power wave ac/dc 1000 sd ce

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
THE LINCOLN ELECTRIC COMPANY
EC DECLARATION OF CONFORMITY
Manufacturer and technical documentation
holder:
The Lincoln Electric Company
Address:
22801 St. Clair Ave.
Cleveland Ohio 44117-1199 USA
EC Company:
Lincoln Electric Europe S.L.
Address:
c/o Balmes, 89 - 80 2a
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.)
Is in conformity with Council Directives
and amendments:
Electromagnetic Compatibility (EMC) Directive 2014/30/EU
Low Voltage Directive (LVD) 2014/35/EU
Standards:
EN 60974-1: 2012, Arc Welding Equipment – Part 1: Welding Power
Sources;
EN 60974-5: 2013, Arc Welding Equipment-Part 5: Wire Feeders;
EN 60974-10: 2014, Arc Welding Equipment-Part 10: Electromagnetic
compatibility (EMC) requirements;
CE marking affixed in 09
Samir Farah, Manufacturer Dario Gatti, European Community Representative Compliance Engineering Manager European Engineering Manager 19 January 2017 MCD240f 20 January 2017
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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 &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications...................................................................................................................................................... 1 Safety .................................................................................................................................................................................. 3 Installation and Operator Instructions ................................................................................................................................. 4 WEEE ................................................................................................................................................................................ 28 Spare Parts ....................................................................................................................................................................... 28 Authorized Service Shops Location .................................................................................................................................. 28 Electrical Schematic .......................................................................................................................................................... 29 Suggested Accessories..................................................................................................................................................... 31 English
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Technical Specifications
POWER WAVE® AC/DC 1000 SD CE (K2803-1*)
INPUT VOLTS 3
PHASE 50/60Hz
380
400
460
500
575
OPEN CIRCUIT
VOLTAGE
71V
70VACpk.
3 PAHESE INPUT
VOLTAGE
50/60Hz
INPUT AT RATED OUTPUT – THREE PHASE ONLY
POWER FACTOR
INPUT
EFFICIENCY @
OUTPUT
IDLE POWER
@ RATED
CURRENT
RATED OUTPUT
CONDITIONS
WATTS
OUTPUT
AMPS
82
79
1000A@44V.
225
.95
86%
69
100% Duty Cycle
62
55
OUTPUT
AUXILIARY POWER (CIRCUIT
PROCESS CURRENT RANGES (AC or DC)
BREAKER PROTECTED)
40 VDC AT
SAW-DC+
100amps@24Volts
10 AMPS
1000Amps@44Volts
SAW-DC115 VAC AT
(Actual range may be limited by process)
SAW-AC
10 AMPS
1
RECOMMENDED INPUT WIRE AND FUSES SIZES
3
TYPE 90°C COPPER WIRE IN
COPPER GROUNDING
TIME DELAY FUSER OR
2
CONDUIT
CONDUCTOR
BREAKER
AMPS
AWG (mm2)
100
8 (10)
90
8 (10)
90
8 (10)
80
8 (10)
70
10 (6)
PHYSICAL DIMENSIONS
HEIGHT (mm)
WIDTH (mm)
DEPTH (mm)
WEIGHT (kg)
1248
501
1184
363
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE (ºC)
STORAGE TEMPERATURE RANGE (ºC)
-10 to +40
-40 to +85
380
400
460
500
575
AWG (mm2)
3 (25)
3 (25)
4 (25)
4 (25)
6 (16)
1
Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C ambient.
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.
2
*
An External filter will be required to meet CE or C-Tick/RCM conducted emission requirements. It will meet CE and CTick/RCM requirements with the use of an optional external filter. (K2444-3 CE and C-Tick/RCM Filter Kit).
PROCESS
SAW
WELDING PROCESSES
OUTPUR RANGE
ELECTRODE DIAMETER RANGE
(Amperes)
2 – 5.6mm
100 -1000
WIRE FEED SPEED
RANGE
See Wire Drive Section
Insulation Class: Class F (155°C)
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Electromagnetic Compatibility (EMC)
01/11
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and
therefore the product is designed to be used in an industrial environment only.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.
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Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
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.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
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CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the
correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which
can cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another
person. Lifting may be dangerous for your physical health.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Installation and Operator Instructions
for the Submerged Arc Process (SAW).
Read this entire section before installation or operation
of the machine.
Equipment Limitations
General Description
The Power Wave® AC/DC 1000 SD can be used in
outdoor environments. The Operating Temperature
Range is 14°F to 104°F(0°C to +40°C).
®
The Power Wave AC/DC 1000 SD CE is a high
performance, digitally controlled inverter welding power
source. It is capable of producing a variable frequency
and amplitude AC output, DC positive output, or DC
negative output without the need for external
reconnection. It utilizes complex, high-speed waveform
control to support a variety of constant current and
constant voltage welding modes in each of its output
configurations.
Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives and
MAXsa™ 10 or MAXsa™ 19 Controllers may be used
®
with a K2803-1 PowerWave AC/DC 1000 SD CE 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 CE will support a
maximum average output current of 1000 Amps at 100%
Duty Cycle.
®
The Power Wave AC/DC 1000 SD CE power source is
designed to be a part of a modular welding system. Each
welding arc may be driven by a single machine, or by a
number of machines in parallel. In multiple arc
applications the phase angle and frequency of different
machines can be synchronized by interconnecting the
units with a control cable to improve performance and
reduce the effects of arc blow.
Location and Mounting
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through the
case sides and front. Dirt, dust, or any foreign material
that can be drawn into the welder should be kept at a
minimum. Failure to observe these precautions can
result in excessive operating temperatures and nuisance
shutdowns. See the Clearance Requirements and Figure
#1 below.
®
The Power Wave AC/DC 1000 SD CE is primarily
designed to interface with compatible ArcLink
equipment. However, it can also communicate with other
industrial machines and monitoring equipment via
DeviceNet, or Ethernet. The result is a highly integrated
and flexible welding cell.
Stacking
WARNING
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface shall
be covered with a steel plate at least 1.6mm thick, which
shall extend not more than 150mm beyond the
equipment on all sides.
Recommended Process
®
The Power Wave AC/DC 1000 SD CE is designed for
submerged arc welding (SAW). Due to its modular
design the Power Wave AC/DC can operate on either
single arc or in multi-arc applications with up to six arcs.
Each machine is factory preprogrammed with multiple
welding procedures to support all types of submerged
®
arc welding. The Power Wave AC/DC 1000 SD CE
carries an output rating of 1000 amps, 44 volts (at 100%
duty cycle). If higher currents are required machines can
be easily paralleled for up to 3000 amps on each arc
(see Duty Cycle section)
®
The Power Wave AC/DC 1000 SD CE machine cannot
be stacked.
Lifting
WARNING
FALLING EQUIPMENT can cause injury.

