• World's Leader in Welding and Cutting Products •
POWER WAVE AC/DC 1000
OPERATOR’ S MANUAL
IM848-AJune, 2009
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overal l safety can beincreased by proper installation ...and thoughtful operation on yourpart. DO NOT I NSTALL,OPERATE OR REPAI R THI SEQUI PMENT WI THOUT READ-I NG THI S MANUAL AND THESAFETY PRECAUTI ONS CON-TAI NED THROUGHOUT. And,most importantly, think before youact and be careful.
For use with machines having Code Numbers: 11124, 11226
This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.
____________________________________________________1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ʻ95
ELECTRIC AND MAGNETIC FIELDSmay be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
ARC RAYS can burn.4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
iiiSAFETYiii
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.
Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
Refer to http://www.lincolnelectric.com/safety for additional safety information.
ivSAFETY iv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.
c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
vSAFETYv
viSAFETYvi
viivii
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE POLICYThe 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, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty 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 controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying 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.comfor any updated information.
Location and Mounting..................................................................................................A-2Stacking ........................................................................................................................A-2Lifting.............................................................................................................................A-2Environmental Limitations .............................................................................................A-2Electromagnetic Compatibility .......................................................................................A-2Input Fuse and Supply Wire Considerations.................................................................A-3Input Voltage Selection and Ground Connections ........................................................A-3Connection/Input Access Door, Connection Diagrams System ....................................A-3System Connection .......................................................................................................A-4Recommended Equipment............................................................................................A-5Optional Equipment.......................................................................................................A-6Connection Diagrams and Check List ...........................................................A-7 thru A-14Electrode and Work Connection .................................................................................A-15Cable Inductance, And its Effects On Welding ...........................................................A-16Remote Sense Lead Specifications ............................................................A-16 thru A-18Control Cable Connections Between Power Source and Wire Feeder .............A-19, A-20External I/O Connector................................................................................................A-21Cables, Connections and Limitations ................................................................A-21, A-22
Wire Drive Gear Ratio Setting, Ethernet Configuration ......................................................A-23Devicenet Configuration, Internal Controls, Settings and Descriptions ..............A-24 thru A-28
Operation.........................................................................................................................Section BSafety Precautions, Definition of Welding Modes ................................................................B-1Graphic Symbols ..................................................................................................................B-2Product Summary, Recommended Process, Process and Equipment Limitations..............B-3Common Equipment Packages and Recommended Equipment .........................................B-3Case Front Control Descriptions....................................................................................B-4,B-5Case Rear Components.......................................................................................................B-6Power-Up Sequence ............................................................................................................B-6Duty Cycle ............................................................................................................................B-7Common Welding Procedures .............................................................................................B-7Overview of the AC/DC Submerged Arc Process ................................................................B-7Multiple Arc System Considerations.....................................................................................B-8Basic Modes of Operation (CC / CV) ...................................................................................B-8Weld Sequence, Start Options, End Options, Re-Strike Timer ............................................B-9Weld Process Adjustment, AC Adjustment, Wave Balance, DC Offset, Frequence ..........B-10Multiple Arc AC adjustments for systems equipped with K2282-1 System Interface .........B-11
Troubleshooting ..............................................................................................Section EHow to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide...........................................................................E-2 thru E-11Using the Status LED to Troubleshoot System Problem.....................................E-12Error Codes................................................................................................E-13, E-14
Wiring Diagrams and Dimension Print ..........................................................Section F________________________________________________________________________
Parts List.................................................................................................................P-509 ________________________________________________________________________
A-1SPECIFICATIONS
POWER WAVE® AC/DC 1000
A-1
TECHNICAL SPECIFICATIONS - POWER WAVE® AC/DC 1000 (K2344-1, K2344-2)
OUTPUT
RECOMMENDED INPUT WIRE AND FUSE SIZES1
PHYSICAL DIMENSIONS
TEMPERATURE RANGES
INPUT AT RATED OUTPUT - THREE PHASE ONLYINPUT VOLTS
3 PHASE50/60 Hz
380400460500575
OPENCIRCUIT
VOLTAGE
25 to 100VRMS
3 PHASE INPUTVOLTAGE 50/60Hz
380400460500575
HEIGHT43.5 in
1105 mm
CONFORMITY MARK
CSA C/UL
MODEL
K2344-1
WIDTH19.2 in
488 mm
DEPTH33 in
838 mm
WEIGHT600 lbs.272 kg.
43.5 in1105 mmK2344-2
19.2 in488 mm
33 in838 mm
650 lbs.296 kg.
TIME-DELAY FUSEOR BREAKER2
AMPS10090908070
COPPER GROUNDINGCONDUCTOR
AWG (mm2)8 (10)8 (10)8 (10)8 (10)10 (6)
TYPE 90°CCOPPER WIRE3 IN
CONDUIT
AWG (mm2) 3(25)3(25)4(25)4(25)6(16)
PROCESS CURRENT RANGES (AC or DC)
SAW-DC+ Output RangeSAW-DC- 200-1000 Average AmpsSAW-AC
OPERATING TEMPERATURE RANGE32°F to 104°F(0°C to 40°C)
STORAGE TEMPERATURE RANGE-40°F to 185°F(-40°C to 85°C)
1 Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.2 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.
* An external filter will be required to meet CE and C-Tick conducted emission requirements. It will meet CE and C-Tick requirements withthe use of an optional external filter. (K2444-1 CE and C-Tick Filter Kit)
}
WELDING PROCESSESProcess
SAW
Electrode Diameter Range
5/64 – 7/32" (2 – 5.6 mm)
Output Range (Amperes
200 - 1000
Wire Feed Speed Range
21 - 300 ipm (.53 – 7.62 m/minute)
EN 60974-1CSA C/UL
*
Insulation Class: Class F(155°C)
LIFTING
Lift the machine by the lift bail only. The lift bail isdesigned to lift the power source only. Do not attemptto lift the Power Wave AC/DC 1000 with accessoriesattached to it.
ENVIRONMENTAL LIMITATIONS
Do not use the Power Wave AC/DC 1000 in an out-door environment. The Power Wave AC/DC 1000power source 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 aspose a safety hazard. The best practice is to keep themachine in a dry, sheltered area.
ELECTROMAGNETIC COMPATIBILITY(EMC)
The EMC classification ot the Power Wave AC/DC1000 is Industrial, Scientific and Medical (ISM) group2, class A. The Power Wave AC/DC 1000 is for indus-trial use only.
Locate the Power Wave away from radio controlledmachinery.
The normal operation of the Power Wave AC/DC1000 may adversely affect the operation of RFcontrolled equipment, which may result in bodilyinjury or damage to the equipment.
SAFETY PRECAUTIONSRead this entire installation section before youstart installation.
ELECTRIC SHOCK can kill.• Only qualified personnel should per-
form this installation.• Turn the input power OFF at the dis-
connect switch or fuse box beforeworking on this equipment. Turn offthe input power to any other equip-ment connected to the welding sys-tem at the disconnect switch or fusebox before working on the equip-ment.
• Do not touch electrically hot parts.• Always connect the Power Wave grounding lug
(located inside the reconnect input access door)to a proper safety (Earth) ground.
Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe case sides and front. Dirt, dust, or any foreignmaterial that can be drawn into the welder should bekept at a minimum. Do not use air filters on the airintake because the air flow will be restricted. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdowns.
STACKING
Power Wave AC/DC 1000 machine cannot bestacked.
WARNING
DO NOT MOUNT OVER COMBUSTIBLE SUR-FACES.Where there is a combustible surface directly understationary or fixed electrical equipment, the surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not more than5.90”(150mm) beyond the equipment on all sides.------------------------------------------------------------------------
CAUTION
• Lift only with equipment ofadequate lifting capacity.
• Be sure machine is stablewhen lifting.
• Do not lift this machine usinglift bail if it is equipped with aheavy accessory such as trail-er or gas cylinder.
The frame of the welder must be grounded. A groundterminal marked with the symbol shown is locatedinside the reconnect / input access door for this pur-pose. See your local and national electrical codes forproper grounding methods.
A-3INSTALLATION
POWER WAVE® AC/DC 1000
A-3
INPUT FUSE AND SUPPLY WIRECONSIDERATIONS
Refer to Specifications page for recommended fuse andwire sizes. Fuse the input circuit with the recommendedsuper lag fuse or delay type breakers (also called "inversetime" or "thermal/magnetic" circuit breakers). Choose inputand grounding wire size according to local or national elec-trical codes. Using fuses or circuit breakers smaller thanrecommended may result in "nuisance" shut-offs fromwelder inrush currents, even if the machine is not beingused at high currents.
INPUT VOLTAGE SELECTION
Welders are shipped connected for the highest input voltagelisted on the rating plate. To move this connection to a dif-ferent input voltage, see the diagram located on the insideof the input access door, or the Reconnect Diagram K2344-1 and K2344-2 shown below. If the Auxiliary lead (indicatedas ʻAʼ) is placed in the wrong position, there are two possi-ble results. If the lead is placed in a position higher than theapplied line voltage, the welder may not come on at all. Ifthe Auxiliary lead is placed in a position lower than theapplied line voltage, the welder will not come on, and thetwo circuit breakers in the reconnect area will open. If thisoccurs, turn off the input voltage, properly connect the aux-iliary lead, reset the breakers, and try again.
INPUT CONNECTION
ELECTRIC SHOCK can kill.
• Only a qualified electrician shouldconnect the input leads to thePower Wave. Connections shouldbe made in accordance with alllocal and National ElectricalCodes and the connection dia-gram located on the inside of thereconnect / input access door ofthe machine. Failure to do so mayresult in bodily injury or death.
Use a three-phase supply line. A 1.75 inch (45 mm)diameter access hole for the input supply is located onthe case back. Connect L1, L2, L3 and groundaccording to the Input Supply Connection Diagram.
WARNING
Reconnect Diagram for K2344-1 Power Wave AC/DC 1000
X
A
Do not operate with covers removedDisconnect input power before servicingDo not touch electrically live partsOnly qualified persons should install,use or service this equipment
Reconnect Diagram for K2344-2 Power Wave AC/DC 1000 ("CE – ready")
S26
047
THE
LIN
CO
LN E
LEC
TRIC
CO
. C
LEV
ELA
ND
, OH
IO U
.S.A
.
VOLTAGE=440-460V
'A'
A
500V
U / L1
V / L2 CR1
W / L3INPUT SUPPLY CONNECTION DIAGRAM
550-575V
ELECTRICSHOCK
CAN KILL
WARNINGDo not operate with covers removedDisconnect input power before servicingDo not touch electrically live partsOnly qualified persons should install,use or service this equipment
440-460V
VOLTAGE=500V
'A'500V550-575V
440-460V
VOLTAGE=550-575V
'A'500V550-575V
440-460V
VOLTAGE=380-415V
'A'500V550-575V
440-460V380-415V 380-415V 380-415V 380-415V
A-4INSTALLATION
POWER WAVE® AC/DC 1000
A-4
SYSTEM CONNECTION
System Overview
The Power Wave AC/DC 1000 power source isdesigned to be a part of a modular welding systemtypically controlled by a Power Feed 10A Controlleror customer supplied Programmable LogicController (PLC). Each welding arc may be driven bya single power source or by a number of powersources connected in parallel. The actual number ofpower sources per arc will vary depending on theapplication. When only one power source is requiredfor an arc group, it must be configured as a Master.When multiple parallel machines are required, one isdesignated as the Master and the rest as Slaves. TheMaster controls the AC switching for the arc group,and the Slaves respond accordingly.
When employed in a multi-arc AC system it is benefi-cial to synchronize the arcs to each other. The Masterfor each arc can be configured to follow a dedicatedexternal synchronization signal to determine its fre-quency and balance. The optional Power WaveSystem Interface provides the means to synchronizethe AC wave shapes of up to four different arcs to acommon carrier frequency. This frequency can rangefrom 10 hertz to 300 hertz, with the most practicalrange being 10 to 100 hertz. It can also control thephase angle between arcs to reduce the effects ofwelding related issues such as "Arc Blow".The arc to arc phase relationship is determined by thetiming of each arcʼs "sync" signal relative to the "sync"signal of ARC 1.
In a typical multi-arc system, each arc is controlled byits own Power Feed 10A Controller. The basic charac-teristics of the individual arcs such as WFS, ampli-tude, and offset are set locally by each arcʼs dedicatedcontroller. The frequency, balance, and phase shiftparameters of each arc are controlled by the PowerFeed 10A Controller for ARC 1, which must be con-nected to its Master through the Power Wave SystemInterface (see multi-arc Connection Diagrams on thenext few pages).
