Lincoln Electric Power Wave AC/DC 1000 MC04-216 User manual

Description
Output Input
Power Wave®AC/DC 1000™
Increase Productivity, Quality and Flexibility
AUTOMATED SOLUTIONS
The Power Wave AC/DC 1000 is the first power source to introduce Waveform Control
Technology™ to submerged arc welding. Variable frequency and amplitude AC, DC
positive or DC negative output allows the user to control the deposition rate and penetra-
tion. An operator can increase weld speeds, yield higher quality welds and improve effi-
ciencies in a single or multi-arc environment. The phase angle and frequency of different
machines can also be synchronized to balance the interactions between multiple arcs and
minimize arc blow. Depending on the output, a welding arc may be driven by a single
machine or multiple machines in parallel for applications that require more than 1000
amps of continuous operation.
Advantage Lincoln
Order
TECHNICAL SPECIFICATIONS
Recommended General Options
Recommended Wire Feeders
• Eliminate downtime with easy polarity switching –– no hardware
reconfiguration required.
• Stable and independent arc controls for multiple arc applications.
• Improved efficiency and reliability with cooler operation through
patented Coaxial Transformer Technology™.
• 95% power factor correction enables connection of more
machines on the same plant infrastructure for lower installation
costs compared to other machines.
• Remote process monitoring and control through ArcLink,
Ethernet, and DeviceNet communication.
• Consistent operation over ± 10% input voltage variation through
built-in line voltage compensation and reliable input voltage
connection.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
•Three-year warranty on parts and labor.
3
PHASE
60
50
Hz
AC
DC
CV
CC
Power Feed 10A Controller K2362-1 (requires either the K2312-1
Power Feed 10SF Wire Feed Head for fixed hard automation, or
the K2370-1 Power Feed 10S Head for mounting a Lincoln TC-3
Travel Carriage), Power Feed 10SM Motor Conversion Kit K2311-1
(Other options may apply).
K2344-1 Power Wave AC/DC 1000 460/500/575/3/60
K2344-2 Power Wave AC/DC 1000 400/460/500/575/3/50/60
System Interface, Interface Control Cable (22-pin), ArcLink Cable (5-pin),
Feeder Control Cable (14-pin), TC-3 Self-Propelled Travel Carriage,
CE Filter(1)
Rated Output Dimensions Net
Product Product Input Current/Voltage/ Input Current Output H x W x D Weight
Name Number Voltage Duty Cycle @Rated Output Range in (mm) lbs (kg)
Power Wave AC/DC 1000 K2344-1 460/500/575/3/60 1000/44/100% 68/62/54 100-1000A 43.5 x 19.2 x 33 600
(1105 x 488 x 838) (272)
Power Wave AC/DC 1000(1) K2344-2(1) 380/400/460/500/575/3/50/60 1000/44/100% 82/79/69/62/55 100-1000A 43.5 x 19.2 x 33 650
(1105 x 488 x 838) (295)
Submerged Arc
Processes
(1) External Filter is required to meet CE conducted emission requirements. The K2444-1 must be used with the K2344-2.
Publication E10.96 1/05
Web Update 1/06
www.lincolnelectric.com

Power Wave AC/DC 1000
A CLOSER LOOK
[2] www.lincolnelectric.com
WHAT IS NEXTWELD®?
Nextweld integrates Lincoln’s technologies, process-
es and products to create a comprehensive, flexible,
user-friendly welding system that can increase
efficiency and reduce fabrication costs. Waveform
Control Technology™ and digital communications
provide the foundation for Nextweld innovations like Pulse-On-
Pulse™, Power Mode™, STT®and ArcLink®.Look for Nextweld
products for ultimate arc control, high efficiency/reliability and
seamless system integration.
Waveform Control Technology™
Driving Superior Welding Performance
Lincoln’s Waveform Control Technology controls and shapes the output waveforms (or weld
modes) to adapt to virtually any application, material or weld position. In addition, you can
have our Application Engineering department add or customize standard waveform programs.
For more information see Nextweld Document NX-1.10
Waveform Control Technology
• Ultimate arc control — Many aspects of the waveform may be varied
as a function of time in order to customize the arc exactly to your
specifications.
• Dynamically controlled output — Arc Current, Voltage or Power
may be controlled and regulated automatically so adjustments and
corrections are made as they arise.
• Different parts of the waveform and wire feed speed may be
modulated at varying rates to accomplish a constant average
condition (Constant Voltage, Constant Current, etc.).
Refer to Publication NX-2.30 Nextweld AC/DC submerged arc
process document for more details.
Variable Frequency – Control Arc Stability
The Power Wave AC/DC 1000™ has the widest range of wave fre-
quency adjustment (10 - 100 Hz) in the industry. Adjust frequency
with the turn of a knob to maximize arc stability.
Turn Frequency down
for more penetration
(less energy) with a less
stable arc.
Turn Frequency up for a
more stable arc with less
penetration (more energy
in less time).
Waveforms are easily changed
through graphical interface
System Interface

