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IM848-A
®
June, 2009
POWER WAVE AC/DC 1000
For use with machines having Code Numbers: 11124, 11226
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be car
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v SAFETY
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vi vi SAFETY
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, pur
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viii viii TABLE OF CONTENTS Page Installation..........................................................................................................................Section A Specifications .......................................................................................................................A-1 Safety Precautions. ..............................................................................................................A-2 Location and Mounting.............................
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ix ix TABLE OF CONTENTS Troubleshooting ..............................................................................................Section E How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide...........................................................................E-2 thru E-11 Using the Status LED to Troubleshoot System Problem.....................................E-12 Error Codes...................................
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A-1 A-1 SPECIFICATIONS TECHNICAL SPECIFICATIONS - POWER WAVE® AC/DC 1000 (K2344-1, K2344-2) INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS INPUT OUTPUT POWER FACTOR IDLE EFFICIENCY 3 PHASE CURRENT AMPS CONDITIONS @ RATED OUTPUT POWER @ RATED OUTPUT 50/60 Hz K2344-1 K2344-2 WATTS 380 --- 82 400 --- 79 1000A@44V. 460 68 69 .95 100% Duty Cycle 225 86% 500 62 62 575 54 55 OUTPUT OPEN AUXILIARY POWER PROCESS CURRENT RANGES (AC or DC) CIRCUIT (C
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A-2 A-2 INSTALLATION LIFTING SAFETY PRECAUTIONS Read this entire installation section before you WARNING start installation. • Lift only with equipment of WARNING adequate lifting capacity. ELECTRIC SHOCK can kill. • Be sure machine is stable • Only qualified personnel should per- when lifting. form this installation. • Do not lift this machine using • Turn the input power OFF at the dis- lift bail if it is equipped with a heavy accessory such as trail- connect switch or fuse box before er or
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A-3 A-3 INSTALLATION INPUT AND GROUND CONNECTIONS INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS MACHINE GROUNDING Refer to Specifications page for recommended fuse and The frame of the welder must be grounded. A ground wire sizes. Fuse the input circuit with the recommended terminal marked with the symbol shown is located super lag fuse or delay type breakers (also called "inverse inside the reconnect / input access door for this pur- time" or "thermal/magnetic" circuit breakers). Choose input po
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A-4 A-4 INSTALLATION SYSTEM CONNECTION A PLC interface is an alternate method of control for larger systems. The PLC is typically connected via System Overview DeviceNet directly to the Power Wave System Interface, and the Master power source of each arc The Power Wave AC/DC 1000 power source is group in the system. designed to be a part of a modular welding system typically controlled by a Power Feed 10A Controller The following list of Recommended and Optional or customer supplied Programm
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A-5 A-5 INSTALLATION RECOMMENDED EQUIPMENT 4 4 3,4 System Part No. Description Single Arc Tandem Arc Triple Arc Identifier K2344-1 Power Source -or- Power Wave AC/DC 1000 Power Source 1 1 1 1 2 3 K2344-2 Welding Power Cables Power Source to contact Nozzle, K2163-xx and Power Source to Work Refer to "Output Cable Guidelines" Weld Cables -or- for recommended size and quantity K1842-xx K2163 Series cables sold in pairs. K1842 Series cables sold individually. See Price Book for details and bu
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A-6 A-6 INSTALLATION OPTIONAL EQUIPMENT System Identifier Part No. Description Ethernet Network Customer Ethernet Switch, Cables, etc. required for arcs > 1000A, or for use of Power Wave Equipment Supplied Submerged Arc Utilities software package. Personal Customer IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater) Computer Supplied required for use with Power Wave Submerged Arc Utilities software package. Travel Carriage K325-x TC-3 Self-Propelled Travel Carriage for t
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A-7 A-7 INSTALLATION Connection Diagram- Typical Single Arc System (Power Feed 10A Controller) Arclink (5 Pin) Work Studs Wire Feeder (14 Pin) Electrode Studs Travel Carriage Connection Flux Hopper Connection K1543-XX Arclink Connection Arclink Control Cable K 2362-1 K1785-XX Wire Feeder Control Cable * Work Cable(s) * Electrode Cable(s) Wire Reel and Mounting 21 Lead Head Electrode Sense K231XXX - Lead (67) 67 Lead Work Piece Work Sense Lead (21) 14 Pin Connector * Refer to "Output Cable Gui
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A-8 A-8 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST SINGLE ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE) (as shown in the Connection Diagram "Typical Single Arc System") Place Power Wave in suitable operating location. Mount PF10A Controller. Install PF10S Wire Drive and other accessories in their operating location. (1) Connect K1785-xx Wire Feeder Control Cable (14 pin) between the Power Wave and Wire Drive. (1) Connect K1543-xx ArcLink Control Cable (5 pin) between Power
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A A A AR RC C 1 1 R R C C 2 2 A AR RC C 2 2 A AR RC C 1 1 A AR RC C 2 2 Y Y M M A A S S S ST TE E IIN NT TE ER RF F C CE E A AR RC C 1 1 A-9 A-9 INSTALLATION Connection Diagram- Typical Tandem Arc System ( Power Feed 10A Controller) Wire Feeder (14 Pin) Arc link (5 Pin) Master Inpu t (S12) Connects to System Interface Work Studs K1795-XX Cables Electrode Studs Wire Reel and Mountings Arclink Input Arclink Output K2282-1 K1785-XX K1543-XX Wire Feeder k Contro bles Arclin l Ca Control Cabl
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A-10 A-10 INSTALLATION STEP BY STEP INSTALLATION CHECKLIST TANDEM ARC SYSTEM CHECKLIST – (PF-10A CONTROLLED, 1 POWER SOURCE PER ARC) (as shown in the Connection Diagram "Typical Tandem Arc System”) Place Power Waves in suitable operating location. Mount PF10A Controllers. Install PF10S Wire Drives and other accessories in their operating location. Mount Power Wave System Interface. (1) Connect K1785-xx Wire Feeder Control Cable (14 pin) between each Power Wave and Wire Drive. Connect K1543-xx