A PLC interface is an alternate method of control forlarger systems. The PLC is typically connected viaDeviceNet directly to the Power Wave SystemInterface, and the Master power source of each arcgroup in the system.
The following list of Recommended and Optionalequipment is included as a reference for the follow-ing connection diagrams. The connection diagramsdescribe the layout of three typical systems. Eachdiagram has a step by step Installation Checklist.Additionally, a dedicated diagram has been provideddetailing the parallel connection of machines forextra output capacity which can be applied to thesystem diagrams as required.
A-5INSTALLATION A-5
RECOMMENDED EQUIPMENTSystem
Identifier
Power Source
Weld Cables
Head
Torch
Power Source toHead
Control Cable
User Interface
ArcLink DigitalCommunication
Cable
PLC (w/ UserInterface)
DeviceNet Cablesand Accessories
System Interface
System Interface to Power Source
Control Cable
Part No.
K2344-1-or-
K2344-2
K2163-xx-or-
K1842-xx
K2370-1-or-
K2312-1
K231-xxx
K1785-xx
K2362-1
K1543-xx 5
CustomerSupplied
AutomationDepartment or
Customer Supplied
K2282-1
K1795-xx 5
Single Arc 4
1 1
1 2
1
1 2
1 2,4
1
---
---
---
---
Tandem Arc 4
2 1
2 2
2
2 2
2 2,4
3
---
---
1 2
2 2
Description
Power Wave AC/DC 1000 Power Source
Welding Power CablesPower Source to contact Nozzle,
and Power Source to Work
K2163 Series cables sold in pairs.K1842 Series cables sold individually.
See Price Book for details and bulk cableavailability.
Power Feed 10S Head for 3/32 to 7/32 in. solidwire (includes hopper, wire straightener, cross
seam adjuster, head mounting hardware, and 2 -5ft 4/0 weld cables).
Power Feed 10S Head for 3/32 to 7/32 in. solidwire (fixture builder's head, with wire straightener -
insulators not included).
Submerged Arc Contact Nozzle Assembly
Feeder Control Cable (14 pin).
Power Feed 10A Controller
ArcLink Control Cables (5 pin).Single Arc:
(1) PF-10A Controller to the power sourceTandem Arc:
(1) Lead Arc to System Interface(2)System Interface to Lead Arc PF-10AController(3) Trail Arc to Trail Arc PF-10A Controller
DeviceNet Cables, Tees, and Terminators (5 pin)sealed "mini style") form a trunk style network con-necting PLC to each power source and the System
Interface.
For additional information refer to the "DeviceNetCable Planning and Installation Manual" (Allen
Bradley publication DN-6.7.2).
Power Wave System Interface provides themeans to synchronize the AC wave shapes of upto four different arcs to a common carrier frequen-cy, and control the phase angle between them to
reduce the effects of "Arc Blow".
Control Cable (22 pin) connects between each
power source and the System Interface.
Triple Arc 3,4
3 1
3 2
3
3 2
---
1
1 4
Cables, Tees,and
Terminatorsas required
per Triple ArcConnectionDiagram 4
1 2
3 2
Refer to "Output Cable Guidelines" for recommended size and quantity
Notes:1. "Recommended Quantity" assumes one power source per arc. Multiple power sources may be used to increase the output capacity per arc (see "Connection Diagram - Parallel
Machines").2. Control Cable connections only required at the Master of each parallel power source arc grouping.3. Can be expanded to 4 or more arcs (Note: The System Interface can currently only synchronize up to four AC arc groupings).4. The triple arc system is an economical breakpoint for a PLC Interface. It does not preclude the use of a PLC for single or tandem arc systems, nor PF-10A's from being used to control
multiple arc systems with greater than two arcs.5. Cables can be connected end to end to extend length.
POWER WAVE® AC/DC 1000
A-6INSTALLATION
POWER WAVE® AC/DC 1000
A-6
OPTIONAL EQUIPMENTSystem
Identifier
Ethernet NetworkEquipment
PersonalComputer
Travel Carriage
Travel Carriage (High Capacity)
ControllerMounting Bracket
User Interface
HorizontalAdjuster
Vertical Adjuster
Wire ReelMounting (single)
Wire ReelMounting (dual)
Mounting for DualHead
Flux Hopper
Flux Hopper
Remote WireDrive Module
Part No.
CustomerSupplied
CustomerSupplied
K325-x
K325-HCx
K2462-1
K96
K29
K299
K390
K387
K219
K389
K2626-1
Description
Ethernet Switch, Cables, etc. required for arcs > 1000A, or for use of Power WaveSubmerged Arc Utilities software package.
IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater)required for use with Power Wave Submerged Arc Utilities software package.
TC-3 Self-Propelled Travel Carriage for traversing standard carriage beam (per G1458)
TC-3 Self-Propelled High Capacity Travel Carriage for traversing standard carriagebeam (per G1458)
PF-10A Mounting Bracket mounts PF-10A Controller to left side of TC-3 carriage.Brackets can be cascaded to accommodate more than one controller.
Note: Bracket uses mounting holes reserved for K299 Wire Reel Assembly (see Wire Reel Mounting options for additional information).
Horizontal Lift Adjuster provides 2" (51mm) crank adjustment of horizontal head posi-tion.
Vertical Lift Adjuster provides 4" (102mm) crank adjustment of vertical head position.Also provides 3.37" (95mm) in-and-out horizontal adjustment with movable stops forrepeatability.
Wire Reel Assembly accommodates one 50-60 lb (22.7-27.2 kg) coil, includes mountingspindle and braking system. Mounts to left side of TC-3 Std. or High Capacity TravelCarriage (K325-x).
Cannot be mounted to TC-3 when K2462-1 PF-10A Mounting Bracket is used (use K390instead).
Electrode Reels and Mountings for mounting up to two 50-60 lb (22.7-27.2 kg) coils,includes mounting spindle and braking system. Mounts to top of TC-3 High CapacityTravel Carriage (K325-HCx). Does not interfere with K2462-1 PF-10A Mounting Bracket.
Tandem Arc Framework includes hex style framework and mounting hardware to attachtwo PF-10S or PF-10SF heads directly to a high capacity TC-3 carriage, or user suppliedfixture or gantry.
Flux Hopper with electric flux valve for Submerged Arc welding.
Flux Hopper with electric flux valve, for K387 tandem mounting. Mounts directly to hexcrossbar.
For wire drive applications greater than 100ft.
A-7INSTALLATION
POWER WAVE® AC/DC 1000
A-7
Wire Feeder (14 Pin)Arclink (5 Pin)
Arclink Connection
K 2362-1
Wire Reeland Mounting
Work Piece
K231-XXXHead
* Work Cable(s)
* Electrode Cable(s)
K1785-XXWire FeederControl Cable
K1543-XXArclink Control Cable
Work SenseLead (21)
Electrode SenseLead (67)
67 Lead
21 Lead
14 Pin Connector
Flux HopperConnection
Travel CarriageConnection
* Refer to "Output Cable Guidelines" for recommended cable size.
Work StudsElectrode Studs
Connection Diagram- Typical Single Arc System (Power Feed 10A Controller)
A-8INSTALLATION
POWER WAVE® AC/DC 1000
A-8
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.
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 Wave and PF10A.(1)
Configure / Install sense leads.
Connect / Install welding cables per recommended "Output Cable Guidelines."
Open all Power Wave front panel and configure DIP switch settings per "Internal Controls" section.
Connect input power to Power Wave per recommended guidelines.
Turn on Power Wave, and verify all system Status Lights are solid green.
NOTES:(1) ArcLink and Wire Feeder control cable connections are only required at the Master power source of each
arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."
A-9INSTALLATION
POWER WAVE® AC/DC 1000
A-9
ARC 2
ARC 1
ARC 11
ARC 22
ARC 1
ARC 2
ARC 1 AR C 2SYSTEM INTERFACE
Master Input (S12)Connects to SystemInterface
Arclink Connection
21 Lead67 Lead
* Work Cables
K1785-XXWire Feeder
Control Cables
K1795-XX Cables
* Electrode Cables
Arc link (5 Pin)
Wire Feeder(14 Pin)
K2282-1
K2362-1
Head
K231-XXX
Work Piece
14 Pin Connector
Work Studs
Electrode Studs
Arclink Output
Work SenseLead (21)
Electrode Sense Lead (67)
* Refer to "Output Cable guidelines" for recommended cable size.
K1543-XXArclink Control Cables
Connection Diagram- Typical Tandem Arc System ( Power Feed 10A Controller)
Arclink Input
Wire Reeland Mountings
Flux HopperConnection
Travel CarriageConnection
A-10INSTALLATION
POWER WAVE® AC/DC 1000
A-10
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.
Connect K1785-xx Wire Feeder Control Cable (14 pin) between each Power Wave and Wire Drive.(1)
Connect K1543-xx ArcLink Control Cables (5 pin) from Power Wave #1 to the System Interface input, andfrom the System Interface output to the PF10A Controller for ARC #1.(1)
Connect K1543-xx ArcLink Control Cable (5 pin) between Power Wave #2 and the PF10A Controller for ARC#2.(1)
Connect K1795-xx System Control Cables (22 pin) between each Power Wave and the System Interface. (2)
Configure / Install sense leads.
Connect / Install welding cables per recommended "Output Cable Guidelines."
Open all Power Wave front panels and configure DIP switch settings per "Internal Controls" section.
Connect input power to Power Waves per recommended guidelines.
Turn on Power Waves, and verify all system Status Lights are solid green.
NOTES:(1) ArcLink and Wire Feeder control cable connections are only required at the Master power source of each
arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."
(2) The "ARC" (formerly "PHASE") connections from the System Interface are only required for the Masterpower source of each arc grouping. For additional information see the "Extra Capacity Parallel ConnectionChecklist."
A-11INSTALLATION
POWER WAVE® AC/DC 1000
A-11
ARC
11
ARC
2ARC
2
ARC
3
ARC
1
ARC
3
ARC
1 A
RC 2
ARC
3SY
STEM
INTE
RFAC
E
Con
nect
ion
Dia
gram
- Typ
ical
Trip
le A
rc S
yste
m (D
evic
eNet
PLC
Con
trol
ler)
67 L
ead
21 L
ead
14 P
in C
onne
ctor
* W
ork
Cab
les
Wor
k Pi
ece
Wor
k Se
nse
L ead
s (2
1)
* E
lect
rod e
Cab
les
* R
efer
to "O
utpu
t Cab
le G
uide
lines
" for
reco
mm
ende
d ca
ble
size
.
Hea
d
K23
1-XX
X
Dev
iceN
et C
able
Net
wor
k
K179
5-XX
Cab
l es
K154
3-XX
Arc
link
Co n
trol C
able
K178
5-X
XW
ire F
eede
rC
ontro
l Cab
les
Arc
link
Inpu
t
Wir e
Fee
der
(14
Pin)
Arc
link
(5 P
in)
Wor
k S
tuds
Elec
trod e
Stu
dsW
ire R
eel
and
Mou
ntin
gs
PLC
Con
trolle
r
Ele
ctro
de S
ense
Lea
d (6
7)
Mas
ter I
nput
(S1
2)C
onne
cts
to S
yste
mIn
terfa
ce
K22
82-1
Use
r Int
erfa
ce
Dev
iceN
et
Dev
ice
Net
(5 P
in)
A-12INSTALLATION
POWER WAVE® AC/DC 1000
A-12
STEP BY STEP INSTALLATION CHECKLIST
TRIPLE ARC SYSTEM CHECKLIST – (DEVICENET PLC CONTROLLED, 1 POWER SOURCE PER ARC)(as shown in the Connection Diagram "Typical Triple Arc System”)
Place Power Waves in suitable operating location.
Mount DeviceNet PLC Controller and User Interface.
Install PF10S Wire Drives and other accessories in their operating location.
Mount Power Wave System Interface.
Connect K1785-xx Wire Feeder Control Cable (14 pin) between each Power Wave and Wire Drive.(1)
Connect K1543-xx ArcLink Control Cable (5 pin) from ARC #1 power source to the System Interface input.(1)
Connect K1795-xx System Control Cables (22 pin) between each Power Wave and the appropriate SystemInterface "ARC" (formerly "PHASE") outputs. (2)
Connect the System Interface and each power source to the PLC via the DeviceNet network.(1)
Configure / Install sense leads.
