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IM10022
POWER WAVE AC/DC 1000 SD ® June, 2009

For use with machines having Code Numbers: 11592

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

IP 23

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work 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.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause 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 this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Jan ‘09
iii iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où l’on pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque d’incendie dû aux étincelles.

Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une grande câbles jusqu’à ce qu’ils se rompent.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble 9. Assurer une ventilation suffisante dans la zone de soudage.
de soudage et la machine à souder en bon et sûr état Ceci est particuliérement important pour le soudage de tôles
defonctionnement. galvanisées plombées, ou cadmiées ou tout autre métal qui
d.Ne jamais plonger le porte-électrode dans l’eau pour le produit des fumeés toxiques.
refroidir.
e. Ne jamais toucher simultanément les parties sous tension 10. Ne pas souder en présence de vapeurs de chlore provenant
des porte-électrodes connectés à deux machines à souder d’opérations de dégraissage, nettoyage ou pistolage. La
parce que la tension entre les deux pinces peut être le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
total de la tension à vide des deux machines. du solvant pour produire du phosgéne (gas fortement toxique)
f. Si on utilise la machine à souder comme une source de ou autres produits irritants.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de 11. Pour obtenir de plus amples renseignements sur la sûreté,
soudage. voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, LES MACHINES À SOUDER À
donc:
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié REDRESSEUR
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la l’électricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
l‘arc. bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à l’interieur de poste, la debranch-
de l’huile, tels que les gants en cuir, chemise épaisse, pan- er à l’interrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93
v SAFETY v

Electromagnetic Compatibility (EMC)

Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe-
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H
vi SAFETY vi

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special applications.
1

_________________________

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”

L10093 3-1-96H
vii vii

Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our
possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to
such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular
purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for
updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand
or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________
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 you
have 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 packet
accompanying 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.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
viii TABLE OF CONTENTS viii
Page

Installation.......................................................................................................................Section A
Specifications .......................................................................................................................A-1
Safety Precautions. ..............................................................................................................A-2
Location and Mounting ..................................................................................................A-2
Stacking ........................................................................................................................A-2
Lifting.............................................................................................................................A-2
Environmental Limitations .............................................................................................A-2
Electromagnetic Compatibility .......................................................................................A-2
Clearance Requirements ..............................................................................................A-3
Input Voltage Selection and Ground Connections ........................................................A-4
Connection Diagram .....................................................................................................A-4
System Connection .......................................................................................................A-5
Connection Diagrams and Check List ...........................................................A-6 thru A-11
Electrode and Work Connection .................................................................................A-12
Cable Inductance, Remote Sense Lead Connection.........................................A-13, A-14
Multi-Arc Circumfirential Welds ...................................................................................A-15
Control Cable Connections, Common Equipment Connections .................................A-16
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions, Definition of Welding Modes, Graphic Symbols ...........................B-1, B-2
Product Summary, Recommended Process, Process and Equipment Limitations ..............B-3
Common Equipment Packages and Recommended Equipment .........................................B-3
Case Front Control Descriptions .........................................................................................,B-4
Input Power Section .............................................................................................................B-4
Case Back Components ...............................................................................................B-5, B-6
Power-Up Sequence ............................................................................................................B-7
Duty Cycle ............................................................................................................................B-7
Common Welding Procedures .............................................................................................B-7
Overview of the AC/DC Submerged Arc Process ................................................................B-7
Multiple Arc System Considerations.....................................................................................B-8
Basic Modes of Operation (CC / CV) ...................................................................................B-8
Weld Sequence, Start Options, End Options, Re-Strike Timer ............................................B-9
Weld Process Adjustment, Wave Balance, DC Offset, Frequency ....................................B-10
Phase Adjustment for Multiple Arc Systems .....................................................................B-11
________________________________________________________________________________
Accessories .....................................................................................................Section C
Kits, Options and Accessories...............................................................................C-1
Software Tools.......................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Calibration Specification ........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Using the Status LED to Troubleshoot System Problem .......................................E-2
Error Codes....................................................................................................E-3, E-4
Troubleshooting Guide ..........................................................................................E-5
________________________________________________________________________
Wiring Diagrams and Dimension Print ..........................................................Section F
Wiring Diagram - Power Wave® AC/DC 1000 SD................................................F-1
Wiring Diagram - AC Switch ................................................................................F-2
Dimension Print .....................................................................................................F-3
________________________________________________________________________
Parts List.................................................................................................................P-612
A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - Power Wave® AC/DC 1000 SD (K2803-1)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS INPUT OUTPUT IDLE POWER FACTOR EFFICIENCY
3 PHASE CURRENT AMPS CONDITIONS POWER @ RATED OUTPUT @ RATED OUTPUT
50/60 Hz WATTS
380 82
400 79 1000A@44V.
460 69 100% Duty Cycle 225 .95 86%
500 62
575 55
OUTPUT
OPEN AUXILIARY POWER PROCESS CURRENT RANGES (AC or DC)
CIRCUIT (CIRCUIT BREAKER
VOLTAGE PROTECTED)