Lift only with equipment of adequate lifting capacity.

Be sure machine is stable when lifting.
Process Limitations
®
The Power Wave AC/DC 1000 SD CE is suitable only
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


Do not lift this machine using lift bail if it is equipped
with a heavy accessory such as trailer or gas
cylinder.
Do not lift machine if lift bail is damaged.
Do not operate machine while suspended from lift
bail
FILTER REMOVAL
FROM SIDE OF
MACHINE
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only . Do not attempt to
lift the Power Wave® AC/DC 1000 SD CE with
accessories attached to it.
Duty Cycle
®
The Power Wave AC/DC 1000 SD CE is capable of
welding 1000Amps,. @44V, at a 100% Duty cycle.
Environmentasl Limitations
®
The Power Wave AC/DC 1000 SD CE can be used in
an outdoor environment with an IP 23 rating. It should
not be subjected to falling water, nor should any parts of
it be submerged in water. Doing so may cause improper
operation as well as pose a safety hazard. The best
practice is to keep the machine in a dry, sheltered area.
*: 33.00” width needed for filter maintenance access.
Figure #1: Clearance Requirements
Clearence Requirements
Input and Ground Connections
®
The maintenance requirements of the Power Wave
AC/DC 1000 SD CE demands that enough clearance
behind the machine be maintained. This is especially
important where more than one machine is to be used or
if the machines are going to be rack mounted.
Machine Grounding
The frame of the welder must be grounded. A ground
terminal marked with a ground symbol shown is located
inside the reconnect/input access door for this purpose.
See your local and national electrical codes for proper
grounding methods.
The rear portion of the machine that contains the filter
and the cooling fans slides out for easy access to clean
the heat sink fins.
Removing the four clips and pulling back on the rear
portion of the machine will provide access for cleaning
the machine and checking the filter. The filter is removed
from the right side of the machine.
Where machines are mounted side by side, the machine
that is furthest to the right will need to have the indicated
clearance to the right side for filter removal. See Figure
#1
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Input Connection
Input Supply Connection for K2803-1
WARNING
ELECTRIC SHOCK can kill
Only a qualified electrician should connect the input
leads to the Power Wave. Connections should be made
in accordance with all local and national electrical codes
and the connection diagrams located on the inside of the
reconnect/input access door of the machine. Failure to
do so may result in bodily injury or death.
WARNING
ELECTRIC SHOCK CAN KILL:

Do 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
Use a three-phrase supply line. A 45mm diameter
access hole for the input supply is located on the case
back. Connect L1, L2, L3 and ground according to the
Input Supply Connection Diagram.
Input Fuse and Supply Wire
Considerations
Refer to Specifications page for recommended fuse and
wire sizes. Fuse the input circuit with the recommended
super lag fuse or delay type breakers (also called
"inverse time" or "thermal/magnetic" circuit breakers).
Choose input and grounding wire size according to local
or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
"nuisance" shut-offs from welder inrush currents, even if
the machine is not being used at high currents.
Voltage=380-415V
Input Voltage Selection
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this
connection to a different input voltage, see the diagram
located on the inside of the input access door, or the
Input Supply Connection Diagram below. If the Auxiliary
lead (indicated as ‘A’) is placed in the wrong position,
there are two possible results.
a)
b)
Voltage=440-460V
If the lead is placed in a position higher than the
applied line voltage, the welder may not come on at
all.
If the Auxiliary lead is placed in a position lower than
the applied line voltage, the welder will not come on,
and the two circuit breakers in the reconnect area
will open. If this occurs, turn off the input voltage,
properly connect the auxiliary lead, reset the
breakers, and try again.
Voltage=500V
Voltage=550-575V
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NOTE: The K2803-1 Power Wave® AC/DC 1000® SD
is backwards compatible with the K2344-2 Power
Wave® AC/DC 1000 in tandem or multi-arc systems.
The K2803- 1 and K2344-2 machines cannot be
connected in parallel. Paralleled machines must be of
the same type. A K1805- 1 (14 to 22 pin adapter cable)
is required to interface to the K2282-1 Systems Interface
in these setups A PLC interface is an alternate method
of control for larger systems. The PLC is typically
connected via DeviceNet directly to the Master power
source of each arc group in the system. MAXsa™ 19
Controller is still required to power the Wire Drive.
Contact your Local Lincoln Electric Representative for
more information.
The connection diagrams describe the layout of several
typical systems including Multi-Arc and Paralleled
machine set-ups. Each system also has a step by step
“Installation Checklist”.
System Connection
System Overview
®
The Power Wave AC/DC 1000 SD CE power source is
designed to be a part of a modular welding system
typically controlled by a MAXsa™ 10 Controller or a
customer supplied Programmable Logic Controller
(PLC). Each welding arc may be driven by a single
power source or by a number of power sources
connected in parallel. The actual number of power
sources per arc will vary depending on the application.
When only one power source is required for an arc
group, it must be configured as a Master. When parallel
machines are required, one is designated as the Master
and the rest as Slaves. The synchronizing connectors for
paralleled machines are on the back of the power
source. The Master controls the AC switching for the arc
group, and the Slaves respond accordingly. See Figure
#3 below.
When employed in a multi-arc AC system the arcs must
be synchronized to each other. The Master for each arc
can be configured to follow a dedicated external
synchronization signal to determine its frequency and
balance. The Synchronizing Connectors on the back of
®
the Power Wave AC/DC 1000 SD CE provide the
means to synchronize the AC wave shapes of up to six
different arcs to a common carrier frequency. (See
Figure #3). This frequency can range from 20 hertz to
100 hertz. It can also control the phase angle between
arcs to reduce the effects of welding related issues such
as "Arc Blow".
The arc to arc phase relationship is determined by the
timing of each arc’s "sync" signal relative to the "sync"
signal of ARC 1. DIP Switches on the Control PC Board
of each machine must be set to identify it as a Master
Lead, Master Trail or Slave. See Figure #2.
MASTER-LEAD
MASTER-TRAIL
SLAVE
Figure #2: Dip Switch Settings
In a typical multi-arc system, each arc is controlled by its
own MAXsa™10 Controller. The basic characteristics of
the individual arcs such as WFS, amplitude, and offset
are set locally by each arc’s dedicated controller. The
frequency, balance, and phase shift parameters of each
arc are controlled by the MAXsa™ 10 Controller for ARC
1 (Master Lead).
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Cruiser Connection Diagram
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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™ Tractor.

Install Work Voltage Sense Lead (21) from the Power Wave AC/DC 1000 SD CE per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (see Table1: Output Cable
Guidelines)

Open the Power Wave AC/DC 1000 SD CE front panel and check the DIP switch settings per the decal on the
panel. Factory Setting is “Master-Lead”. (see Figure #2: Dip Switch Settings).

Connect input power to Power Wave® AC/DC 1000 SD CE per recommended guidelines

Turn on Power Wave AC/DC 1000 SD CE, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.
®
®
®
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Single Arc Connection Diagram
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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.

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 CE per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines." (see Table1: Output Cable
Guidelines).

Open the Power Wave AC/DC 1000 SD CE front panels and check the DIP switch settings per the decal on the
panel. Factory Setting is “Master-Lead”. (see Figure #2: Dip Switch Settings).

Connect input power to Power Wave® AC/DC 1000 SD CE per recommended guidelines.

Turn on Power Wave AC/DC 1000 SD CE, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options
®
®
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Tandem Arc Connection Diagram
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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.

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 SD CE Master per guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" ." (see Table1: Output Cable
Guidelines)

Open the Power Wave® AC/DC 1000 SD CE front panels and configure DIP switch settings per the decal on the
panel. (see Figure #2: Dip Switch Settings).

Connect input power to Power Wave AC/DC 1000 SD CE units per recommended guidelines.

Turn on Power Wave® AC/DC 1000 SD CE and verify all system Status Lights are solid green.

Confirm that the latest software is updated in all equipment prior to installation (www.powerwavesoftware.com).

Run the subarc cell configurator from PC Tools (see section accessories of this manual or go to
www.powerwavesoftware.com).

Select a Welding process and configure starting and ending options.
®
®
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Paralleling Connection Diagram
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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™ 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 CE Master per guidelines.

Connect / Install welding cables to both the “master” and “slave” machine per recommended "Output Cable
Guidelines" (see Table1: Output Cable Guidelines).

Open the Power Wave AC/DC 1000 SD CE front panels and configure DIP switch settings per the decal on the
panel. (see Figure #2: Dip Switch Settings).