Connect / Install welding cables per recommended "Output Cable Guidelines."
Open all Power Wave front panels and configure DIP switch settings (including the DeviceNet MAC ID andBaud Rate settings) per "Internal Controls" section.
Connect input power to Power Waves per recommended guidelines.
Turn on Power Waves, and verify all system Status Lights are solid green.
NOTES:(1) ArcLink, DeviceNet and Wire Feeder control cable connections are only required at the Master power source
of each arc grouping. For additional information see the "Extra Capacity Parallel Connection Checklist."
(2) The "ARC" (formerly "PHASE") connections from the System Interface are only required for the Masterpower source of each arc grouping. For additional information see the "Extra Capacity Parallel ConnectionChecklist."
A-13INSTALLATION
POWER WAVE® AC/DC 1000
A-13
MASTERSLAVE
K1795-XX Cables
Connection Diagram - Parallel Machines(Example depicts a single arc grouping, and may be repeated for each arc in the system)
Connect additional SLAVEmachines as required to reachdesired capacity.
Note: Each arc is limited to 5SLAVE machines per MASTER(6 machines total)
S12 (Input)
S13 (Output)
Connect to optionalK2282-1 System Interfacefor SynchronizedMultiple Arc Applications
Ethernet
Note:Ethernet connectivity allows machines to share criticalparameter information. Proper configuration requires the use ofthe Weld Manager and SubarcCellConfigsoftware utilities.
Common bus connections recommended for excessive cable lengthapplications. (Locate close to power sources.)
* Electrode Cables
* Work Cables
Work
Electrode
Front view of machines
Rear view of machines
* Refer to "Output Cable Guidelines" for recommended cable size.
Ethernet Switch
A-14INSTALLATION
POWER WAVE® AC/DC 1000
A-14
STEP BY STEP INSTALLATION CHECKLIST
EXTRA CAPACITY PARALLEL CONNECTION(as shown in the Connection Diagram "Parallel Machines”)
Follow all steps of Single, Tandem, or Triple Arc checklists.
Be sure input power is disconnected prior to following the remaining steps.
Control Cable Connections:
PF-10S Connections:
Each PF-10S must be connected to the Master power source of its associated arc.
PF-10A Controlled Systems:
Each PF-10A Controller must be connected to the Master power source of its arc via a K1543-xxArcLink Control Cable (5 pin), but should not be connected to the Slave(s).
In a multi-arc system, the System Interface must also be connected to the ARC #1 Master powersource via a K1543-xx ArcLink Control Cable (5 pin).
DeviceNet PLC Controlled Systems:
Only the Master power source of each arc should be connected to the PLC Controller via theDeviceNet network.
In a multi-arc system, the System Interface must connected to the PLC via the DeviceNet network.It must also be connected to the ARC #1 Master power source via a K1543-xx ArcLink ControlCable (5 pin).
Connect K1795-xx System Control Cables (22 pin) between the Master and Slaves of each arc grouping perthe Parallel Machines Connection Diagram.
Connect / Install welding cables per the recommended "Output Cable Guidelines" and the "ParallelMachines Connection Diagram" for each arc grouping.
Configure / Install sense leads (the sense lead configuration of all machines in a given parallel arc groupingmust be the same).
Open Power Wave front panels and configure DIP switch settings per "Internal Controls" section.
Connect Power Wave to LAN (Local Area Network). See "Connection Between Power Source and EthernetNetwork."
Connect input power to Power Waves per recommended guidelines.
Run the Submerged Arc Cell Configuration software utility to configure the Master / Slave relationships ofeach arc grouping (follow instructions provided).
A-15INSTALLATION
POWER WAVE® AC/DC 1000
A-15
ELECTRODE AND WORKCONNECTIONS
General GuidelinesThe unique switching structure of the Power WaveAC/DC 1000 allows it to produce DC positive, DCnegative or AC output waveforms without reposition-ing the work and electrode leads. Additionally, no DIPswitch changes are required to switch between the dif-ferent polarities. All of this is controlled internally bythe Power Wave AC/DC 1000, and based exclusivelyon the weld mode selection.
The following recommendations apply to all outputpolarities and weld modes:
• Select the appropriate size cables per the"Output Cable Guidelines" below. Excessive volt-age drops caused by undersized welding cablesand poor connections often result in unsatisfactorywelding performance. Always use the largest weld-ing cables (electrode and work) that are practical,and be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicatesundersized cables and/or bad connections.
• Route all cables directly to the work and wirefeeder, avoid excessive lengths and do not coilexcess cable. Route the electrode and work cablesin close proximity to one another to minimize theloop area and therefore the inductance of the weldcircuit.
• Always weld in a direction away from the work(ground) connection.
TABLE A.1 - Output Cable Guidelines
Electrode ConnectionsConnect an electrode cable of sufficient size andlength (Per Table A.1) to the "electrode" stud on thepower source (located behind the cover plate on thelower left side). For convenience, the cable can berouted down through the two holes in the left cabletray before being connected to the output terminals.Connect the other end of the electrode cable to thewire drive feed plate on the wire feeder. Be sure theconnection to the feed plate makes tight metal-to-metal electrical contact.
For parallel applications with excessive electrodecable lengths, a common bus connection should beused. The common electrode connection serves tominimize voltage drops associated with resistive loss-es in the electrode path. It should be made of copper,and located as close as possible to the powersources. (See "Connection Diagram – ParallelMachines")
Work ConnectionsConnect a work lead of sufficient size and length (PerTable 1) between the "work" stud (located beneath thespring loaded output cover on the top, front of themachine) and the work piece. For convenience, thework lead can be routed along the left cable tray, andout the back of the machine. Be sure the connectionto the work makes tight metal-to-metal electrical con-tact.
For parallel and/or multiple arc applications withexcessive ground path lengths, a common work con-nection bus should be used. The common work con-nection serves to minimize voltage drops associatedwith resistive losses in the ground paths. It should bemade out of copper, and located as close as possibleto the power sources (See Common ConnectionDiagram).
Total Cable Lengthft (m)
Electrode and WorkCombined
0 (0) to 250 (76.2)
0 (0) to 250 (76.2)
Duty Cycle
80%
100%
Number ofParallel Cables
2
3
Cable SizeCopper
4/0 (120 mm2)
3/0 (95 mm2)
WORK PIECE
COMMON CONNECTION(LOCAT ED CLOSE TO
POWER SOURCES)
Common Connection Diagram
A-16INSTALLATION
POWER WAVE® AC/DC 1000
A-16
CABLE INDUCTANCE, AND ITS EFFECTSON WELDING
Excessive cable inductance will cause the weldingperformance to degrade. There are several factorsthat contribute to the overall inductance of the cablingsystem including cable size, and loop area. The looparea is defined by the separation distance betweenthe electrode and work cables, and the overall weldingloop length. The welding loop length is defined as thetotal of length of the electrode cable (A) + work cable(B) + work path (C) (see Figure A.1 below). To mini-mize inductance always use the appropriate sizecables, and whenever possible, run the electrode andwork cables in close proximity to one another to mini-mize the loop area. Since the most significant factor incable inductance is the welding loop length, avoidexcessive lengths and do not coil excess cable. Forlong work piece lengths, a sliding ground should beconsidered to keep the total welding loop length asshort as possible.
REMOTE SENSE LEAD CONNECTIONS
Voltage Sensing Overview
The best arc performance occurs when the PowerWave AC/DC 1000 has accurate data about the arcconditions. Depending upon the process, inductancewithin the electrode and work cables can influence thevoltage apparent at the studs of the welder, and havea dramatic effect on performance. To counteract thisnegative effect, remote voltage sense leads are usedto improve the accuracy of the arc voltage informationsupplied to the control pc board.
There are several different sense lead configurationsthat can be used depending on the application. Inextremely sensitive applications it may be necessaryto route cables that contain the sense leads awayfrom the electrode and work welding cables.
If the remote voltage sensing is enabled but thesense leads are missing, improperly connected, orif the electrode polarity switch is improperly con-figured extremely high welding outputs mayoccur.
The remote ELECTRODE sense lead (67) is built intothe wire feeder control cable (K1785) and accessibleat the wire drive. It should always connected to thewire drive feed plate when a wire feeder is present.Enabling or disabling electrode voltage sensing isapplication specific, and automatically configuredthrough software.
Work Voltage Sensing
For most applications the use of a remote work volt-age sense lead is recommended. The Power WaveAC/DC 1000 is shipped from the factory with theremote work voltage sense lead enabled. It must beattached to the work as close to the weld as practical,but out of the weld current path. For more informationregarding the placement of remote work voltagesense leads, see the section entitled "Voltage SensingConsiderations for Multiple Arc Systems." The remoteWORK sense lead (21) can be accessed at one of twolocations. Either at the wire drive via the wire feedercontrol cable (K1785), or at the four-pin WORK senselead connector located under the spring loaded outputcover. Whenever possible, use the WORK sense leadthat is built into wire feeder control cable (K1785)since it is closely coupled with the ELECTRODEsense lead and will tend to be more immune to electri-cal noise. If it is not possible to sense the WORK volt-age near the feeder, the four-pin WORK sense leadconnector at the power source should be used (a plugand pigtail assembly is provided for this purpose).
Never connect the WORK sense lead at two differ-ent locations.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts orelectrodes with your skin or wetclothing.
• Insulate yourself from the work andground.
• Always wear dry insulating gloves.-----------------------------------------------------------Some simplified applications may perform adequatelyby sensing the work voltage directly at the WORKSTUD without the use of a remote work voltage senselead. If a remote work voltage sense lead is not used,it must be disabled as follows: 1. Turn off power to the power source at the dis-
connect switch.2. Remove the front cover from the power source.
B
A
C
POWERWAVE
FIGURE A.2
WORK
WARNING
CAUTION
CAUTION
A-17INSTALLATION
POWER WAVE® AC/DC 1000
A-17
c. Locate the 8-position DIP switch on the controlboard and look for switch 8 of the DIP switch.
d. Using a pencil or other small object, slide theswitch to the OFF position if the work sense leadis NOT connected. Conversely, slide the switchto the ON position if the work sense lead is pre-sent.
e. Replace the cover and screws. The PC board willread the switch at power up, and configure the workvoltage sense lead appropriately.
Voltage Sensing for "Slave" machinesIf "Slave" machines are configured to use remote volt-age sensing they receive these signals directly fromthe "Master" machine. The K1795 control cable usedfor parallel connection of machines contains both theELECTRODE sense lead (67) and the WORK senselead (21). No other external sense lead connectionsare required for "Slave" machines.
NOTE: All of the machines of a given arc group(both Master and Slaves) must have theirwork voltage sensing configured identical-ly. All must either use a remote lead orsense directly from the stud. For addition-al information see the "Work VoltageSensing" section of this document.
VOLTAGE SENSING CONSIDERATIONS FORMULTIPLE ARC SYSTEMS
Special care must be taken when more than one arcis welding simultaneously on a single part. Multiplearc applications do not necessarily dictate the use ofremote work voltage sense leads, but they are strong-ly recommended.
If Sense Leads ARE NOT Used:• Avoid common current paths. Current from adja-
cent arcs can induce voltage into each others cur-rent paths that can be misinterpreted by the powersources, and result in arc interference.
If Sense Leads ARE Used:• Position the sense leads out of the path of the
weld current. Especially any current paths com-mon to adjacent arcs. Current from adjacent arcscan induce voltage into each others current pathsthat can be misinterpreted by the power sources,and result in arc interference.
• For longitudinal applications, connect all workleads at one end of the weldment, and all of thework voltage sense leads at the opposite end of theweldment. Perform welding in the direction awayfrom the work leads and toward the sense leads.
(See Figure A.2)
1 2 3 4 5 6 7 8ON
DIRECTIONOF TRAVEL
CONNECT ALLWORK LEADS AT THE BEGINNINGOF THE WELD.
CONNECT ALL SENSELEADS AT THE ENDOF THE WELD.
FIGURE A.2
A-18INSTALLATION
POWER WAVE® AC/DC 1000
A-18
• For circumferential applications, connect all work leads on one side of the weld joint, and all of the work volt-age sense leads on the opposite side, such that they are out of the current path.