70V
70VACpk.
40 VDC AT
10 AMPS
115 VAC AT
SAW-DC+
SAW-DC-
SAW-AC
} 100 amps @24 Volts
1000 Amps @44 Volts
(Actual range may be limited by process)
10 AMPS
RECOMMENDED INPUT WIRE AND FUSE SIZES1
3 PHASE INPUT TYPE 90°C COPPER GROUNDING TIME-DELAY FUSE
VOLTAGE 50/60Hz COPPER WIRE3 IN CONDUCTOR OR BREAKER2
CONDUIT

AWG (mm2) AWG (mm2) AMPS

380 3(25) 8 (10) 100
400 3(25) 8 (10) 90
460 4(25) 8 (10) 90
500 4(25) 8 (10) 80
575 6(16) 10 (6) 70

PHYSICAL DIMENSIONS
MODEL CONFORMITY MARK HEIGHT WIDTH DEPTH WEIGHT
EN 60974-1 49.2 in 19.2 in 46.2 in 650 lbs.
K2803-1 * CSA C/UL 1250 mm 488 mm 1174 mm 296 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
14°F to 104°F(-10°C to 40°C) -40°F to 185°F(-40°C to 85°C)

Insulation Class: Class F(155°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 with the
use of an optional external filter. (K2444-3 CE and C-Tick Filter Kit)

WELDING PROCESSES
Process Electrode Diameter Range Output Range (Amperes) Wire Feed Speed Range

SAW 5/64 – 7/32" (2 – 5.6 mm) 100 - 1000 21 - 300 ipm (.53 – 7.62 m/minute)

POWER WAVE® AC/DC 1000 SD

A-2 INSTALLATION A-2

SAFETY PRECAUTIONS LIFTING

Read this entire installation section before you WARNING

start installation.