Power Wave AC/DC 1000
www.lincolnelectric.com
[3]
A CLOSER LOOK
Variable Balance – Control Deposition
By setting the correct wave balance (that is, the ratio between positive and negative waveforms), the operator is able to work faster and fill
the weld joint with fewer passes. The Power Wave AC/DC 1000™ has wave balance range of 25% to 75%.
The more positive the wave,
the more penetration.
The more negative the
wave, the greater the
weld deposition.
DC Offset (Variable Amplitude) – Control Penetration
Wave amplitude and the duration of positive and negative cycles are independently adjustable, so the operator can obtain deep/shallow
penetration and higher/lower deposition rates, depending on the application. The Power Wave AC/DC 1000 has the widest range of vari-
able amplitude, or DC offset, (-25% to 25%) in the industry.
Increasing the negative amplitude
(offset) decreases penetration.
Multi-Arc Environment
In a multiple arc welding, as many as five arcs operate in a single weld puddle. Changes to the positive/negative polarity phases and/or cycle
balances of the AC waveform enable the operator to control deposition rate, penetration and travel speed without a change in voltage or current
settings. Using the Power Wave AC/DC 1000 in a multi-arc system can increase your weld speeds, yield higher quality welds and improve
efficiencies.
Phase Relationship – Controlling Arc Blow
In a multi-arc environment, arc interaction plays an important role in the behavior of the weld. Two positive electrodes pull together, as do
two negative electrodes, while a positive and negative repel each other, causing arc blow. The Power Wave AC/DC 1000 balances the
"push" and "pull" of the multi-arc relationship using phase shifting to prevent arc blow.
By phase shifting the AC
waveforms, the amount of
"push" and "pull" of the arc
interactions can be bal-
anced using alternating
current to avoid arc blow.
Increasing the positive amplitude
(offset) increases penetration.

Applications
Whether it is a cross country pipeline or an offshore platform, the Power Wave AC/DC 1000 is meeting and exceeding expectations
around the world.
Power Wave AC/DC 1000
www.lincolnelectric.com
[4]
A CLOSER LOOK
75% DC NEGATIVE BALANCED AC LEAD ARC
75% DC NEGATIVE BALANCED AC TRAIL ARC
BALANCED AC LEAD ARC
BALANCED AC TRAIL ARC
STANDARD
TECHNOLOGY
75% DC NEGATIVE LEAD ARC
75% DC NEGATIVE TRAIL ARC WITH
30% DC NEGATIVE AMPLITUDE OFFSET
2 ARCS
3 ARCS
2 Arc 2 Arc 3 Arc 3 Arc
2 Arc 2 Arc 3 Arc
Multi-Arc Submerged Arc Welding
AC/DC 1000
Small diameter circumferential welds, pipe double-
ending, storage tanks, seam welders
Large diameter circumferential welds [40”(1m) and up], spiral pipe mills,
bridge girders, pressure vessels, wind mill towers.
Long straight welds, pipe mills, panel lines.
Single Arc
Tandem Arc
Multiple Arcs (3 to 5)
tt t
Lead Arc — DC+
Deep Penetration
Trailing Arcs — AC
Greater negative components
produces greater deposition and
a flattened bead shape
Variable Positive/Negative
Proportions — Optimize Welding
Variable Frequency and Phase Relationship
— Reduce Arc Blow
Arc Performance
The capabilities of the Power Wave AC/DC 1000™ in a multi-arc environment offer digital control over the critical welding variables for
optimum performance whatever your needs require. As shown below, these digital controls can be used for each arc to provide unprece-
dented arc welding characteristics.
Productivity Comparison
The Power Wave AC/DC 1000 delivers optimized productivity through the ability to adjust phase relationships between the arcs. Multiple
arcs can be tuned to work together rather than interfere with each other.
Productivity Improvement
DC +
DC –