POWERSOURCE #2
POWERSOURCE #1
POWERSOURCE #1
POWERSOURCE #2
POWERSOURCE #2
POWERSOURCE #1
A-19INSTALLATION
POWER WAVE® AC/DC 1000
A-19
CONTROL CABLE CONNECTIONS
General Guidelines
Genuine Lincoln control cables should be used atall times (except where noted otherwise). Lincolncables are specifically designed for the communica-tion and power needs of the Power Wave / PowerFeed systems. Most are designed to be connectedend to end for ease of extension. However, it is rec-ommended that the total length not exceed 100 feet(30.5 m). The use of non-standard cables, especiallyin lengths greater than 25 feet, can lead to communi-cation problems (system shutdowns), poor motoracceleration (poor arc starting), and low wire drivingforce (wire feeding problems). Always use the shortestlength of control cable possible, and DO NOT coilexcess cable.
Regarding cable placement, best results will beobtained when control cables are routed separatefrom the weld cables. This minimizes the possibility ofinterference between the high currents flowingthrough the weld cables, and the low level signals inthe control cables. These recommendations apply toall communication cables including optional DeviceNetand Ethernet connections.
COMMON EQUIPMENT CONNECTIONS
Connection Between Power Source and PowerFeed 10S Series Wire feeder (K1785 - ControlCable). The 14-pin wire feeder control cable connectsthe power source to the wire drive. If there is morethan one power source per arc, it connects from thewire drive to the power source designated as theMaster. It contains all of the necessary signals to drivethe motor and monitor the arc, including the motorpower, tachometer, and arc voltage feedback signals.The wire feeder connection on the Power WaveAC/DC 1000 is located under the spring loaded outputcover on the case front. The control cable is keyedand polarized to prevent improper connection. Forconvenience, the control cables can be routed alongthe right channel of the Power Wave, out the back,and to the wire feeder. Control cables SHOULD NOTbe routed through the same (left) channel as the weld-ing cables.
Connection Between Power Source and PowerFeed 10A Controller (K1543 – ArcLink ControlCable). Single and tandem arc systems are typicallycontrolled by a Power Feed 10A Controller (K2362-1).In a tandem, or multi-arc system, each arc requires itsown dedicated Power Feed 10A (PF-10A).
The 5-pin ArcLink control cable connects the powersource to the PF-10A. If there is more than one powersource per arc, it connects from the PF-10A to thepower source designated as the Master for that arc.The control cable consists of two power leads, onetwisted pair for digital communication, and one leadfor voltage sensing. The ArcLink connection on thePower Wave AC/DC 1000 is located under the springloaded output cover on the case front. The controlcable is keyed and polarized to prevent improper con-nection. For convenience, the control cables can berouted along the right channel of the Power Wave, outthe back, and to the PF-10A. Control cables SHOULDNOT be routed through the same (left) channel as thewelding cables.
In multiple arc systems equipped with a Power WaveSystem Interface (K2282-1), and controlled by PF-10Acontrollers, the system interface must be connected tothe ArcLink network of the ARC1 Master powersource. See the "Tandem Arc Connection Diagram"for detailed information.
Connections Between Power Source and OptionalDeviceNet Programmable Logic Controller(PLC). Itis sometimes more practical and cost effective to usea custom PLC interface to control a multi-arc system(refer to the "DeviceNet Configuration" section forinterface information). The Power Wave AC/DC 1000is equipped with a 5-pin DeviceNet mini style recepta-cle for this purpose. The receptacle is located underthe spring loaded output cover on the case front. TheDeviceNet cable is keyed and polarized to preventimproper connection. For convenience, it can be rout-ed along the right channel of the Power Wave, andout the back. DeviceNet cables SHOULD NOT berouted through the same (left) channel as the weldingcables.
In a typical system, a DeviceNet connection is madebetween the master power source of each arc, andthe PLC interface. When a Power Wave SystemInterface (K2282-1) is used to synchronize the arcs, itmust also be connected to the DeviceNet network. Forbest results, route DeviceNet cables away from weldcables, wire drive control cables, or any other currentcarrying device that can create a fluctuating magneticfield. DeviceNet cables must be sourced locally by thecustomer. For additional guidelines refer to the"DeviceNet Cable Planning and Installation Manual"(Allen Bradley publication DN-6.7.2).
A-20INSTALLATION
POWER WAVE® AC/DC 1000
A-20
Connections Between Multiple Power SourcesRun in Parallel (K1795 - Control Cable). To increasethe output capacity for a given arc, the output studs ofmultiple Power Wave AC/DC 1000 machines can beconnected in parallel. The parallel machines utilize amaster/slave control scheme to distribute the load andcoordinate AC switching. The 22 pin parallel controlcable contains all of the necessary signals to keep themachine outputs synchronized, including polarity,ready, kill, and arc voltage feedback signals. Thecable connects between the Master/Slave I/O connec-tors (S12 & S13) located on the rear of the PowerWave AC/DC 1000. The input connector (S12) islocated on the lower left side of the case back (asviewed from the rear), and the output connector (S13)is located on the lower right side. The output connec-tor (S13) on the master connects to the input connec-tor (S12) on the slave. If needed the output connectoron the slave machine can be used to connect to theinput connector of another slave machine in a daisychain fashion. This connection scheme can be repeat-ed as required until the desired output capacity isachieved. The system is currently limited to a maxi-mum of 5 slaves per master, or a total of 6 machinesper arc.
NOTE: In addition to the parallel control cable, parallelconnected machines also require an Ethernetconnection to share critical weld parameterinformation. For more information refer to the"Connections Between a Power Source andEthernet Network" section of this document.
Connection Between Power Source and EthernetNetwork. Ethernet connections are required for sys-tems with parallel connected power sources (morethan one power source per arc), or to utilize the toolsprovided in the Power Wave Submerged Arc Utilitiessoftware package. To facilitate this, the Power WaveAC/DC 1000 is equipped with an RJ-45 Ethernet con-nector, which is located under the spring loaded out-put cover. External Ethernet equipment (cables,switches, etc.) must be supplied by the customer. It iscritical that all Ethernet cables external to either a con-duit or an enclosure are solid conductor, shielded cat5 cable, with a drain. The drain should be groundedat the source. The use of cat 5+, cat 5E, cat 6 orstranded cable is not recommended. For best results,route Ethernet cables away from weld cables, wiredrive control cables, or any other current carryingdevice that can create a fluctuating magnetic field. Foradditional guidelines refer to ISO/IEC 11801. Failureto follow these recommendations can result in anEthernet connection failure during welding.
NOTE: See Ethernet Configuration section for addi-tional information.
Connections Between a Power Source andSystem Interface (K1795 - Control Cable). Whenmultiple arcs need to be synchronized, a Power WaveSystem Interface (K2282-1) is required. The systeminterface provides a dedicated synchronization signalfor frequency and balance to each of the four ARC(a.k.a. PHASE) receptacles. The synchronization sig-nals for ARC1 through ARC4 can be phase shiftedwith respect to one another to reduce the effects of"arc blow" and other welding related issues. The indi-vidual synchronization signals are relayed to the mas-ter machine of their corresponding arc via a 22 pincontrol cable. The control cable(s) connect betweenthe individual ARC receptacles on the system inter-face, and the Master/Slave input connector on themaster of each corresponding arc group. TheMaster/Slave input connector (S12) is located on thelower left side of the case back (as viewed from therear) of the Power Wave AC/DC 1000.
NOTE: In addition to the 22-pin arc synchronizationcables, the system interface also requires aconnection to the system controller either viaArcLink for Power Feed 10A controlled sys-tems (see "Connection Between PowerSource and Power Feed 10A Controller" ), orvia DeviceNet for PLC controlled systems (see"Connection Between a Power Source andOptional DeviceNet PLC Controller").
Connections Between a Power Source and LocalPC (RS-232 – Null Modem Cable). For diagnosticand set up purposes it is sometimes necessary toconnect the power source directly to a PC (personalcomputer). The Power Wave AC/DC 1000 is equippedwith an RS-232 DB-25 style serial connector for thispurpose. It is located under the spring loaded outputcover on the case front. RS-232 cables must be sup-plied by the user (Radio Shack part # 26-269; Note:USB port adapter - part #26-183 - is also required forPCʼs equipped with USB instead of a serial port). Forbest results, route the RS-232 cable away from weldcables, wire drive control cables, or any other currentcarrying device that can create a fluctuating magneticfield.
A-21INSTALLATION
POWER WAVE® AC/DC 1000
A-21
EXTERNAL I/O CONNECTOR
The Power Wave AC/DC 1000 is equipped with a ter-minal strip for making simple input signal connections.(See Figure A.2a) The terminal strip is located under-neath the spring-loaded cover, and divided into threegroups:
FIGURE A.2a
Trigger group, Cold Inch Group and Shutdown Group.When the Power Wave AC/DC 1000 is controlled viaDeviceNet, the Trigger and Cold Inch Groups caninterfere with the welding sequence and should not beused.
All inputs use "normally open" logic except the shut-down group. The shutdown inputs use "normallyclosed" logic, and are always enabled. Shutdown2 istypically used for signaling low flow in the water cool-er. Unused shutdowns must be tied to the +15V sup-ply for the shutdown group. Machines are shippedfrom the factory with jumpers installed on both shut-down inputs. (See Figure A.3)
Notes:1. Activating the Trigger or Cold Inch group inputs on
a system without a user interface or other meansof configuring the Weld Sequencer will result indefault values for Weld Mode, WFS and Workpoint settings.
2. Trigger and Cold Inch group inputs may be rede-fined as "Weld Profile Selections" by ProductionMonitoring software (see Production MonitoringLiterature for details)
3. On later machines, pin 12 has been redefined as agear ratio selection input. See “Setting the WireDrive Gear Ratio” for further information.
Pin FunctionA Motor "+"B Motor "-"C +40 VDC for solenoidD Solenoid inputE Tach 2A differential signal F Single Tach InputG +15 VDC TachH Tach commonI Work voltage sense lead 21J Electrode voltage sense lead 67K Tach 1A differential signalL Tach 1B differential signalM Tach 2B differential signalN Electrode voltage sense lead 67
PIN Lead # Function1 851 +15vdc for Trigger group2 852 Trigger input3 853 Dual procedure input4 854 4 step input (Disabled as of S25564-19)5 855 +15vdc for cold inch group (Disabled as of S25564-19)6 856 cold inch forward7 857 cold inch reverse8 858 gas purge input9 859 +15vdc for shutdown group10 860 shutdown1 input11 861 shutdown2 input12 862 input B
A Reserved for future use Reserved for future use ---B Reserved for future use Reserved for future use ---C Sync In Reserved for future use Sync OutD Sync In Reserved for future use Sync OutE Ready In Ready In ---F Ready In Ready In ---G Polarity Out Polarity Out ---H Polarity Out Polarity Out --- I Ground --- ---J Reserved for future use Reserved for future use ---K Reserved for future use Reserved for future use ---L +40v (COM) Reserved for future use ---M +40v ("+") Reserved for future use ---N Reserved for future use Reserved for future use ---P Reserved for future use Reserved for future use ---R Reserved for future use Reserved for future use ---S Reserved for future use Reserved for future use ---T Drain (ethernet) Drain (ethernet) ---U Kill Out Kill Out ---V Kill Out Kill Out ---W Work voltage sensing (21) Work voltage sensing (21) ---X Electrode Voltage Sensing (67) Electrode Voltage Sensing (67) ---
A-23INSTALLATION
POWER WAVE® AC/DC 1000
A-23
WIRE DRIVE GEAR RATIO SETTINGChanging the wirefeeder gear ratio requires a gearchange in the wire drive, and a configuration changeat the power source. The Power Wave AC/DC 1000can be configured to support up to 4 unique gearratios. The gear ratio configuration is selected via aDIP switch on the Feed Head PC Board and a jumperon the External I/O connector (S7 - located beneaththe spring loaded output cover on the top, front of themachine).
As shipped from the factory, the low speed (hightorque) gear is installed. To change the gear ratio ofthe feeder, see the Wirefeeder Instruction Manual. Toachieve the correct speed, the power source mustalso be configured for the actual gear ratio installed inthe wire drive per the instructions below:
ELECTRIC SHOCK can kill.• Do not touch electrically live parts
1. Turn off power to the power source at the dis-connect switch. All configuration changes mustbe made with the power OFF.
2. Access the Feed Head board and External I/O con-nector to configure the power source per tableA.9a.
3. Replace the cover and screws as required. TheFeed Head PC board will "read" the new configura-tion at power up, and automatically adjust all controlparameters for the speed range selected.