WARNING • Lift only with equipment of

adequate lifting capacity.
ELECTRIC SHOCK can kill.
• Be sure machine is stable
• Only qualified personnel should
when lifting.
perform this installation.
• Do not lift this machine using
• Turn the input power OFF at the lift bail if it is equipped with a
disconnect switch or fuse box heavy accessory such as
before working on this equipment. trailer or gas cylinder.
Turn off the input power to any other FALLING • Do not lift machine if lift bail is
equipment connected to the welding
EQUIPMENT can damaged.
system at the disconnect switch or
fuse box before working on the cause injury. • Do not operate machine while
equipment. suspended from lift bail.
• Do not touch electrically hot parts. -----------------------------------------------------------------------
• Always connect the Power Wave grounding lug
(located inside the reconnect input access door) Lift the machine by the lift bail only. The lift bail is
to a proper safety (Earth) ground. designed to lift the power source only. Do not attempt
----------------------------------------------------------------------- to lift the Power Wave® AC/DC 1000 SD with
accessories attached to it.
LOCATION AND MOUNTING
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through ENVIRONMENTAL LIMITATIONS
the case sides and front. Dirt, dust, or any foreign
The Power Wave® AC/DC 1000 SD can be used in
material that can be drawn into the welder should be
an outdoor environment with an IP 23 rating. It should
kept at a minimum. Failure to observe these
not be subjected to falling water, nor should any parts
precautions can result in excessive operating
of it be submerged in water. Doing so may cause
temperatures and nuisance shutdowns. See the
improper operation as well as pose a safety hazard.
Clearance Requirements and Figure A.1. in this
The best practice is to keep the machine in a dry,
section.
sheltered area.
CAUTION ELECTROMAGNETIC COMPATIBILITY
DO NOT MOUNT OVER COMBUSTIBLE (EMC)
SURFACES.
The EMC classification ot the Power Wave® AC/DC
Where there is a combustible surface directly 1000 SD is Industrial, Scientific and Medical (ISM)
under stationary or fixed electrical equipment, the group 2, class A. The Power Wave® AC/DC 1000 SD
surface shall be covered with a steel plate at least is for industrial use only.
.06”(1.6mm) thick, which shall extend not more
than 5.90”(150mm) beyond the equipment on all Locate the Power Wave away from radio controlled
sides. machinery.
-----------------------------------------------------------------------
CAUTION
The normal operation of the Power Wave® AC/DC
STACKING 1000 SD may adversely affect the operation of RF
Power Wave® AC/DC 1000 SD machine cannot be controlled equipment, which may result in bodily
stacked. injury or damage to the equipment.
-----------------------------------------------------------------------

POWER WAVE® AC/DC 1000 SD

A-3 INSTALLATION A-3

CLEARANCE REQUIREMENTS

The maintenance requirements of the Power Wave® Removing the four(4) clips and pulling back on the
AC/DC 1000 SD demands that enough clearance rear portion of the machine will provide access for
behind the machine be maintained. This is especially cleaning the machine and checking the filter. The filter
important where more than one machine is to be used is removed from the right side of the machine.
or if the machines are going to be rack mounted.
Where machines are mounted side by side, the
The rear portion of the machine that contains the filter, machine that is furthest to the right will need to have
the cooling fans and many of the heat sinks slides out the indicated clearance to the right side for filter
for easy access. removal. See Figure A.1.
FIGURE A.1 - CLEARANCE REQUIREMENTS

33.00”

WIDTH NEEDED FOR FILTER 22.63

MAINTENANCE ACCESS
61.30

POWER WAVE® AC/DC 1000 SD

A-4 INSTALLATION A-4
INPUT AND GROUND CONNECTIONS INPUT FUSE AND SUPPLY WIRE
MACHINE GROUNDING CONSIDERATIONS
The frame of the welder must be grounded. A ground Refer to Specifications page for recommended fuse and
terminal marked with the symbol shown is located wire sizes. Fuse the input circuit with the recommended
inside the reconnect / input access door for this super lag fuse or delay type breakers (also called "inverse
purpose. See your local and national electrical codes time" or "thermal/magnetic" circuit breakers). Choose input
for proper grounding methods. and grounding wire size according to local or national
electrical codes. Using fuses or circuit breakers smaller than
INPUT CONNECTION recommended may result in "nuisance" shut-offs from
welder inrush currents, even if the machine is not being
WARNING used at high currents.

ELECTRIC SHOCK can kill. INPUT VOLTAGE SELECTION

• Only a qualified electrician should Welders are shipped connected for the highest input voltage
connect the input leads to the listed on the rating plate. To move this connection to a
Power Wave. Connections should different input voltage, see the diagram located on the inside
be made in accordance with all of the input access door, or the diagram shown below
local and National Electrical (Figure A.2). If the Auxiliary lead (indicated as ‘A’) is placed
Codes and the connection in the wrong position, there are two possible results.
diagram located on the inside of
a. If the lead is placed in a position higher than the applied
the reconnect / input access door
line voltage, the welder may not come on at all.
of the machine. Failure to do so
may result in bodily injury or b. If the Auxiliary lead is placed in a position lower than the
death. applied line voltage, the welder will not come on, and the
two circuit breakers in the reconnect area will open. If
-----------------------------------------------------------------------
this occurs, turn off the input voltage, properly connect
Use a three-phase supply line. A 1.75 inch (45 mm)
the auxiliary lead, reset the breakers, and try again.
diameter access hole for the input supply is located on
the case back. Connect L1, L2, L3 and ground
according to the Input Supply Connection Diagram.

