. While the use of continuous high frequency can interfere with surrounding shop equipment, instantaneous bursts designed to aid arc starting have little or no effect. The Advanced Module incorporates a high frequency starting mode that can be controlled at the wire feeder or power source user interface. The careful use of high frequency starting can improve the appearance of TIG welding arc starts and helps to reduce contamination caused by scratch starts. Power Wave Advanced Module | [ 3 ] THREE REASONS TO BUY, CONT’D. 3 STT STT is a controlled MIG short circuit transfer process that uses current controls to adjust the heat independent of wire feed speed, resulting in superior arc performance, good penetration, low heat input control and reduced spatter and fumes. For more information see Nextweld® Document NX-2.20 Conventional CV short circuit transfer using carbon dioxide (CO2) and 0.045 in. solid wire. Advantages of STT • Reduces lack of fusion • Increases puddle control • Capable of producing consistent X-ray quality welds • Reduces training time • Lowers fume generation and spatter • Uses various compositions of shielding gas • Uses 100 percent CO2 on mild steel • Functions four times faster than MIG • Uses vertical down welding • Shields gas using various compositions • Welds stainless, nickel alloys and mild steel • Provides consistent x-ray quality welds STT Application STT using CO2 and 0.045 in. solid wire (Note reduced spatter and fume). Using STT STT is the process of choice for low heat input welds and is ideal for the following: • Open root – pipe and plate • Thin gauge material – automotive • Stainless steel and nickel alloy – petrochemical utility and food industry • Silicon bronze – automotive • Galvanized steel • Semiautomatic and robotic applications Inside of an 8 in. x .375 in. wall API 5L-X52 pipe, welded in 5G position Inside of an 8 in. x 0.375 in. wall API 5L-X52 pipe, welded in 5G position. PRODUCT SPECIFICATIONS Product Name Product Number Input Power Rated Output Capacity(1) Current/Voltage/Duty Cycle HxWxD inches (mm) Net Weight lbs. (kg) Power Wave Advanced Module K2912-1 40 V DC 100% Duty Cycle: 300A@32V 40% Duty Cycle: 350A@34V Peak (Max.): 600A 11.5 x 14 x 25 (292.1 x 355.6 x 635) 70.5 (32) Power Wave Advanced Module Aluminum K4192-1 (1) Host welding power source will be limited to these outputs. Manufactured at a facility with certified ISO Quality and Environmental Management Systems. Go to www.lincolnelectric.com for details. For best welding results with Lincoln Electric equipment, always use Lincoln Electric consumables. Visit www.lincolnelectric.com for more details. CUSTOMER ASSISTANCE POLICY T he business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is specifically disclaimed. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
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