WARNING
WARNING
S1S1
FEFEEDHEDHEADP.P.C. BOA BOARD
EXEXTERNAL I/OAL I/OCONNECTORCTOR
FIGURE A.3a
ETHERNET CONFIGURATION
Ethernet capability is provided for data monitoring, orto enable parallel machine operation. To utilize thesefeatures the network settings of each Power WaveAC/DC 1000 must be properly configured. This isaccomplished through the use of the Weld Managersoftware utility. Follow the instructions provided withthe utility to properly configure the Ethernet address.
When used in a system with parallel machines, theSubmerged Arc Cell Configuration software utilitymust be used to map the master/slave relationshipswithin and between the different arc groups. This utili-ty allows the user to configure the system by selectingfrom a list of master and slave machines (as deter-mined by their individual dip switch settings).
NOTE: Each machine must be configured as either aMaster or Slave via the dip switches on theEthernet PC Board. Furthermore, Mastermachines must be configured for either inter-nal synchronization (stand alone applica-tions), or external synchronization (multiplearc applications util izing a Power WaveSystem Interface). See the "Internal Controls"section of this document.
Ratio
142:195:157:1*
Reserved*(Presently57:1)
Dip Switch #8(Feed Head PCB - Bank S1)
OFFONOFF
ON
External I/O Jumper(Pin 5 to Pin 12)
NONOYES
YES
* These Gear Ratios options are enabled in S25564-11 and later Feed Head software.
TABLE A.9a
123456789101112
JUMPER PIN 5JUMPER PIN 12
A-24INSTALLATION
POWER WAVE® AC/DC 1000
A-24
ELECTRIC SHOCK can kill.
• Do not touch electrically live partsor electrodes with your skin or wetclothing.
2. Remove the screws securing the front accesspanel.
3. Open the access panel, allowing the weight of thepanel to be carried by the hinge tab at the bottom.Make sure the weight of the access panel is sup-ported by the hinge tabs, not the wiring harness.
4. Adjust the DIP switches as necessary (see infor-mation below).
5. Replace the panel and screws, and restore power.
CONTROL P.C. BOARD
S1
S1
ETHERNETP.C. BOARD
S1S2
S4 S3FEEDHEADP.C. BOARD
FIGURE A.4
DEVICENET CONFIGURATION
For systems controlled via DeviceNet, The MAC IDand baud rate must be properly configured (see theInternal Controls section of this document). Otherinformation regarding basic system integration of thePower Wave AC/DC 1000 with a DeviceNet PLC isprovided in the DeviceNet Interface Specification (partof the Power Wave Submerged Arc Utilities softwarepackage available on CD from the Lincoln Electric
The P.C. Boards located behind the Power WaveAC/DC 1000 front access panel are equipped withDIP switches for custom configuration. To access theDIP switches:
WARNING
Switch Description1 Object Instance LSB* (see table A.14)2 Object Instance MSB** (see table A.14)3 Equipment Group 1 Select (default OFF)4 Equipment Group 2 Select (default OFF)5 Equipment Group 3 Select (default OFF)6 Equipment Group 4 Select (default OFF)
Arclink Object Auto mapping enabled (default)Arclink Object Auto mapping disabledWork sense lead not connectedWork sense lead connected (default)
Comments
Arclink configuration
Default settingRequires manual configurationUsed for configuring work sense lead ( See section A )
Comments
ArcLink Configuration
Must be OFF for Power Wave AC/DC 1000Gear ratio configuration.
These two options available in S25564-11 and later software.
Comments
Used for ArclinkConfiguration
Comments
Used for DeviceNetConfiguration
CONTROL BOARD DIP SWITCH (S1):
FEED HEAD BOARD DIP SWITCH (S1):
ETHERNET BOARD DIP SWITCHES (S1, S2):
A-25INSTALLATION
POWER WAVE® AC/DC 1000
A-25
7
8
1 2 3 4 5 6 7 8ON
{
OBJECT INSTANCE
(*DEFAULT SETTINGS SHOWN)
GROUP SELECT
AUTO MAP
WORK VOLTAGESENSE ENABLE
1 2 3 4 5 6 7 8ON
{
OBJECT INSTANCE
GROUP SELECT
ELECTRODE POLARITY
SPEED RANGE
(*DEFAULT SETTINGS SHOWN)
1 2 3 4 5 6 7 8ON
{ {
OBJECT INSTANCE
GROUP SELECT
RESERVED
(*DEFAULT SETTINGS SHOWN)
1 2 3 4 5 6 7 8ON
{
BAUD RATE (125K)
DEVICENET MAC ID (62)
(*DEFAULT SETTINGS SHOWN)
*LSB - Least Significant Bit**MSB - Most Significant Bit
Switch Description1 Object Instance LSB (see table A.14)2 Object Instance MSB (see table A.14)3 Equipment Group 1 Select (default OFF)4 Equipment Group 2 Select (default OFF)5 Equipment Group 3 Select (default OFF)6 Equipment Group 4 Select (default OFF)
Switch Description1 Object Instance LSB (see table A.14)2 Object Instance MSB (see table A.14)3 Equipment Group 1 Select (default OFF)4 Equipment Group 2 Select (default OFF)5 Equipment Group 3 Select (default OFF)6 Equipment Group 4 Select (default OFF)7 Reserved for future use (default OFF)8 Reserved for future use (default OFF)
DescriptionDeviceNet Baud Ratesee Table A.15
DeviceNet Mac IDsee Table A.16
Switch12345678
7
8
offonoff1
on1
off2on2
offonoffon
TABLE A.10
TABLE A.11
TABLE A.12
TABLE A.13
BANK S1
BANK S1
Bank S1 – ArcLink Set-up
Bank S2 – DeviceNet Set-up
Notes: 1. No jumper installed on External I/O connector (pin 5 to pin 12).2. Jumper installed on External I/O connector (pin 5 to pin 12).
}
A-26INSTALLATION
POWER WAVE® AC/DC 1000
A-26
TABLE A.14
OBJECT INSTANCEswitch 2 switch 1 Instance
off off 0(default) off on 1on off 2on on 3
TABLE A.15
Switch 1 Switch 2 Baud Rateoff off 125K (default)on off 250Koff on 500Kon on Programmable value.
Read this entire section of operating instructionsbefore operating the machine.
ELECTRIC SHOCK can kill.
• Unless using cold feed feature, whenfeeding with gun trigger, the elec-trode and drive mechanism arealways electrically energized andcould remain energized several sec-onds after the welding ceases.
• Do not touch electrically live parts or electrodeswith your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can bedangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes frombreathing zone.
WELDING SPARKS can causefire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com-bustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional guidelines detailed in thebeginning of this manual.
WARNING
DEFINITIONS OF WELDING MODES
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all weldingprocess variables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity ofsingle knob control. The machine will select the cor-rect voltage and amperage based on the wire feedspeed (WFS) set by the operator.
COMMON WELDING ABBREVIATIONS
SAW • Submerged Arc Welding
B-2OPERATION
POWER WAVE® AC/DC 1000
B-2
INPUT POWER
ON
OFF
HIGH TEMPERATURE
MACHINE STATUS
CIRCUIT BREAKER
WIRE FEEDER
POSITIVE OUTPUT
NEGATIVE OUTPUT
3 PHASE INVERTER
INPUT POWER
THREE PHASE
DIRECT CURRENT
OPEN CIRCUIT VOLTAGE
INPUT VOLTAGE
OUTPUT VOLTAGE
INPUT CURRENT
OUTPUT CURRENT
PROTECTIVEGROUND
WARNING or CAUTION
Explosion
Dangerous Voltage
Shock Hazard
GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL
U0
U1
U2
I1
I2
B-3OPERATIONB-3
POWER WAVE® AC/DC 1000
PRODUCT SUMMARY
The Power Wave AC/DC 1000 is a high performance,digitally controlled inverter welding power source. It iscapable of producing a variable frequency and ampli-tude AC output, DC positive output, or DC negativeoutput without the need for external reconnection. Itutilizes complex, high-speed waveform control to sup-port a variety of constant current and constant voltagewelding modes in each of its output configurations.
The Power Wave AC/DC 1000 power source isdesigned 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 arcapplications the phase angle and frequency of differ-ent machines can be synchronized with the use of anexternal System Interface to improve performanceand reduce the effects of arc blow.
The Power Wave AC/DC 1000 is primarily designed tointerface with compatible ArcLink equipment.However, it can also communicate with other industri-al machines and monitoring equipment via DeviceNet,or Ethernet. The result is a highly integrated and flexi-ble welding cell.
RECOMMENDED PROCESSES
The Power Wave AC/DC 1000 is designed for sub-merged arc welding (SAW). Due to its modular designthe Power Wave AC/DC can operate on either singlearc or multiple arc applications. Each machine is fac-tory preprogrammed with multiple welding proceduresto support all types of submerged arc welding. ThePower Wave AC/DC 1000 carries an output rating of1000 amps, 44 volts (at 100% duty cycle). If highercurrents are required machines can be easily paral-leled.
PROCESS LIMITATIONS
The Power Wave AC/DC 1000 is suitable only for theprocesses listed.
Do not use Power Wave AC/DC 1000 for pipe thaw-ing.
EQUIPMENT LIMITATIONS
The Power Wave AC/DC 1000 is not to be used inoutdoor environments.
Operating Temperature Range is 32°F to 104°F(0°Cto +40°C).
Only the ArcLink Power Feed 10S series wire feedersand Power Feed 10A controller may be used in astandard system. Other Lincoln or non-Lincoln wirefeeders can only be used with custom interfaces.The Power Wave AC/DC will support a maximumaverage output current of 1000 Amps at 100% DutyCycle.
COMMON EQUIPMENT PACKAGES
Basic Package
K2344-1 or Power Wave AC/DC 1000K2344-2
K2370-1 Power Feed 10S Head Wire Feeder
K2362-1 Power Feed 10A Controller / UserInterface
K1543-xx Control Cable (5 pin – 5 pin) - powersource to controller.
K1785-xx Control Cable (14 pin – 14 pin) -power source to wire feeder.
Optional kits
K2282-1 System Interface - for Synchronizingmultiple arc applications.
K2312-1 Power Feed 10SF wire feeder (for fix-ture builders).
K2311-1 Power Feed 10SM Motor ConversionKit (to convert existing NA-3/NA-4/NA-5wire feeder gear boxes).
K2444-1 CE, C-Tick Filter Kit
RECOMMENDED EQUIPMENT(See Installation Section)
(See Figure B.5)
4. 10 Amp Wire Feeder Circuit Breaker: Protects 40volt DC wire feeder power supply.
5. 115 VAC Auxiliary Power Circuit Breaker:Protects case front receptacle auxiliary supply. (10amps)
6. 21 Work Sense Lead Connector(4-Pin)
7. Arclink Connector (5-Pin)
8. DeviceNet Connector (5-Pin)
9. Work Output Studs
10. Electrode Output Studs
11. Auxiliary Output
12. Ethernet Connector (RJ-45)
13. Wire Feeder Connection (14-Pin)-Connects thecontrol cable between the power source and wirefeeder.
14. External Input Connector
15. Serial Communication (RS-232)
B-4OPERATIONB-4
CASE FRONT CONTROL DESCRIPTIONS
(See Figure B.4)
1. Power Switch: Controls input power to the PowerWave
2. Status Lights: A two color light that indicates sys-tem errors. Normal operation is a steady greenlight. Error condit ions are indicated in theTroubleshooting Section.
NOTE: The robotic PowerWavesʼ status light willflash green, for up to 15 seconds when themachine is first turned on. This is a normal sit-uation as the machine goes through a selftest at power up.
3. Thermal Fault Light : A yellow light that comes onwhen an over temperature situation occurs. Output isdisabled until the machine cools down. When cool,the light goes out and output is enabled.
FIGURE B.4
POWER WAVE® AC/DC 1000
2
3
1
B-5OPERATIONB-5
POWER WAVE® AC/DC 1000
8
12
7
11
9
10
4
5
13
14
615
FIGURE B.5
B-6OPERATIONB-6
9. AC Switch Assembly W/Impeller Fan
10. Optional CE Filter Assembly (not shown): CEcompliance filter connects in series with input con-nection. Available for K2344-2 only.
POWER-UP SEQUENCE
When power is applied to the Power Wave AC/DC1000, the status lights will flash green, for up to 15seconds. This is normal and indicates Power WaveAC/DC 1000 is performing a self test, and mapping(identifying) each component in the local ArcLink sys-tem. The status lights will also flash green as a resultof a system reset or configuration change during oper-ation. When the status lights become steady greenthe system is ready for normal operation.