FIGURE A.2 - INPUT SUPPLY CONNECTION FOR K2803-1 POWER WAVE® AC/DC 1000 SD

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

S26047
INPUT SUPPLY CONNECTION DIAGRAM
W / L3
WARNING
Do not operate with covers removed V / L2 CR1
Disconnect input power before servicing U / L1
Do not touch electrically live parts
Only qualified persons should install,
ELECTRIC use or service this equipment
SHOCK
CAN KILL

VOLTAGE=380-415V VOLTAGE=440-460V VOLTAGE=500V VOLTAGE=550-575V

380-415V 380-415V 380-415V 380-415V
440-460V 440-460V 440-460V 440-460V
500V 'A' 500V 'A' 500V 'A' 500V 'A'
550-575V 550-575V 550-575V 550-575V
A

POWER WAVE® AC/DC 1000 SD

A-5 INSTALLATION A-5
SYSTEM CONNECTION

System Overview In a typical multi-arc system, each arc is controlled

by its own MAXsa 10 Controller. The basic
The Power Wave® AC/DC 1000 SD power source is characteristics of the individual arcs such as WFS,
designed to be a part of a modular welding system amplitude, and offset are set locally by each arc’s
typically controlled by a MAXsa 10 Controller or a dedicated controller. The frequency, balance, and
customer supplied Programmable Logic Controller phase shift parameters of each arc are controlled by
(PLC). Each welding arc may be driven by a single the MAXsa 10 Controller for ARC 1 (Master Lead).
power source or by a number of power sources
connected in parallel. The actual number of power NOTE: The K2803-1 Power Wave® AC/DC 1000 SD
sources per arc will vary depending on the application. is backwards compatible with some of the
When only one power source is required for an arc components of earlier systems. There are
group, it must be configured as a Master. When some restrictions and in some cases the
parallel machines are required, one is designated as need for adapters etc.. See the Compatibility
the Master and the rest as Slaves. The synchronizing Chart, Table A.1
connectors for paralleled machines are on the back of
the power source. The Master controls the AC A PLC interface is an alternate method of control for
switching for the arc group, and the Slaves respond larger systems. The PLC is typically connected via
accordingly. See Figure A.4. DeviceNet directly to the Master power source of
each arc group in the system. A MAXsa 10 or
When employed in a multi-arc AC system the arcs MAXsa 19 Controller is still required to power the
must be synchronized to each other. The Master for Wire Drive. Contact your Local Lincoln Electric
each arc can be configured to follow a dedicated Representative for more information.
external synchronization signal to determine its
frequency and balance. The Synchronizing The following list of Recommended and Optional
Connectors on the back of the Power Wave® AC/DC equipment is included as a reference for the
1000 SD provide the means to synchronize the AC following connection diagrams. The connection
wave shapes of up to six different arcs to a common diagrams describe the layout of several typical
carrier frequency. (See Figure A.4). This frequency systems including Multi-Arc and Paralleled machine
can range from 10 hertz to 100 hertz. It can also set-ups. Each system also has a step by step
control the phase angle between arcs to reduce the “Installation Checklist”.
effects of welding related issues such as "Arc Blow".
FIGURE A.4 - SYNCHRONIZING CONNECTORS
The arc to arc phase relationship is determined by the
timing of each arc’s "sync" signal relative to the "sync"
signal of ARC 1. DIP Switches on the Control PC
Board of each machine must be set to identify it as a
Master Lead, Master Trail or Slave.
FIGURE A.3 - DIP SWITCH SETTINGS Multi-arc Input
Output