Connect input power to Power Wave® AC/DC 1000 SD CE units per recommended guidelines. Turn on Power
Wave® AC/DC 1000 SD CE, and verify all system Status Lights are solid green.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

For tandem setups, run the subarc cell configurator from PC Tools (See Section "Accessories" of this manual or go
to www.powerwavesoft- ware.com).

Select a Welding process and configure starting and ending options.
®
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MAXsa™ 19 Connection Diagram
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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.

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave® AC/DC 1000 SD CE 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 CE per recomennded guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines" (Table 1).

Open the Power Wave AC/DC 1000 SD CE front panels and configure DIP switch settings per the decal on the
panel. Factory setting is “Master-Lead”.(See Figure #2).

Connect input power to Power Wave® AC/DC 1000 SD CE per recommended guidelines.

Turn on Power Wave

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.

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

Select a Welding process and configure starting and ending options.
®
®
English
®
AC/DC 1000 SD and verify all system Status Lights are solid green.
17
English
Electrode Connections
Connect cable(s) of sufficient size and length (Per Table
1: Output Cable Guidelines) to the "ELECTRODE" studs
on the power source (located behind the cover plate on
the lower right rear corner). Connect the other end of the
elec-trode cable(s) to the tab of the contact nozzle. Be
sure the connection to the nozzle makes tight metal-tometal electrical contact.
Electrode and Work Connections
General Guidelines
®
The unique switching structure of the Power Wave
AC/DC 1000 SD CE allows it to produce DC positive, DC
negative or AC output waveforms without reposition-ing
the work and electrode leads. Additionally, no DIP switch
changes are required to switch between the different
polarities. All of this is controlled internally by the Power
®
Wave AC/DC 1000 CE, and based exclusively on the
weld mode selection.
Work Connections
Connect cable(s) of sufficient size and length (Per Table
1) between the "WORK" studs (located behind the cover
on the lower left rear corner) and the work piece. Be
sure the connec tion to the work makes tight metal-tometal electrical contact.
The following recommendations apply to all output
polarities and weld modes:

Select the appropriate size cables per the
"Output Cable Guidelines" below. Excessive
voltage drops caused by undersized welding cables
and poor connections often result in unsatisfactory
welding performance. Always use the largest welding cables (electrode and work) that are practical,
and be sure all connections are clean and tight.
NOTE: For parallel and/or multiple arc applications with
excessive electrode cable lengths, a com-mon bus
connection should be used. The common electrode
connection serves to mini-mize voltage drops associated
with resistive losses in the electrode path. It should be
made of copper, and located as close as possible to the
power sources. (See Figure #4).
Note: Excessive heat in the weld circuit indicates
undersized cables 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 one another to minimize the
loop area and therefore the inductance of the weld
circuit.

Always weld in a direction away from the work
(ground) connection.
Table1: Output Cable Guidelines
Total Cable
Number
Length
of
(m)
Duty Cycle
Parallel
Electrode and
Cables
Work
Combined
Cable Size
Copper
0 to 76.2
80%
2
4/0 (120 mm2)
0 to 76.2
100%
3
3/0 (95 mm )
A. Common connection (located close to power
sources)
B. Work piece
Figure #4
2
Cable Inductance, and its Effects on
Welding
Excessive cable inductance will cause the welding
performance to degrade. There are several factors that
contribute to the overall inductance of the cabling system
including cable size, and loop area. The loop area is
defined by the separation distance between the
electrode and work cables, and the overall welding loop
length. The welding loop length is defined as the total of
length of the electrode cable (A) + work cable (B) + work
path (C) (see Figure #6). To minimize inductance always
use the appropriate size cables, and whenever possible,
run the electrode and work cables in close proximity to
one another to minimize the loop area. Since the most
significant factor in cable inductance is the welding loop
length, avoid excessive lengths and do not coil excess
cable. For long work piece lengths, a sliding ground
should be considered to keep the total welding loop
length as short as possible.
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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. For more information regarding the
placement of remote work voltage sense leads, see the
section entitled "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 the Power Wave
AC/DC 1000 SD CE.
Figure #6
Remote Sense Lead Connections
Voltage Sensing Overview
The best arc performance occurs when the Power
®
Wave AC/DC 1000 SD CE has accurate data about the
arc conditions. Depending upon the process, inductance
within the electrode and work cables can influ-ence the
voltage apparent at the studs of the welder, and have a
dramatic effect on performance. To counteract this
negative effect, remote voltage sense leads are used to
improve the accuracy of the arc voltage information
supplied to the control pc board.
NOTE: All of the machines of a given arc group (Master
and Slaves) will relate to the Voltage Sense Lead of the
Master machine.
WARNING
Never connect the WORK sense lead at two different
locations.
There are several different sense lead configurations
that can be used depending on the application. In
extremely sensitive applications it may be necessary to
route cables that contain the sense leads away from the
electrode and work welding cables.
WARNING
ELECTRIC SHOCK can kill.

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.
WARNING
If the remote voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity is improperly configured extremely
high welding outputs may occur.
Voltage Sensing Considerations for
Multiple Arc Systems
Special care must be taken when more than one arc is
welding simultaneously on a single part. Remote sensing
is required in Multi-arc applications.