If the status lights do not become steady green con-sult the troubleshooting section of this manual for fur-ther instruction.
POWER WAVE® AC/DC 1000
1
2
9
8
34
5
7
6
FIGURE B.6
CASE REAR COMPONENTS DESCRIPTION (See Figure B.6)
1. Input Contactor: Connection point for incoming 3Phase power (see "Recommended Input Wire andFuse Size" chart in this document).
2. Case Ground: The frame of the welder must begrounded to earth at this terminal. See your localand national electrical codes for proper groundingmethods.
3. Auxiliary Reconnect: Select proper tap based oninput voltage.
4. CB3: Primary side protection for auxiliary trans-former (T2).
5. CB4: Primary side protection for auxiliary trans-former (T1).
6. Impeller Fan Technology TM provides superiorcooling.
The Power Wave AC/DC is capable of welding at a100% duty cycle (continuous welding).
COMMON WELDING PROCEDURES
MAKING A WELD
The serviceability of a product or structure utiliz-ing the welding programs is and must be the soleresponsibility of the builder/user. Many variablesbeyond the control of The Lincoln ElectricCompany affect the results obtained in applyingthese programs. These variables include, but arenot limited to, welding procedure, plate chemistryand temperature, weldment design, fabricationmethods and service requirements. The availablerange of a welding program may not be suitablefor all applications, and the build/user is and mustbe solely responsible for welding program selec-tion.
The steps for operating the Power Wave AC/DC 1000will vary depending upon the user interface of thewelding system. The flexibility of the Power WaveAC/DC 1000 lets the user customize operation for thebest performance.
First, consider the desired welding procedures andthe part to be welded. Choose an electrode material,diameter, and flux.
Second, find the program in the welding software thatbest matches the desired welding process. The stan-dard software shipped with the Power Wave AC/DC1000 encompasses a wide range of common process-es and will meet most needs. If a special welding pro-gram is desired, contact the local Lincoln Electricsales representative.
To make a weld, the Power Wave AC/DC 1000 needsto know the desired welding parameters. WaveformControl Technology ™ allows full customization ofStrike, Run-in, Crater and other parameters for exact-ing performance.
OVERVIEW OF THE AC/DC SUBMERGEDARC PROCESS
The Power Wave AC/DC 1000 combines the advan-tages of AC and DC Submerged Arc Welding (SAW)into a single power source. The limiting factor of AC-SAW welding has always been the time it takes totransition from positive to negative polarity. This lagthrough the zero crossing can cause arc instability,penetration, and deposition problems in certain appli-cations. The Power Wave AC/DC 1000 utilizes thespeed of an inverter based power source, and theflexibility of Waveform Control Technology™ toaddress this issue. By adjusting the Frequency, WaveBalance and Offset of the AC waveform the operatorcan now control the balance (relationship) betweenthe penetration of DC positive and the deposition ofDC negative while taking full advantage of the reduc-tion in arc blow associated with AC.
FIGURE B.1
POWER WAVE® AC/DC 1000
TimePositive
Current
NegativeCurrent
Cur
rent
Output waveform variations made possible by Waveform Control Technology
Depending on the process, different parts of the output waveform and wire feedspeed may be modulated at varying rates to achieve a smooth and stable arc.
AC/DC Submerged Arc Process
TM
Frequency
Pulse Width
Transition Ratedi/dT
B-8OPERATIONB-8
MULTIPLE ARC SYSTEMCONSIDERATIONS
Large scale SAW applications often employ multiplearcs to increase deposition rates. In multiple arc sys-tems, magnetic forces created by like and opposingweld currents of adjacent arcs can result in arc inter-action that can physically push or pull the arc columnstogether. To counteract this effect, the phase relation-ship between adjacent arcs can be adjusted to alter-nate and equalize the duration of magnetic push andpull forces. This is accomplished by the use of anoptional K2282-1 Power Wave System Interface,which not only synchronizes the arcs, but alsoenables adjustment of the phase relationship betweenthem. Ideally, the net result is a cancellation of theinteracting forces.
FIGURE B.2
FIGURE B.3
Never simultaneously touch electrically "hot"parts in the electrode circuits of two differentwelders. The electrode to electrode no load volt-age of multiple arc systems with opposite polari-ties can be double the no load voltage of each arc.Consult the Safety information located at the frontof the Instruction Manual for additional informa-tion.------------------------------------------------------------------------
BASIC MODES OF OPERATION
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.
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.
POWER WAVE® AC/DC 1000
+ -- +
PUSH
+ +- -
PULL
+ -- ++ -+
PUSH
+ +- -
PULLPUSH
+ +- -+ +-+ +- -
PULL
Lead Arc
Trai l Arc
Pos
itive
Neg
ativ
e
Posi
tive
Posi
tive
Neg
ativ
eN
egat
ive
Pos
itive
Neg
ativ
e
Pos
itive
Neg
ativ
e
Lead Arc
Trai l Arc
PU
SH
PU
SH
PU
SH
PU
LL
PU
LL
CAUTION
ExtensionHeating= Vir
Arc Length= Varc
Total ElectricalStick outV= Vir+Varc
TO
MAINTAIN CONSTANT ARC LENGTH
AND
WIRE FEED SPEED VARIED
CURRENT HELDCONSTANT
AMPS
CONSTANT CURRENT (CC)
WIRE FEED SPEED
ExtensionHeating= Vir
Arc Length= Varc
Total ElectricalStick outV= Vir+Varc
TO
MAINTAIN CONSTANTARC LENGTH
AND
WIRE FEED SPEEDHELD CONSTANT
CURRENT VARIED
AMPS
CONSTANT VOLTAGE (CV)
WIRE FEED SPEED
B-9OPERATIONB-9
WELD SEQUENCE:
The weld sequence defines the weld procedure frombeginning to end. The Power Wave AC/DC 1000 notonly provides adjustment of basic welding parameters,but also allows the operator to fine tune the start andfinish of each weld for superior performance.
All adjustments are made through the user interface.Because of the different configuration options, yoursystem may not have all of the following adjustments.Regardless of availability, all controls are describedbelow.
START OPTIONS
The Strike, Start, and Upslope parameters are used atthe beginning of the weld sequence to establish a sta-ble arc and provide a smooth transition to the weldingparameters.
• Strike settings are valid from the beginning of thesequence (Trigger) until the arc is established. Theycontrol Run-in (speed at which the wire approachesthe workpiece), and provide the power to establishthe arc.
- Typically output levels are increased andWFS is reduced during the Strike portion ofthe weld sequence
• Start values allow the arc to become stabilized onceit is established.
- Extended Start times or improperly set para-meters can result poor starting
• Upslope determines the amount of time it takes toramp from the Start parameters to the Weld para-meters. The transition is linear and may be up ordown depending on the relationship between theStart and Weld settings.
END OPTIONS
The Downslope, Crater, and Burnback parametersare used to define the end of the weld sequence.
• Downslope determines the amount of time it takesto ramp from the Weld parameters to the Craterparameters. The transition is linear and may be upor down depending on the relationship between theWeld and Crater settings.
• Crater parameters are typically used to fill the craterat the end of the weld, and include both time andoutput settings.
• Burnback defines the amount of time the outputremains on after the wire has stopped. This featureis used to prevent the wire from sticking in the weldpuddle, and condition the end of the wire for thenext weld. A Burnback time of 0.4 sec is sufficient inmost applications. The output level for Burnback isgenerally set to the same level as the last activeweld sequence state (either Weld or Crater).
RE-STRIKE TIMER
If the arc goes out for any reason (short circuit or opencircuit), the Power Wave AC/DC 1000 will enter a Re-strike state. During this state the system will automati-cally manipulate the WFS and output in an attempt tore-establish the arc. The Re-strike timer determineshow long the system will attempt to re-establish thearc before it shuts down.
• Used to protect the welding system and/or workpiece being welded.
• A Re-strike time of 1 to 2 sec is sufficient in mostapplications.
POWER WAVE® AC/DC 1000
Time
Out
put
Weld Sequence adjustments made possible by Wavefor m Control Technology
Weld sequence adjustments allow the operator to fine tune the start and finishof each weld for superior performance.
Weld SequenceTM
Start(Strike)
Upslope Weld Crater(Burnback)
Downslope
B-10OPERATIONB-10
WELD PROCESS ADJUSTMENTS
Depending on the weld mode, there are a number ofadjustments that can be made, including but not limit-ed to Current, Voltage and WFS. These adjustmentsapply to either AC or DC processes, and control thebasic parameters of the weld.
AC ADJUSTMENTS
In addition to the basic weld parameters, there are anumber of unique adjustments related to the ACwaveform of the Power Wave AC/DC 1000. Theseadjustments enable the operator to balance the rela-tionship between penetration and deposition to tailorthe output for specific applications.
WAVE BALANCE
• Refers to amount of time the waveform spends inDC+ portion of the cycle.
• Use Wave Balance to control the penetration anddeposition of a given process.
DC OFFSET
• Refers to +/- shift of the current waveform withrespect to the zero crossing.
• Use Offset to control the penetration and depositionof a given process.
FREQUENCY
• POWER WAVE AC/DC 1000 can produce OutputFrequencies from 10 - 100Hz
• Use Frequency to fine tune stability• Higher frequencies in multiple arc setups can help
1000 Use Frequency to fin e tune stability ofimbalanced waveform s and multipl e arc syst ems
Frequency
IncreaseDecrease
500
-500
0
-1000
1000
Nominal Offset
Positive OffsetMore PenetrationLess Deposition
Negative OffsetLess PenetrationMore Deposition
DC Offset
B-11OPERATIONB-11
MULTIPLE ARC AC ADJUSTMENTS FORSYSTEMS EQUIPPED WITH K2282-1SYSTEM INTERFACE
PhaseThe phase relationship between the arcs helps tominimize the magnetic interaction between adjacentarcs. It is essentially a time offset between the wave-forms of different arcs, and is set in terms of an anglefrom 0 to 360°, representing no offset to a full periodoffset. The offset of each arc is set independentlywith 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.
ARC 1 ARC2 ARC3 ARC 42 Arc System 0° 90° X X3 Arc System 0° 90° 180° X4 Arc System 0° 90° 180° 270°
• For unbalanced waveforms:– Avoid switching at same time– Break up long periods of unchanged polarity
relative to adjacent arcs
POWER WAVE® AC/DC 1000
Phase Relationship
500
-500
0
Use Phase Relation ship to minimize arc blowin multip le arc systems. (Balanced two arc system shown)
0°(PULL)
90°(PUSH/PULL)
180°(PUSH)
BAD GOOD BAD
ARC 1ARC 2
Best results obtained by alternating and equalizing the duration ofmagnetic forces between adjacent arcs.
C-1ACCESSORIESC-1
KITS, OPTIONS AND ACCESSORIES
OPTIONAL KITS AND ACCESSORIES
K2282-1 Power Wave System Interface
The optional Power Wave System Interface providesthe means to synchronize the AC wave shapes of upto four different arcs to a common carrier frequency.This frequency can range from 10 hertz to 300 hertz,with the most practical range being 10 to 100 hertz. Itcan also control the phase relationship between arcsto reduce the effects of welding related issues such as"Arc Blow".
K2444-1 CE – C-Tick Filter Kit
This external filter kit is available for the K2344-2Power Wave AC/DC 1000, and mounts directly to thereconnect area on the rear of the machine. The filter isnecessary to meet CE conducted emission require-ments.
SOFTWARE TOOLS
The Power Wave AC/DC 1000 is shipped with a CD including software tools and other documents related to theintegration, configuration, and operation of the system. The Power Wave Submerged Arc Utilities CD includesthe following items and all of the documentation to support them.
POWER WAVE® AC/DC 1000
Name Purpose
Weld Manager Setup Ethernet address information, and apply security settings.
Command Center AC/DC system tool to observe and log welding operation, verify DeviceNet welding configuration, and facilitate quality analysis.
Submerged Arc Cell Configuration Used to configure and verify a multi-arc or parallel connected powersource (more than one Power Wave per arc) systems.
Production Monitoring Allows user to setup Production Monitoring options on the Power Waveincluding Email notification, Shift Timers, Wire Package Tracking. Alsoprovides means to retrieve statistical welding data, generate machinereports, and update the Power Wave Firmware and Welding Software.