Input
Paralleling
Output

POWER WAVE® AC/DC 1000 SD

 A-6

K2803-1
Power Wave AC/DC 1000 SD

K1811-XX
Sense Lead

K2683-XX
K2607-1 Arclink Cable
Cruiser
INSTALLATION

POWER WAVE® AC/DC 1000 SD

FIGURE A.5 - CRUISER CONNECTION DIAGRAM

Electrode
Weld Cable

Work
Work
Weld Cable
A-6
 A-7

K2803-1
Power Wave AC/DC 1000 SD

K2683-XX
Arclink Cable

K2814-1
MAXsa 10

K1785-XX
14-Pin Cable
INSTALLATION

K2370-2
MAXsa 22

POWER WAVE® AC/DC 1000 SD

67 Lead

K231-XX Electrode
Weld Cable
FIGURE A.6 - SINGLE ARC CONNECTION DIAGRAM

Contact Nozzle
K1811-XX
Sense Lead

Work
Work Weld Cable
A-7
 A-8

K2683-XX K1785-XX 14-Pin Cable

Arclink Cable

K1811-XX
Sense Lead

K2814-1 K2814-1
MAXsa 10 MAXsa 10

K2683-XX
Arclink Cable

K1785-XX
14-Pin Cable K2803-1 K2803-1
K1785-XX Power Wave Power Wave
14-Pin Cable AC/DC 1000 SD AC/DC 1000 SD
INSTALLATION

K2370-2
MAXsa 22 67 Leads

POWER WAVE® AC/DC 1000 SD

K2370-2
MAXsa 22 Electrode
K231-XX Weld Cable
Contact Nozzle
FIGURE A.7 - TANDEM ARC CONNECTION DIAGRAM

Work
Work Weld Cable

Electrode Weld Cable

A-8
 A-9

Connection Diagram - Parallel Machines

K1785-XX 14-Pin Cable

K1811-XX
Sense Lead

K2814-1
MAXsa 10

K2683-XX
Arclink Cable

K2803-1 K2803-1
PowerWave PowerWave
AC/DC 1000 SD AC/DC 1000 SD
K1785-XX
14-Pin Cable
INSTALLATION

POWER WAVE® AC/DC 1000 SD

K2370-2
MAXsa 22 67 Lead
FIGURE A.8 - PARALLELING CONNECTION DIAGRAM

Electrode
Weld Cable

K231-XX Work Weld Cable

Contact Nozzle

Work
Electrode Weld Cable
A-9
A-10 INSTALLATION A-10

STEP BY STEP INSTALLATION CHECKLIST

APPLICABLE TO ALL:

Confirm that latest software is updated in all equipment prior to installation (www.powerwavesoftware.com)

CRUISER™ SYSTEM CHECKLIST (See Figure A.5)

Place Power Wave® AC/DC 1000 SD in suitable operating location.

Place the Cruiser™ Tractor in it’s operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave® AC/DC 1000 SD and
the Cruiser™ Tractor

Install Work Voltage Sense Lead (21) from the Power Wave® AC/DC 1000 SD per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open the Power Wave® AC/DC 1000 SD front panel and check the DIP switch settings per the decal on the
panel. Factory Setting is “Master-Lead”. (See Figure A.3).

Connect input power to Power Wave® AC/DC 1000 SD per recommended guidelines.

Turn on Power Wave® AC/DC 1000 SD, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

SINGLE ARC SYSTEM CHECKLIST (See Figure A.6)

Place Power Wave® AC/DC 1000 SD in suitable operating location.

Mount MAXsa 10 Controller.

Install MAXsa 22 Wire Drive and other accessories in their operating location.

Connect K2683-xx Heavy Duty ArcLink Control Cable (5 pin) between Power Wave and MAXsa 10.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa 10 and the MAXsa 22.