Avoid common current paths. Current from
adjacent arcs can induce voltage into each others
current paths that can be misinterpreted by the
power sources, and result in arc interference.
Electrode Voltage Sensing
The remote ELECTRODE sense lead (67) is built into
the wire feeder control cable (K1785) and accessible at
the wire drive. It should always be connected to the
Contact Assembly where the Weld Cable is connect-ed.
Enabling or disabling electrode voltage sensing is
application specific, and automatically configured
through software.
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19

Position the sense leads out of the path of the
weld current. Especially any current paths common
to adjacent arcs. Current from adjacent arcs can
induce voltage into each others current paths that
can be misinterpreted by the power sources, and
result in arc interference.

For longitudinal applications, connect all work
leads at one end of the weldment, and all of the
work voltage sense leads at the opposite end of the
weldment. Perform welding in the direction away
from the work leads and toward the sense leads.
See figure #7.

For circumferential applications, connect all work
leads on one side of the weld joint, and all of the
work voltage sense leads on the opposite side, such
that they are out of the current path. (see Figure
#8).
English




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
1.
2.
3.
General Guidelines
These Guidelines apply to all commumication cables
including optional DeviceNet and Ethernet
connections.

Genuine Lincoln control cables should be used
at all times (except where noted otherwise).
Lincoln cables are specifically designed for the
communication and power needs of the Power
Wave®/MAXsa™ systems. Most are designed to be
connected end to end for ease of operation.

Always use the shortest cable lenghts possible.
DO NOT coil excess cable. It is recommended that
the total length of Control cable does not exceed
30.5m. The use of non standard cables, especially
in lengths greater than 7,5m, can lead to
communication problems (system shutdowns), poor
motor acceleration (poor arc starting), and low wire
driving force (wire feeding problems).

Best results will be obtained when control
cables are routed separate from the weld cables.
This minimizes the possibility of interference
between the high currents flowing through the weld
cables, and the low level signals in the control
cables.
Direction of travel.
Connect all sense leads at the end of the weld.
Connect all work leads at the beginning of the weld.
Figure #7
Bad connection
Common Equipment Connections



Connection Between MAXsa™ Controller and
MAXsa™ series Wire Drive (K1785-xx)
The 14 pin Wire Drive Control Cable (K1785-xx)
connects the Controller (MAXsa™ 10 or MAXsa™ 19) to
the Wire Drive (MAXsa™ 22 or MAXsa™ 29). This cable
should be kept as short as possible.
Current flow from Arc#1 affects Sense#2.
Current flow from Arc#2 affects Sense#1.
Neither sense lead picks up the correct work
voltage, causing starting and welding arc instability.
Better connection
Connection Between Power Source and the
MAXsa™ Controller (K2683-xx - ArcLink Control
Cable).
Single and tandem arc systems are typically controlled
by a MAXsa™ 10 Controller. In a tandem, or multi-arc
system, each arc requires its own dedicated controller.