Diagnostics Utility Utility to diagnose Power Wave problems, read system information, cali-brate output voltage and current, test sense leads, and diagnose feedhead issues. Can also setup and verify DeviceNet operation.
Weld Manager Palm based utility used to configure, backup and restore various PowerFeed 10A Controller settings (can be used to copy settings from onePF-10A to another). Also provides means to retrieve version informationand setup Ethernet address of the local Power Wave system (only thosecomponents directly connected to the PF-10A via ArcLink).
(Palm Application)
D-1MAINTENANCED-1
POWER WAVE® AC/DC 1000
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only Qualified personnel shouldperform this maintenance.
• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on this equip-ment.
ROUTINE MAINTENANCE Routine maintenance consists of periodicallyblowing out the machine, using a low-pressureairstream, to remove accumulated dust and dirtfrom the intake and outlet louvers, and the cool-ing channels in the machine.
PERIODIC MAINTENANCECalibration of the Power Wave AC/DC 1000 iscritical to its operation. Generally speaking thecalibration will not need adjustment. However,neglected or improperly calibrated machines maynot yield satisfactory weld performance. Toensure optimal performance, the calibration ofoutput Voltage and Current should be checkedyearly.
CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at thefactory. Generally speaking the machine calibrationwill not need adjustment. However, if the weld per-formance changes, or the yearly calibration checkreveals a problem, use the calibration section ofthe Diagnostics Utility to make the appropriateadjustments.
The calibration procedure itself requires the use ofa grid (Resistive Load Bank), and certified actualmeters for voltage and current. The accuracy of thecalibration will be directly affected by the accuracyof the measuring equipment you use. TheDiagnostics Utility includes detailed instructions,and is available on the Power Wave Submerged
WARNING
E-1TROUBLESHOOTINGE-1
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.
Input fuses keep blowing.
Machine will not power up (nolights)
1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.
1. Improperly sized input fuses.
2. Improper Weld Procedurerequiring output levels inexcess of machine rating.
3. Major physical or electricaldamage is evident when thesheet metal covers areremoved.
1. No Input Power.
2. Circuit breaker CB4 (in recon-nect area) may have tripped.Power Down and Reset CB4.
3. Input voltage selection madeimproperly.
1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.
1. Make sure fuses are properlysized. See Installation sectionof this manual for recom-mended sizes.
2. Reduce output current, dutycycle, or both.
3. Contact an authorized LincolnElectric Service facility.
1. Make sure input supply dis-connect has been turned ON.Check input fuses. Make cer-tain that the Power Switch(SW1) on the power source isin the "ON" position.
2. Power Down and Reset CB4.
3. Power down, check input volt-age reconnect according todiagram on reconnect cover.(Qualified person shouldperform this operation)
E-3TROUBLESHOOTINGE-3
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
OUTPUT PROBLEMSMachine wonʼt weld, canʼt get any
output. (CR1 will not pull in.)
This problem will normally beaccompanied by an error code.Error codes are displayed as aseries of red and green flashes bythe status light(s). See "StatusLight" section of this document foradditional information.
Thermal LED is on.
1. Input voltage is too low or toohigh.
2. Thermal Error.
3. Primary current limit has beenexceeded. (CR1 drops out whenoutput is initiated).
4. Inverter Fault - switch pc board,contactor problem, etc.
1. Improper fan operation.
2. Switch Board or AC OutputChopper board thermostat.
3. DC Bus PC board thermostat
4. Open thermostat circuit.
1. Make certain that input voltage isproper, according to the RatingPlate located on the rear of themachine.
2. See "Thermal LED is ON" sec-tion.
3. Possible short in output circuit.Turn machine off. Remove allloads from the output of themachine. Turn back on, and acti-vate output. If condition persists,turn power off, and contact anauthorized Lincoln Electric FieldService facility.
4. Contact your local authorizedLincoln Electric Field Servicefacility for technical assistance.
1. Check for proper fan operation.(Fans should run whenever out-put power is on.) Check formaterial blocking intake orexhaust louvers, or for excessivedirt clogging cooing channels inmachine.
2. After machine has cooled,reduce load, duty cycle, or both.Check for material blockingintake or exhaust louvers.
3. Check for excessive load on40VDC supply.
4. Check for broken wires, openconnections or faulty ther-mostats DC Bus, Switch, and ACChopper PC Board heat sinks.
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
E-4TROUBLESHOOTINGE-4
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Auxiliary receptacle is “dead”.
General degradation of weld per-formance
Wire burns back to tip when the arcis initiated.
Wire burns back to tip at the end ofthe weld.
1. Circuit breaker CB2 (on casefront) may have tripped.
2. Circuit breaker CB3 or CB4 (inreconnect area) may havetripped.
1. Wire feed problem.
2. Cabling problems.
3. Verify weld mode is correct forprocess.
4. Machine calibration.
1. Voltage sense lead problem.
2. Wire feed problem.
1. Burnback Time
1. Power down and reset CB2.
2. Power down and reset CB3 orCB4.
1. Check for feeding problems.Make sure proper gear ratiohas been selected.
2. Check for bad connections,excessive loops in cable, etc.
NOTE: The presence of heat inthe external welding circuitindicates poor connectionsor undersized cables.
3. Select the correct weld modefor the application.
4. The power source mayrequire calibration. (current,voltage, WFS).
1. Check sense lead connec-tions. Check DIP switch set-tings for sense lead configura-tion and arc polarity. Makesure Electrode and Work con-nections are not reversed.
2. Check for feeding problems.Make sure proper gear ratiohas been selected.
1. Reduce burnback time and/orwork point.
WELD AND ARC QUALITY PROBLEMS
OUTPUT PROBLEMS
E-5TROUBLESHOOTINGE-5
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Cannot weld AC.
Machine output shuts down during aweld.
Machine wonʼt produce full output.
Excessively long and erratic arc.
1. Improper Ethernet I/OConfiguration.
2. AC Switch Problem.
1. Secondary current limit has beenexceeded, and the machineshuts down to protect itself.
2. Single phase input (loss of L2).
3. Re-strike Time exceeded.
1. Input voltage may be too low,limiting output capability of thepower source.
2. Machine calibration.
1. Voltage sensing problem.
2. Machine calibration.
1. Verify Ethernet board DIP Switchsettings.
2. If major physical or electricaldamage is evident when thesheet metal cover is removedfrom the AC Switch (lower sec-tion of the machine).Contact yourlocal authorized Lincoln ElectricField Service facility for technicalassistance.
1. Adjust procedure or reduce loadto lower current draw from themachine.
2. Single phase input (loss of L2). Asingle phase input (loss of L2)will reduce the secondary currentlimit and cause secondary overcurrent shutdown at lower outputlevels. Check the input fuses andsupply lines.
3. Adjust the process parameters toavoid excessive arc loss time orincrease the re-strike time.
1. Make certain that the input volt-age is proper, according to theRating Plate located on the rearof the machine.
2. Calibrate secondary current andvoltage.
1. Check for proper configurationand implementation of voltagesensing circuits.
2. Calibrate secondary current andvoltage.
WELD AND ARC QUALITY PROBLEMS
E-6TROUBLESHOOTINGE-6
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Device does not go on Line.
Device goes off line during welding
1. 24v bus power.
2. Baud rate.
3. MAC ID.
4. Termination.
5. Wiring.
6. EDS Files.
1. Interference / Noise.
2. Termination.
3. Shielding.
1. Verify that LED 2 is on when theDeviceNet network is powered.This can be done with the PowerWave turned on or off.
2. Verify the baud rate setting is thesame as the DeviceNet Master.The baud rate is set via dipswitch on the Ethernet PC Board.The current value of the baudrate setting can be viewed on theDeviceNet tab of theDiagnostics Utility.
3. Verify the DeviceNet MAC ID iscorrect. The Mac ID is set via dipswitch on the Ethernet PC Board.The current value of the MAC IDcan be viewed on the DeviceNettab of the Diagnostics Utility.
4. Verify that the DeviceNet bus is ter-minated correctly.
5. Verify the wiring of all multi-port tapsand field attachable ends.
6. (Electronic Data Sheet Files) Verifythat the correct EDS files are beingused if they are needed. TheDeviceNet tab of the DiagnosticsUtility displays the current ProductCode and Vendor Revision of thePower Wave.
1. Verify that DeviceNet cables are notrunning next to (in close proximitywith) current carrying conductors.This includes the welding cables,input cables, etc.
2. Verify that the DeviceNet bus is ter-minated correctly.
3. Verify that the cable shielding is cor-rectly grounded at the bus powersupply. The shield should be tiedinto the bus ground at only one point.
DEVICENET-PLC CONTROLLED SYSTEM
E-7TROUBLESHOOTINGE-7
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Output will not come on.
4. Power Supply.
5. Expected Packet Rate.
1. DeviceNet trigger not asserted.
2. Touch Sense command.
3. Passive Mode.
4. Welding Cables.
5. Output Disabled.
6. Other modules faulted.
4. Verify that the DeviceNet bus powersupply can supply sufficient currentfor the devices on the network.
5. Verify that 1000/(Expected PacketRate) ≤ (scans per second). TheDeviceNet tab of the DiagnosticsUtility displays these values.
1. From the DeviceNet tab of theDiagnostics Utility, select Monitor.The Monitor window wil l be dis-played. Verify under the "ProducedAssembly" that "Trigger" is highlight-ed.
2. From the DeviceNet tab of theDiagnostics Utility, select Monitor.The Monitor window wil l be dis-played. Verify under the "ProducedAssembly" that "Touch Sense" isNOT highlighted.
3. The DeviceNet tab of theDiagnostics Utility displays thePower Waveʼs passive mode status.If the status needs to be changed,select Configure, and make the nec-essary modification.
4. Verify that welding cables are con-nected properly.
5. From the DeviceNet tab of theDiagnostics Utility, select Monitor.The Monitor window wil l be dis-played. Verify under the "ProducedAssembly" that "Disable Output" isNOT highlighted.
6. Verify no other modules are faulted(all system Status Lights should besteady green). Use DiagnosticsUtility to display any current faults inthe system.
DEVICENET-PLC CONTROLLED SYSTEM
E-8TROUBLESHOOTINGE-8
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
Bad Weld Starting 1. Wire Feed problem.
2. Strike Wire Feed Speed.
3. Incorrect Weld Schedule.
4. Voltage Sense Leads.
5. Analog Scans Between Updates.
6. Analog Hysteresis.
7. Limit Error.
8. Fan Out.
9. Gas.
1. Verify Feeders drive roll tensionis not too low allowing the wire toslip in the rolls. Verify wire can bepulled easily through the wireconduit. Verify Contact tip is notblocked.
2. Verify the Strike Wire FeedSpeed set correctly.
3. Verify the correct weld scheduleis selected.
4. Verify voltage sense leads areproperly connected and config-ured as described in the instruc-tion manual.
5. The DeviceNet tab of theDiagnostics Utility displays thePower Waveʼs "Analog ScansBetween Updates" and "I/OScans/Sec." Verify that "AnalogScans Between Updates" is 1/4of "I/O Scans/Sec" value.
6. From the DeviceNet tab of theDiagnostics Utility , selectConfigure. Verify in "Analog InputChannels" that the Hysteresissettings are all 0.
7. Verify all analog input values arewithin limits.
8. From the DeviceNet tab of theDiagnostics Utility , selectMonitor. Verify under "AnalogInput Fan Out" that Burnback ispresent for all analogs in.
9. Verify Gas is being turned onbefore the output.
DEVICENET-PLC CONTROLLED SYSTEM
E-9TROUBLESHOOTINGE-9
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Analog Inputs donʼt respond or donʼtrespond quickly.
Gas purge not working.
1. Analog Scans Between Updates.
2. Analog In Active Selections.
3. Analog Hysteresis.
4. Passive Mode.
1. Out of gas.
2. Gas Purge not asserted.
3. Passive Mode.
4. Gas Lines.
1. The DeviceNet tab of theDiagnostics Utility displays thePower Waveʼs "Analog ScansBetween Updates" and "I/OScans/Sec." Verify that "AnalogScans Between Updates" is 1/4of "I/O Scans/Sec" value.
2. From the DeviceNet tab of theDiagnostics Utility , selectConfigure. Verify in "Analog InputChannels" that the requiredchannels are set active.
3. From the DeviceNet tab of theDiagnostics Utility , selectConfigure. Verify in "Analog InputChannels" that the Hysteresissettings are all 0.