[5]
Power Wave AC/DC 1000
www.lincolnelectric.com
A CLOSER LOOK
RECOMMENDED EQUIPMENT
Product Number Product Description
Power Source K2344-1 or K2344-2 Power Wave AC/DC 1000™ Power Source 1
Head K2370-1 Power Feed 10S head for 3/32 to 7/32 in. solid wire 1
or (Includes hopper, wire straightener, cross seam adjuster,
K2312-1 head mounting hardware)
or
Power Feed 10SF Head for 3/32 to 7/32 in. solid wire
Fixture Builders Head (Insulators not included)
User Interface K2362-1 Power Feed 10A Controller 1
ArcLink Digital K1543-xx ArcLink Cables (5 pin) from Power Feed 10A Controller 1
Communication Cable to Power Source. Can be extended.
Welding Cables K2163-xx or Weld Power Cables from the Power Source to the 4 Cables
K1842-xx Contact Nozzle and from Power Source to Work Per Arc
Power Source to K1785-xx Feeder Control Cable (14 pin) from the 1
Head Control Cable Head to the Power Source. Cannot be extended.
Torch K231-xx Submerged Arc Contact Nozzle Assembly 1
System Identifier Qty. Required
AC/DC Submerged Arc Single Arc
OPTIONAL EQUIPMENT
PLC (customer supplied)
Ethernet Switch (customer supplied).
Required for arcs > 1000A or with
use of the Submerged Arc Software Suite.
Computer (customer supplied).
Required for use of the
Submerged Arc Software Suite.
K325-x TC-3 Travel Carriage
K96 Horizontal Lift Adjuster
K29 Vertical Lift Adjuster
K299 Wire Reel Assembly
K2462-1 Power Feed 10A Mounting
Bracket (K299 cannot be used if the
mounting bracket is attached. A K390 is
recommended instead.)
System Component
Electrode Studs Work Studs
K2362-1
K1543-XX
Arclink Control Cable
Arclink Connection
Flux Hopper Connection
Travel Carriage Connection
Wire Feeder (14 Pin)
Arclink (5 Pin)
Wire Reel
and Mounting
(1)Work Cable(s)
21 Lead
(1)Electrode Cable(s)
67 Lead
Electrode Sense Lead (67)
Work Sense Lead (67)
K1785-XX
Wire Feeder
Control Cable
K231-XXX
Head
Work Piece
14 Pin Connector
(1)Consult wth your Lincoln representative for recommended cable size.
•
•

A CLOSER LOOK
Power Wave AC/DC 1000
[6] www.lincolnelectric.com
AC/DC Submerged Arc Dual Arc
RECOMMENDED EQUIPMENT
Product Number Product Description
Power Source K2344-1 or Power Wave AC/DC 1000™ Power Source 2
K2344-2
Mounting for Heads K387 Tandem Arc Framework 1
Head K2312-1 or Power Feed 10S head for 3/32 to 7/32 in. solid wire (Includes hopper, 2
K2370-1 wire straightener, cross seam adjuster, head mounting hardware) or
Power Feed 10SF Head for 3/32 to 7/32 in. solid wire
Fixture Builders Head (Insulators not included)
User Interface K2362-1 Power Feed 10A Controller 2
System Interface K2282-1 System Interface 1
ArcLink Digital K1543-xx ArcLink Cables (5 pin). Can be extended. 3
Communication (1) Lead Arc: Power Source to System Interface
Cable (2) System Interface to User Interface
(3) Trail Arc: Power Source to User Interface
Welding Cables K2163-xx or Weld Power Cables from the Power Source to the contact Nozzle 4 Cables
K1842-xx and from the Power Source to the Work Per Arc
Power Source to K1785-xx Feeder Cable (14 pin) from the Head to the Power Source 2
Head Control Cable Cannot be extended.
Torch K231-xxx Submerged Arc Contact Nozzle Assembly 2
System Interface to K1795-xx Control Cable (22 pin) from each Power Wave AC/DC 1000 to 2
Power Source Cable System Interface. Can be extended.
Product Name Qty. Required
OPTIONAL EQUIPMENT
Ethernet Switch (customer supplied).
Required for arcs > 1000A or with
use of the Submerged Arc Software Suite.
Computer (customer supplied).
Required for use of the
Submerged Arc Software Suite.
K325-x TC-3 Travel Carriage
K96 Horizontal Lift Adjuster
K29 Vertical Lift Adjuster
K299 Wire Reel Assembly
K390 Two Wire Reel Mounting for TC-3
K389 Flux Hopper for K387 Mountings
K2462-1 Power Feed 10A Mounting
Bracket (K299 cannot be used if the
mounting bracket is attached. A K390 is
recommended instead.)
System Component
Arcklink (5 Pin)
Wire Feeder (14 Pin)
Master Input (S12)
Connects to System
Interface
K1795-XX Cables
Arclink Input
Arclink Output
K2282-1
K1543-XX Arclink Control Cables
Travel Carriage Connection
Flux Hopper Connection
Arclink Connection
(1)Electrode Cables
Work Sense Lead (21)
Electrode
Sense
Lead (67)
Work Piece
(1)Work Cables
14 Pin Connector
67 Lead
21 Lead
K231-XXX
Head
K1785-XX
Wire Feeder
Control Cables
Wire Reel and
Mountings
Electrode Studs
K2362-1
Work Studs
(1)Consult wth your Lincoln represen-
tative for recommended cable size.
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•
•