The 5-pin ArcLink control cable connects the power
source to the MAXsa™ 10. If there is more than one
power source per arc, it connects from the MAXsa™ 10
to the power source designated as the Master for that
arc. The control cable consists of two power leads, one
twisted pair for digital communication, and one lead for
voltage sensing (67).
Sense#1 is only affected by weld current from
Arc#1.
Sense#2 is only affected by weld current from
Arc#2.
Due to voltage drops across work piece, Arc
voltage may be low, causing need for deviation
from standard procedures.
NOTE: Connections Between Power Source and
Optional DeviceNet Programmable Logic
Controller(PLC).
Best connection
It is sometimes more practical and cost effective to use a
custom PLC interface to control a multi-arc sys-tem
(refer to the "DeviceNet Configuration" section for
interface information). The Power Wave AC/DC 1000 is
equipped with a 5-pin DeviceNet mini style recepta-cle
for this purpose. The receptacle is located on the rear
panel of the machine See Figure Case Back
Components. The DeviceNet cable is keyed and
polarized to prevent improper connection.
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20
English
NOTE: DeviceNet cables should not be routed with
weld cables, wire drive control cables, or any other
current carrying device that can create a fluctuating
magnetic field.
DEVICENET CONNECTOR
x
In a typical system, a DeviceNet connection is made
between the master power source of each arc, and the
PLC interface. DeviceNet cables must be sourced locally
by the customer. For additional guidelines refer to the
"DeviceNet Cable Planning and Installation Manual"
(Allen Bradley publication DN-6.7.2).
115VAC RECEPTABLE
x
x
Connections Between Parallel Power Sources
(K1785-xx - Control Cable).
To increase the output capacity for a given arc, the
®
output studs of multiple Power Wave AC/DC 1000 SD
CE machines can be connected in parallel. The parallel
machines utilize a master/slave control scheme to distribute the load evenly and to coordinate AC switch-ing.
K1785-xx cables connect the paralleled machines via
the synchronizing connectors on the back of the
machine. The system is currently limited to a maxi-mum
of 2 slaves per master, or a total of 3 machines per arc.
WORK SENSE LEAD CONNECTOR
INPUT POWER
ON
OFF
HIGH TEMPERATURE
Connections Between Power Sources in Multi-Arc
Applications (K1785-xx - Control Cable).
Synchronizing Connectors are available on the rear
panel of the machine for Multi-Arc applications using the
K1875-xx control cables. The system is currently limited
to six(6) arcs, or a “Lead” and five “Trail” arcs.
MACHINE STATUS
Definitions of Welding Modes
CIRCUIT BREAKER
NON-SYNERGIC WELDING MODES
A Non-synergic welding mode requires all welding
process variables to be set by the operator.
WIRE FEEDER
SYNERGIC WELDING MODES
A Synergic welding mode offers the simplicity of single
knob control. The machine will select the correct voltage
and amperage based on the wire feed speed (WFS) set
by the operator.
POSITIVE OUTPUT
NEGATIVE OUTPUT
COMMON WELDING ABBREVIATIONS
3 PHASE INVERTER
SAW
Submerged Arc Welding
INPUT POWER
Graphic Symbols that Appear on this
Machine or in this Manual
THREEE PHASE
DIRECT CURRENT
MULTI-ARC CONNECTOR
OPEN CIRCUIT
INPUT VOLTAGE
PARALLEL ARC CONNECTOR
OUTPUT VOLTAGE
INPUT CURRENT
ETHERNET CONNECTOR
OUTPUT CURRENT
ARCLINK CONNECTOR
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PROTECTIVE GROUND
21
English
5.
Cord Connector: Input power cord strain relief.
WARNING or CAUTION
EXPLOSION
DANGEROUS VOLTAGE
SHOCK HAZARD
Case Front Controls
1.
Power Switch: Controls input power to the Power
Wave® AC/DC 1000 SD CE and any auxiliary
equipment that may be connected to it.
2.
Status Light: A two color LED that indicates system
errors. Normal operation is steady green. Flashing
green or red/green indicates a system error.
NOTE: The Power Wave Status Light will flash green for
up to 60 seconds at power up as the machine runs
through a self test routine, and then go to steady green.
3.
Thermal Light: A yellow light that comes ON when
an over temperature situation occurs. The machine
output is disabled until the machine cools down and
the thermal light goes OFF
NOTE: The Thermal Light may also indicate a problem
with the AC Switch portion of the power source.
Figure: Input Section (left side)
Case Back Components
1.
10 Amp Circuir 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.
Auxilary Output Receptacle: Provides 10 amps of
115VAC power.
9.
Ethernet Connector (RJ-45): Provides Ethernet
communication to remote equipment.
Figure: Case Front
Input Power Section
1.
Input Contactor: Connection point for incoming 3
phase power. See the Installation Section for input
wiring and fusing information.
2.
Case Ground: Used to provide an “earth ground”
for the frame of the welder. Consult your local and
national electrical codes for proper grounding
information.
3.
Auxiliary Reconnect: Select the proper tap based
on the supply voltage.
4.
Fuse (F1): Protection for the primary side of the
auxiliary transformer
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10. Master Input: From Lead or previous trail arc in a
Multi-arc system
22
English
customize operation for the best performance.
Consult the User Interface documentation for more
detailed set up information. (MAXsa™ 10, Command
Center, PLC, Robot etc..)
11. Master Output: To subsequent trail arc in a Multiarc system.
12. Parallel Input: From Master or previous Slave in a
parallel machine set up.
First, consider the desired welding procedures and the
part to be welded. Choose an electrode material,
diameter, and flux.
13. Parallel Output: To Slave in a parallel machine set
up
Second, find the program in the welding software that
best matches the desired welding process. The standard
®
software shipped with the 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.
Waveform Control Technology™ allows full
customization of Strike, Run-in, Crater and other
parameters for exacting performance.
Overview of the AC/DC Submerged Arc
Process
®
The Power Wave AC/DC 1000 SD CE combines the
advantages of AC and DC Submerged Arc Welding
(SAW) into a single power source. The limiting factor of
AC-SAW welding has traditionally been the time it takes
to transition from positive to negative polarity. This lag
through the zero crossing can cause arc instability,
penetration, and deposition problems in certain
applications. The Power Wave® AC/DC 1000 SD CE
utilizes the speed of an inverter based power source,
and the flexibility of Waveform Control Technology™ to
address this issue.
Stud cover
doors removed
for clarity
By adjusting the Frequency, Wave Balance and Offset of
the AC waveform the operator can now control the
balance (relationship) between the penetration of DC
positive and the deposition of DC negative while taking
full advantage of the reduction in arc blow associated
with AC.
Figure: Case Back Components
Power-Up Sequence
When power is applied to the Power Wave® AC/DC
1000 SD CE, the status lights will flash green for up to
®
60 seconds. During this time the Power Wave AC/DC
1000 SD CE is performing a self test, and mapping
(identifying) each component in the local ArcLink
system. The status lights will also flash green as a result
of a system reset or configuration change during
operation. When the status lights become steady green
the system is ready for use.
Output waveform variations made possible by Waveform
Control Technology™
Common Welding Procedures
Making a weld
The serviceability of a product or structure utilizing
the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric Company
affect the results obtained in applying these
programs. These variables include, but are not
limited to, welding procedure, plate chemistry and
temperature, weldment design, fabrication methods
and service requirements. The available range of a
welding program may not be suitable for all
applications, and the build/user is and must be
solely responsible for welding program selection.
Depending on the process, different parts of the output
waveform abd wire feed speed may be modulated at
varying rates to achive a smooth and stable arc.
Multiple Arc System Consideration
Large scale SAW applications often employ multiple arcs
to increase deposition rates. In multiple arc systems,
magnetic forces created by like and opposing weld
currents of adjacent arcs can result in arc interaction that
can physically push or pull the arc columns together.
See Figure below. To counteract this effect, the phase
relationship between adjacent arcs can be set to
alternate and equalize the duration of magnetic push
and pull forces. This is accomplished through the
synchronizing cables (K1785-xx). Ideally, the net result
®
The steps for operating the Power Wave AC/DC 1000
SD CE will vary depending upon the user interface of the
welding system. The flexibility of the system lets the user
English
23
English
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.