4. The DeviceNet tab of theDiagnostics Utility displays thePower Waveʼs passive modestatus. If the status needs to bechanged, select Configure, andmake the necessary modifica-tion.
1. Verify there is gas available atthe input of the gas solenoid.
2. From the DeviceNet tab of theDiagnostics Utility , selectMonitor. The Monitor window willbe displayed. Verify under the"Produced Assembly" that "GasPurge" is highlighted.
3. The DeviceNet tab of theDiagnostics Utility displays thePower Waveʼs passive modestatus. If the status needs to bechanged, select Configure, andmake the necessary modifica-tion.
4. Verify nothing is obstructing theflow of gas.
DEVICENET-PLC CONTROLLED SYSTEM
E-10TROUBLESHOOTINGE-10
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Bad Weld Ending
Bad Welding
1. Burnback Disabled.
2. Burnback Time.
3. Analog Scans Between Updates.
4. Limit Error reported at the end of a weld.
5. Fan Out.
6. Welding set points.
7. Analog Hysteresis.
8. Gas.
1. Analog Scans Between Updates.
2. Voltage Sense Leads.
1. From the DeviceNet tab of theDiagnostics Utility, select Monitor. TheMonitor window will be displayed. Verifyunder the "State Enabled" that "Burnback"is present.
2. Using Command Center verify thatBurnback Time for the active schedule inthe main window has a value other than 0.
3. The DeviceNet tab of the DiagnosticsUtility displays the Power Waveʼs "AnalogScans Between Updates" and "I/OScans/Sec." Verify that "Analog ScansBetween Updates" is 1/4 of "I/OScans/Sec" value.
4. Verify all welding settings for Burnbackand Crater states.
5. From the DeviceNet tab of theDiagnostics Utility, select Monitor. Verifyunder "Analog Input Fan Out" thatBurnback is present for all analogs in.
6. Verify Burnback set points for work point,trim, and wave values.
7. From the DeviceNet tab of theDiagnostics Utility, select Configure.Verify in "Analog Input Channels" that theHysteresis settings are all 0.
8. Verify Gas is turned on.
1. The DeviceNet tab of the DiagnosticsUtility displays the Power Waveʼs "AnalogScans Between Updates" and "I/OScans/Sec." Verify that "Analog ScansBetween Updates" is 1/4 of "I/OScans/Sec" value.
2. Verify voltage sense leads are properlyconnected and configured as described inthe instruction manual.
DEVICENET-PLC CONTROLLED SYSTEM
E-11TROUBLESHOOTINGE-11
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
Cannot Connect.
Connection Drops while welding.
3. Analog Hysteresis.
4. Limit Errors.
5. Gas.
6. Welding set points.
1. Physical connection.
2. IP address information.
3. Ethernet Speed.
1. Cable Location.
3. From the DeviceNet tab of theDiagnostics Utility , selectConfigure. Verify in "Analog InputChannels" that the Hysteresis set-tings are all 0.
4. Verify all welding set point values arewithin limits.
5. Verify Gas remains on until after theweld is complete.
6. Verify welding set points for workpoint, trim, and wave values.
1. Verify that the correct patch cable orcross over cable is being used (referto local IT department for assis-tance).
• Verify the cables are fully insertedinto the bulk head connector.
• LED 10 will be lit when the board isconnected to another network device.
2. User Weld Manager to verify thecorrect IP address information hasbeen entered.
• Verify that the PC has the correct IPaddress information entered.
• Verify that another device on the net-work is not already using the IPaddress entered into the WeldManager utility.
3. Verify that the network device con-nected to the Power Wave is either a10-baseT device or a 10/100-baseTdevice.
1. Verify Network cable is not locatednext to current carrying conductors.This would include input powercables and welding output cables.
ETHERNET
DEVICENET-PLC CONTROLLED SYSTEM
E-12TROUBLESHOOTINGE-12
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS
The Power Wave AC/DC 1000 is equipped with threeexternally mounted status lights, one for the powersource, and each module contained in the powersource. If a problem occurs it is important to note thecondition of the status lights. Therefore, prior tocycling power to the system, check the powersource status light for error sequences as notedbelow.
Included in this section is information about the powersource, Wire Drive Module, and CommunicationModule Status LEDʼs, and some basic troubleshoot-ing charts for both machine and weld performance.
The STATUS LIGHTS are dual-color LEDʼs that indi-cate system errors. Normal operation for each issteady green. Error conditions are indicated in the fol-lowing chart.
Steady Green
Blinking Green
Fast Blinking Green
Alternating Green and Red
Steady Red
Blinking Red
System OK. Power source is operational, and is com-municating normally with all healthy peripheral equip-ment connected to its ArcLink network.
Occurs during power up or a system reset, and indi-cates the Power Wave AC/DC 1000 is mapping (identi-fying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the systemconfiguration is changed during operation.
Indicates Auto-mapping has failed
Non-recoverable system fault. If the Status lights areflashing any combination of red and green, errors arepresent. Read the error code(s) before the machineis turned off.
Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will be sepa-rated by a green light. Only active error conditions willbe accessible through the Status Light.
Error codes can also be retrieved with the DiagnosticsUtility (included on the Power Wave Submerged ArcUtilities and Service Navigator CDʼs). This is the pre-ferred method, since it can access historical informa-tion contained in the error logs.
To clear the active error(s), turn power source off, andback on to reset.
Not applicable.
Not applicable.
Troubleshooting the Power Wave AC/DC 1000 Using the External Status LEDʼs
E-13TROUBLESHOOTINGE-13
POWER WAVE® AC/DC 1000
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES The following is a partial list of possible error codes for the Power Wave AC/DC 1000. For a complete listing con-sult the Service Manual for this machine.
Error Code #
31 Primary (Input) overcurrent error.
32 Capacitor "A" under voltage (Leftside facing machine)
33 Capacitor "B" under voltage (Rightside facing machine)
34 Capacitor "A" over voltage (Leftside facing machine)
35 Capacitor "B" over voltage (Rightside facing machine)
36 Thermal error
37 Soft start error
41 Secondary (Output) overcurrent error
43 Capacitor delta error
46 Secondary (Output) overcurrent error
49 Single phase error
54 Secondary (Output) overcurrent error
Other
Indication
Excessive Primary current present. May be related to a switch board or outputrectifier failure.
Low voltage on the main capacitors. May be caused by improper input configu-ration, or an open/short circuit in the primary side of the machine.
Excess voltage on the main capacitors. May be caused by improper input con-figuration, , excessive line voltage, or improper capacitor balance (see Error43)
Indicates over temperature. Usually accompanied by Thermal LED. Check fanoperation. Be sure process does not exceed duty cycle limit of the machine.
Capacitor pre-charge failed. Usually accompanied by codes 32-35.
The long term average secondary (weld) current limit has been exceeded. This error will cause the machine output to phase back to 100 amps, typi-cally resulting in a condition referred to as “noodle welding”.
NOTE: The long term average secondary current limit is 1050 amps.
The maximum voltage difference between the main capacitors has beenexceeded. May be accompanied by errors 32-35. May be caused by an openor short in the primary or secondary circuit(s).
Absolute maximum output level has been exceeded. Usually associated withexcessive short circuit currents and/or specific weld mode issues. This is ashort term average designed to protect the inverter switching circuitry.
Indicates machine is running on single phase input power. Usually caused bythe loss of the middle leg of the input power (L2).
The long term average secondary (weld) current limit has been exceeded. This error will immediately turn off the machine output.
Error codes that contain three or four digits are defined as fatal errors. Thesecodes generally indicate internal errors on the Power Source Control Board. Ifcycling the input power on the machine does not clear the error, contact theService Department.
POWER SOURCE- WELD CONTROLLER
E-14TROUBLESHOOTINGE-14
POWER WAVE® AC/DC 1000
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
WIRE DRIVE MODULEError Code #
81 Motor Overload
82 Motor Overcurrent
83 Shutdown #1
84 Shutdown #2
Indication
Long term average motor current limit has been exceeded. Typicallyindicates mechanical overload of system. If problem continues considerhigher gear ratio.
Absolute maximum motor current level has been exceeded. This is ashort term average to protect drive circuitry.
The normally closed circuit of Shutdown #1 has been interrupted.Check the connection between pins 9 and 10 on the External I/O con-nector (S7).
The normally closed circuit of Shutdown #2 has been interrupted.Check the connection between pins 9 and 11 on the External I/O con-nector (S7).
COMMUNICATION MODULE Error Code #
118 DeviceNet connection error
119 DeviceNet de-allocation error
133 Write ArcLink action failure
145 Duplicate MAC ID error
146 DeviceNet Bus off
147 DeviceNet polled I/O error
149 DeviceNet I/O data error
169 Ethernet Connection Time out171 Ethernet Socket Time out172 Ethernet Watch Dog Time out
194 Ethernet Send Problem195 Ethernet Problem197 Ethernet Problem
198 Ethernet Client Time out
216 Ethernet Problem
224 Ethernet Problem
226 Ethernet Problem
Indication
Lost Connection with DeviceNet Master
The DeviceNet Master de-allocated the connection
May be caused by activating Cold Inch while welding throughDeviceNet
Check MAC ID assignments on DeviceNet Setup Dip switch Bank (S2)
Check condition of on board DeviceNet Status indicators
Problem changing attribute over polled I/O
Received DeviceNet I/O data with wrong number of bytes
Loss of communication with PC Application.
Communication problem between Master and Slave machines.
Master lost communications with Slave Machine.
Communication problem between Master and Slave machines.
Master had problem connecting to a Slave machine.
Communication problem between Master and Slave machines.
F-1DIAGRAMSF-1
POWER WAVE® AC/DC 1000
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
F-2DIAGRAMSF-2
POWER WAVE® AC/DC 1000
NO
TE
: T
his
diag
ram
is fo
r re
fere
nce
only
. It
may
not
be
accu
rate
for
all m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a
part
icul
ar c
ode
is p
aste
d in
side
the
mac
hine
on
one
of th
e en
clos
ure
pane
ls.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e S
ervi
ce D
epar
tmen
t for
a r
epla
cem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
F-3AC SWITCH WIRING DIAGRAMF-3
POWER WAVE® AC/DC 1000
F-4AC SWITCH WIRING DIAGRAMF-4
POWER WAVE® AC/DC 1000
F-5DIMENSION PRINTF-5
POWER WAVE® AC/DC 1000
L123
02
A.01
19.7
0
19.1
6
9.56
18.8
4
40.9
4
43.4
4
33.0
0
34.3
4
14.6
2
NOTES
POWER WAVE® AC/DC 1000
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
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READ AND UNDERSTAND THE MANUFACTURERʼS INSTRUCTION FOR THIS EQUIPMENT AND THECONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYERʼS SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DEESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DESU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENTET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTREEMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.
• Do not touch electrically live parts orelectrode with skin or wet clothing.
• Insulate yourself from work andground.
• No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
• Aislese del trabajo y de la tierra.
• Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
• Isolieren Sie sich von denElektroden und dem Erdboden!
• Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
• Isole-se da peça e terra.
• Keep flammable materials away.
• Mantenga el material combustiblefuera del área de trabajo.
• Gardez à lʼécart de tout matérielinflammable.
• Entfernen Sie brennbarresMaterial!
• Mantenha inflamáveis bem guarda-dos.
• Wear eye, ear and body pro-tection.
• Protéjase los ojos, los oídos yel cuerpo.
• Protégez vos yeux, vosoreilles et votre corps.
• Tragen Sie Augen-, Ohren-und Kör-perschutz!
• Use proteção para a vista,ouvido e corpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTESDE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Keep your head out of fumes.• Use ventilation or exhaust to
remove fumes from breathingzone.
• Los humos fuera de la zona de res-piración.
• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
• Gardez la tête à lʼécart des fumées.• Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées deszones de travail.
• Vermeiden Sie das Einatmen vonSchweibrauch!
• Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
• Mantenha seu rosto da fumaça.• Use ventilação e exhaustão para
remover fumo da zona respiratória.
• Turn power off before servicing.
• Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
• Débranchez le courant avant lʼen-tretien.
• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
• Não opere com as tampas removi-das.
• Desligue a corrente antes de fazerserviço.
• Não toque as partes elétricas nuas.
• Do not operate with panel open orguards off.
• No operar con panel abierto oguardas quitadas.
• Nʼopérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
• Mantenha-se afastado das partesmoventes.
• Não opere com os paineis abertosou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
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