A CLOSER LOOK
AC/DC Submerged Arc Multi-Arc
RECOMMENDED EQUIPMENT
Product Number Product Description
Ethernet Network Equipment Customer Supplied Ethernet Switch, Cables, etc. required for arcs >1000A or for use
with Power Wave Submerged Arc Utilities software package As Needed
Personal Computer Customer Supplied IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, 1
or greater) required for use with Power Wave Submerged Arc Utilities software package
Controls Customer Supplied Programmable Logic Controller 1
DeviceNet Cables Automation Department DeviceNet Cable from the Power Source to PLC and
or Customer Supplied System Interface to PLC (Cables, Tees, and Terminators as required) As Needed
Ethernet Switch Customer Supplied Ethernet Switch 1
Power Source K2344-1 or K2344-2 Power Wave AC/DC 1000™ Power Source 3+
Head K2312-1 or K2370-1 Power Feed 10S head for 3/32 to 7/32 in. solid wire(Includes hopper, wire, straightener 3+
cross seam adjuster, head mounting hardware) or Power Feed 10SF Head for 3/32 to 7/32 in.
solid wire Fixture Builders Head (Insulators not included)
System Interface K2282-1 System Interface 1
Welding Cables K2163-xx or Weld Power Cables from the Power Source to the Contact Nozzle 4 Cables
K1842-xx and from the Power Source to the Work Per Arc
Power Source to K1785-xx Feeder Cable (14 pin) from the Head to the Power Source 3+
Head Control Cable Cannot be extended.
Torch K231-xxx Submerged Arc Contact Nozzle Assembly 3+
System Interface to K1795-xx Control Cable (22 pin) from each Power Wave AC/DC 1000 to 3+
Power Source Cable System Interface. Can be extended.
Product Name Qty. Required
PLC Controller
User
Interface
DeviceNet Cable
Network
Electrode Studs
Wire Reel and
Mountings
(1)Work Cables
Head
K231-XXX
K1543-XX Arclink
Control Cable
K1795-XX Cables K2282-1 DeviceNet
Arclink Input
Work Studs
(1)Electrode Cables
K1785-XX Wire Feeder
Control Cables
Electrode Sense Lead (67)
67 Lead
14 Pin Connector
21 Lead
Work Piece Work Sense Leads (21)
DeviceNet (5 Pin)
Arclink (5 Pin)
Wire Feeder (14 Pin)
Master Input (S12)
Connects to
System
Interface
(1)Consult wth your Lincoln representative for recommended cable size. Power Wave AC/DC 1000
www.lincolnelectric.com
[7]
•
•

Power Wave AC/DC 1000
www.lincolnelectric.com
[8]
A CLOSER LOOK
What is Coaxial Transformer Technology™?
To transform large amounts of power as is needed for welding, the
power source transformer is a critical factor. Traditional transformers
become more inefficient the larger they become. This becomes a
problem especially for large power sources (i.e. submerged arc power
sources). If the transformer becomes inefficient, it requires more
power to be dissipated in all of the components before the trans-
former. This results in a drastically reduced overall efficiency, compo-
nents that run at higher temperatures, and reduced reliability.
Coaxial Transformer Technology eliminates these problems. Regardless
of the size (power level) a coaxial transformer has superior coupling and
efficiency. This is obtained through the coaxial orientation of the primary
and secondary windings.
The benefits for the customer include:
• Higher power capabilities (submerged arc inverters)
• Higher efficiency (reduced energy costs)
• Higher reliability (lower stresses on components)
Impeller Cooling Technology™
High Efficiency Cooling
Conventional-cooling mechanisms for welders rely on a fan to blow
through the machine, while Lincoln’s patented Impeller Cooling
Technology uses an impeller fan to create a high-pressure chamber.
This high-pressure chamber forces airflow across the heated
components in the machine cooling the Power Wave AC/DC 1000™
transformer and power switchgear.
Power Input Amps
Technology Volts Amps Efficiency Factor @ 460 Volt
Miller Electric®
Summit Arc 1000™ 44 1000 0.84 0.54 122
Power Wave AC/DC 1000 44 1000 0.86 0.95 68
Industry-leading Efficiency, Power Factor and Input Current Draw
Reduce Energy Spending!
The Power Wave® AC/DC 1000 has better efficiency and a
higher Power Factor than the Summit Arc 1000™. Two
Power Wave® AC/DC 1000 machines can be installed for
the same capacity that it takes to install one Summit Arc 1000™.
NOTE: Summit Arc 1000™ is not a trademark of the Lincoln Electric Company.