Arc Length is proportional to Voltage.

Traditionally used for smaller diameter wires and
faster travel speeds.
Figure: Arc Interference
Figure: Constant Voltage
Weld Sequence
The weld sequence defines the weld procedure from
®
beginning to end. The Power Wave AC/DC 1000 SD
CE not only provides adjustment of basic welding
parameters, but also allows the operator to fine tune the
start and finish of each weld for superior performance.
Figure: Synchronized Arcs
WARNING
Never simultaneously touch electrically "hot" parts in the
electrode circuits of two different welders. The electrode
to electrode no load voltage of multiple arc systems with
opposite polarities can be double the no load voltage of
each arc. Consult the Safety information located at the
front of the Instruction Manual for additional information.
All adjustments are made through the user interface.
Because of the different configuration options, your
system may not have all of the following adjustments.
Regardless of availability, all controls are described
below.
Start Options
Basic Modes of Operation
The Strike, Start, and Upslope parameters are used at
the beginning of the weld sequence to establish a stable
arc and provide a smooth transition to the welding
parameters.
Constant Current (CC)
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 the desired Set point.

Arc Length is proportional to Voltage.

Traditionally used for larger diameter wires and
slower travel speeds.




Figure: Constant Current
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24
Arc Delay inhibits the wire feed for up to 5 seconds
to pro- vide an accurate weld start point. Typically
used in multi-arc systems
Strike settings are valid from the beginning of the
sequence (Start Button Pressed) until the arc is
established. They control Run-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 reduced during the Strike portion of the weld
sequence
Start values allow the arc to become stabilized once
it is established.
Extended Start times or improperly set
parameters can result poor starting
Upslope determines the amount of time it takes to
ramp from the Start parameters to the Weld
parameters. The transition is linear and may be up
or down depending on the relationship between the
Start and Weld settings.
English
End Options
Wave Balance

The Downslope, Crater, Burnback and Restrike
Timer parameters are used to define the end of the weld
sequence.





Downslope determines the amount of time it takes
to ramp from the Weld parameters to the Crater
parameters. The transition is linear and may be up
or down depending on the relationship between the
Weld and Crater settings.
Crater parameters are typically used to fill the crater
at the end of the weld, and include both time and
output settings.
Burnback defines the amount of time the output
remains on after the wire has stopped. This feature
is used to prevent the wire from sticking in the weld
puddle, and condition the end of the wire for the
next weld. A Burnback time of 0.4 sec is sufficient in
most applications. The output level for Burnback is
generally set to the same level as the last active
weld sequence state (either Weld or Crater).
Re-strike Timer is used to protect the welding
system and/or work piece being welded. If the arc
goes out for any reason (short circuit or open
®
circuit), the Power Wave AC/DC 1000 SD CE will
enter a Re-strike state and automatically manipulate
the WFS and output in an attempt to re-establish the
arc. The Re-strike timer determines how long the
system will attempt to re-establish the arc before it
shuts down.
o A Re-strike time of 1 to 2 sec is sufficient in
most applications.
o A Re-Strike setting of “OFF” allows for
infinite restriking attempts until a shutdown
occurs.
Refers to amount of time the waveform spends in
DC+ portion of the cycle.
Use Wave Balance to control the penetration and
deposition of a given process.
Figure: Wave Balance
DC Offset


Refers to +/- shift of the current waveform with
respect to the zero crossing.
Use Offset to control the penetration and deposition
of a given process.
Figure: Weld Sequence
Figure: DC Offset
Weld Process Adjustments
Frequency
Depending on the weld mode, there are a number of
adjustments that can be made, including but not limited
to Current, Voltage and WFS. These adjustments apply
to either AC or DC processes, and control the basic
parameters of the weld.