Power Wave AC/DC 1000
[9]
A CLOSER LOOK
www.lincolnelectric.com
4
FEATURES
• Machines can be easily configured for multiple arc applications.
• Fully programmable AC or DC wave shape.
• Ethernet capability gives the user the ability to monitor, control
and troubleshoot from remote locations.
• All system components communicate and transfer information.
• Arc performance independent of input power variations.
• Utilizes digital signal processing and microprocessor control.
•Constant current or constant voltage capability.
Key Controls
1. Power Switch
2. Thermal Light
3. Status Light
4. Electrode Stud
5. 10 Amp Wire Feeder Circuit Breaker
6. Auxiliary Power Circuit Breaker
7. Wire Feeder Interface Connector
8. Work Sense Lead Connector
9. RS232 Connector
10. Arclink Connector
11. DeviceNET Connector
12. Ethernet Connector
13. Auxiliary Output
14. Work Stud
15. I/O Connector
32
1
6
5
15
14
13
12
11 10 987
QUALITY AND RELIABILITY
• Lincoln’s design philosophy adds an extra factor of safety in all
components and construction to maximize reliability and service.
• Open construction for preventative maintenance.
• Thermostatically protected against overheating.
• Electronic output over-current protection and electronic input
over-voltage protection.
• Operating Temperature Range: -20˚C (-37.7ºF) to +40˚C (-22.2ºF);
Storage Temperature Range: -40˚C (-40ºF) to +40˚C (-22.2ºF).
• Designed to the IEC 60974-1 standards.
• F.A.N. (Fan As Needed). Cooling fan runs during output and for five
minutes after output is turned off.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
• Three-year warranty on parts and labor.
• Printed circuit boards are environmentally-shielded using Lincoln's
engineered potting and protective frame trays.
• 100% software controlled – Software based controls can be
upgraded as new features become available.
• Easy access for serviceability.
• Modular construction allows for easy service/maintenance.

Power Wave AC/DC 1000
[10]
A CLOSER LOOK
www.lincolnelectric.com
Real-time welding data is
automatically recorded and saved
Operator Screen Communication
Set Points
Remote Monitoring and Control
Monitor performance from anywhere in the world!
Waveforms are easily changed
through graphical interface
System Interface
The Power Wave AC/DC 1000™ includes software products to
assist with the installation and operation of the equipment. From
an intelligent configuration utility that allows you to automatically
sense and verify the system has been configured properly to a
tool capable of high-level monitoring, control, and data logging
for the system these packages were designed for ease of use
and convenience for the operators and the administrators.
Provides monitoring and control of each arc in a multiple arc system, presenting master/slave relationships and configuration of the arcs in
the system, as well as weld mode selection, parameters of weld states, and diagnostics.
Command Center
Effortlessly change welding
parameters for all arc states
Remotely monitor and diagnose
machine status and system
information
Diagnostics
Digital Communications
Fast, Reliable, System-Wide
ArcLink is the leading digital communications protocol for the arc welding industry. It integrates all welding components for seamless,
time-critical data transfer. The strength of ArcLink lies in the ability to communicate with each system component in a pre-defined welding
language. In addition, ArcLink is an open communications protocol, meaning that Lincoln Electric publishes how it works and encourages
other companies to adopt it.
DeviceNet is a communications protocol widely used throughout the automotive, semiconductor, and packaging industries. In its typical
application, DeviceNet works in conjunction with a programmable Logic Controller (PLC) and several system devices to provide a framework
for data trafficking and monitoring.
Ethernet is a specification for networking that provides the ability to pull large amounts of information into monitoring and supervisory applications.
For more information see Nextweld Document NX-1.30
Data Viewer