AC Adjustments
®
Power Wave AC/DC 1000 SD CE can produce
Output Frequencies from 10 - 100Hz
Use Frequency to help provide stability.
Higher frequencies in multiple arc setups can help
reduce arc interaction.
Lower frequencies will help overcome output limitations due to inductance in the Weld Circuit.
In addition to the basic weld parameters, there are a
number of unique adjustments related to the AC
®
waveform of the Power Wave AC/DC 1000 SD CE.
These adjustments enable the operator to balance the
relationship between penetration and deposition to tailor
the output for specific applications.
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25
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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
duration of magnetic forces between adjacebt arcs.
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. The offset of each arc is set
independently with respect to the lead arc of the
system (ARC 1).
Recommendations

For balanced waveforms a phase relationship of 90°
should be maintained between adjacent arcs.

For unbalanced waveforms:
– Avoid switching at same time.
– Break up long periods of unchanged polarity
relative to adjacent arcs.
TABLE B.1 - PHASE RELATIONSHIP
ARC 1 ARC 2 ARC 3 ARC 4 ARC 5 ARC 6
Lead
Trail
Trail
Trail
Trail Trail
2 Arc
System
0°
90°
X
X
X
X
3 Arc
System
0°
90°
180°
X
X
X
4 Arc
System
0°
90°
180°
270°
X
X
5 Arc
System
0°
90°
180°
270°
0°
X
6 Arc
System
0°
90°
180°
270°
0°
90°
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Maintenance
Customer Assistance Policy
The 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 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. We expressly
disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of
practical consideration, we also cannot assume any
respon- sibility for updating or correcting any such
information or advice once it has been given, nor does
the provision of information or advice create, expand or
alter any warranty with respect to the sale of our
products
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.
WARNING
For any maintenance or repair operations it is
recommended to contact the nearest technical service
center or Lincoln Electric. Maintenance or repairs
performed by unauthorized service centers or personnel
will null and void the manufacturers warranty.
WARNING
Do not open this machine and do not introduce anything
into its openings. Power supply must be disconnected
from the machine before each maintenance and service.
After each repair, perform proper tests to ensure safety.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing out
the machine, using a low-pressure airstream, to remove
accumulated 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,
the cooling fans and many of the heat sinks slides out for
easy access. Removing the four(4) clips and pulling
back on the rear portion of the machine will provide
access for cleaning the machine and checking the filter.
The filter may be removed from the right side of the
machine.
PERIODIC MAINTENANCE
Calibration of the Power Wave® AC/DC 1000 SD CE 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. To ensure optimal
performance, the calibration of output Voltage and
Current should be checked yearly.
CALIBRATION SPECIFICATION
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 reveals a problem, use
the calibration section of the Weld Manager Utility to
make the appropriate adjustments.
The calibration procedure itself requires the use of a grid
(Resistive Load Bank), and certified actual meters for
voltage and current. The accuracy of the calibration will
be directly affected by the accuracy of the measuring
equipment you use. The Weld Manager Utility includes
detailed instructions, and is available on the internet at
®
powerwavesoftware.com under Power Wave
Submerged Arc Utilities.
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WEEE
07/06
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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. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
For Spare Parts references visit the Web page: https://www.lincolnelectric.com/LEExtranet/EPC/
Authorized Service Shops Location
09/16


The purchaser must contact a Lincoln Authorized Service Facility (LASF) about any defect claimed under Lincoln's
warranty period.
Contact your local Lincoln Sales Representative for assistance in locating a LASF or go to
www.lincolnelectric.com/en-gb/Support/Locator.
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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. Give the equipment code number.
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®
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. Give the equipment code number.
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Suggested Accessories
BASIC PACKAGE
Item number
K2803-1
K2370-2
K2814-1
K2683-XX
K1785-xx
OPTIONAL KITS
K1785-xx
K2312-2
K2311-1
K2444-1
K2626-2
Description
(R)
Power Wave AC/DC 1000 SD CE
MAXsaTM 22 Wire Drive
TM
MAXsa 10 Controller/User interface
Control Cable (5 pin- 5pin) – power source to controller
Control Cable (14 pin- 14pin) – Controller to Wire Drive
Control Cable (14 pin- 14pin) – for paralleling/multiple arc applications
MAXsa 29 Wire Drive (for Fixture builders)
Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5 wire feeder gear boxes)
CE, C-Tick Filter Kit
MAXsa™ 19 Controller (for fixture builders that do not require the MAXsa 10 Controller)
Options and Accessories are available at www.lincolnelectric.com
Follow
1.
2.
3.
these steps:
Go to www.lincolnelectric.com
In the Serach field type E9.181 and click on the Search icon (or hit “Enter” on the keyboard)
On the results page, scroll down to the Equipment list and click on E9.181.
All of the information for the PowerWave System accessories ca 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 the system is available at www.powerwavesoftware.com. Power Wave® Submerged Arc Utilities includes
the following items and all of the documentation to support them.
Name
Weld Manager
Command Center
Submerged Arc Cell
Configuration
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Purpose
Setup Ethernet address information, and apply security settings.
Utility to diagnose Power Wave® problems, read system information, calibrate output
voltage and current, test sense leads, and diagnose feed head issues. Can also setup
and verify DeviceNet operation.

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
AC/DC system tool to observe and log welding operation, verify DeviceNet welding
configuration, and facilitate quality analysis.
Used to configure and verify a multi-arc or parallel connected power source (more
than 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
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