Install Electrode Sense Lead (67) at the feeder and the Work Sense Lead (21) from the Power Wave®
AC/DC 1000 SD per recommended guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open the Power Wave® AC/DC 1000 SD front panels and check the DIP switch settings per the decal on the
panel. Factory Setting is “Master-Lead”. (See Figure A.3).

Connect input power to Power Wave® AC/DC 1000 SD per recommended guidelines.

Turn on Power Wave® AC/DC 1000 SD, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

POWER WAVE® AC/DC 1000 SD

A-11 INSTALLATION A-11
STEP BY STEP INSTALLATION CHECKLIST (Cont.)
TANDEM ARC (2-ARC) SYSTEM CHECKLIST (See Figure A-7)

Place Power Wave® AC/DC 1000 SD units in suitable operating location.

Mount MAXsa 10 Controllers.

Install MAXsa 22 Wire Drives and other accessories in their operating location.

Connect a K1785-xx Wire Feeder Control Cable (14 pin) between the two power sources (top connectors).

Connect K2683-xx Heavy Duty ArcLink Control Cables (5 pin) between Power Wave units and MAXsa 10 con-
trollers.

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the MAXsa 10 controllers and the MAXsa 22 feed-
ers.

Install Electrode Sense Lead (67) at each feeder and the Work Sense Lead (21) from the Lead Power Wave®
AC/DC 1000 SD Master per guidelines.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open the Power Wave® AC/DC 1000 SD front panels and configure DIP switch settings per the decal on the panel.
(See Figure A.3).

Connect input power to Power Wave® AC/DC 1000 SD units per recommended guidelines.

Turn on Power Wave® AC/DC 1000 SD

Run the subarc cell configurator from PC Tools (need detail here).

Verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

PARALLEL CONNECTION CHECKLIST (See Figure A.8)

Follow all steps of Cruiser, Single or Tandem Arc Checklists

Be sure Input power is disconnected.

The MAXsa Feeders and Controllers must be connected to the Master Power Source

Connect K1785-xx Wire Feeder Control Cable (14 pin) between the Master Power Wave® AC/DC 1000 SD and the
Slave Power Wave® AC/DC 1000 SD unit.

No additional sense leads are required.

Connect / Install welding cables per recommended "Output Cable Guidelines."

Open the Power Wave® AC/DC 1000 SD front panels and configure DIP switch settings per the decal on the panel.
(See Figure A.3).

Connect input power to Power Wave® AC/DC 1000 SD units per recommended guidelines.

Turn on Power Wave® AC/DC 1000 SD, and verify all system Status Lights are solid green.

Select a Welding process and configure starting and ending options.

POWER WAVE® AC/DC 1000 SD

A-12 INSTALLATION A-12

ELECTRODE AND WORK NOTE: For parallel and/or multiple arc applications
with excessive electrode cable lengths, a com-
CONNECTIONS mon bus connection should be used. The
common electrode connection serves to mini-
General Guidelines mize voltage drops associated with resistive
losses in the electrode path. It should be made
The unique switching structure of the Power Wave of copper, and located as close as possible to
AC/DC 1000 SD allows it to produce DC positive, DC the power sources. (See Figure A.9).
negative or AC output waveforms without reposition-
ing the work and electrode leads. Additionally, no DIP FIGURE A.9
switch changes are required to switch between the dif-
ferent polarities. All of this is controlled internally by
the Power Wave AC/DC 1000, and based exclusively
on the weld mode selection.

The following recommendations apply to all output

polarities and weld modes:

• Select the appropriate size cables per the COMMON CONNECTION

"Output Cable Guidelines" below. Excessive volt- (LOCAT ED CLOSE TO
POWER SOURCES)
age drops caused by undersized welding cables
and poor connections often result in unsatisfactory
welding 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 indicates Work Connections

undersized cables and/or bad connections.
Connect cable(s) of sufficient size and length (Per
• Route all cables directly to the work and wire Table A.1) between the "WORK" studs (located
feeder, avoid excessive lengths and do not coil behind the cover on the lower left rear corner) and the
excess cable. Route the electrode and work cables work piece. Be sure the connection to the work makes
in close proximity to one another to minimize the tight metal-to-metal electrical contact.
loop area and therefore the inductance of the weld
circuit. NOTE: For parallel and/or multiple arc applications
with excessive ground path lengths, a com-
• Always weld in a direction away from the work mon work connection bus should be used. The
(ground) connection. common work connection serves to minimize
voltage drops associated with resistive losses
TABLE A.1 - Output Cable Guidelines in the ground paths. It should be made out of
Total Cable Length copper, and located as close as possible to
ft (m) Duty Cycle Number of Cable Size the power sources (See Figure A.10).
Electrode and Work Parallel Cables Copper FIGURE A.10
Combined

0 (0) to 250 (76.2) 80% 2 4/0 (120 mm2)

0 (0) to 250 (76.2) 100% 3 3/0 (95 mm2)

Electrode Connections

Connect cable(s) of sufficient size and length (Per

COMMON CONNECTION
Table A.1) to the "ELECTRODE" studs on the power (LOCAT ED CLOSE TO
POWER SOURCES)
source (located behind the cover plate on the lower
right rear corner). Connect the other end of the elec- WORK PIECE
trode cable(s) to the tab of the contact nozzle. Be sure
the connection to the nozzle makes tight metal-to-
metal electrical contact.

POWER WAVE® AC/DC 1000 SD

A-13 INSTALLATION A-13

CABLE INDUCTANCE, AND ITS EFFECTS Electrode Voltage Sensing

ON WELDING The remote ELECTRODE sense lead (67) is built into
the wire feeder control cable (K1785) and accessible
Excessive cable inductance will cause the welding at the wire drive. It should always be connected to the
performance to degrade. There are several factors Contact Assembly where the Weld Cable is connect-
that contribute to the overall inductance of the cabling ed. Enabling or disabling electrode voltage sensing is
system including cable size, and loop area. The loop application specific, and automatically configured
area is defined by the separation distance between through software.
the electrode and work cables, and the overall welding
loop length. The welding loop length is defined as the Work Voltage Sensing
total of length of the electrode cable (A) + work cable For most applications the use of a remote work volt-
(B) + work path (C) (see Figure A.11). To minimize age sense lead is recommended. The Power Wave®
inductance always use the appropriate size cables, AC/DC 1000 SD is shipped from the factory with the
and whenever possible, run the electrode and work remote work voltage sense lead enabled. It must be
cables in close proximity to one another to minimize attached to the work as close to the weld as practical,
the loop area. Since the most significant factor in but out of the weld current path. For more information
cable inductance is the welding loop length, avoid regarding the placement of remote work voltage
excessive lengths and do not coil excess cable. For sense leads, see the section entitled "Voltage Sensing
long work piece lengths, a sliding ground should be Considerations for Multiple Arc Systems." The remote
considered to keep the total welding loop length as WORK sense lead (21) can be accessed at the four-
short as possible. pin WORK sense lead connector located on the back
FIGURE A.11 panel of the Power Wave AC/DC 1000 SD.

POWER Some simplified applications may perform adequately

WAVE A by sensing the work voltage directly at the WORK
STUD without the use of a remote work voltage sense
C lead. This can be accomplished by simply connecting
WORK the lead from the “Work Sense Lead Connector”
B directly to one of the WORK Studs.
NOTE: All of the machines of a given arc group
REMOTE SENSE LEAD CONNECTIONS
(Master and Slaves) will relate to the
Voltage Sense Lead of the Master machine.
Voltage Sensing Overview
The best arc performance occurs when the Power
Wave® AC/DC 1000 SD has accurate data about the
arc conditions. Depending upon the process, induc-
CAUTION
tance within the electrode and work cables can influ-
Never connect the WORK sense lead at two differ-
ence the voltage apparent at the studs of the welder,
ent locations.
and have a dramatic effect on performance. To coun-
teract this negative effect, remote voltage sense leads
are used to improve the accuracy of the arc voltage
information supplied to the control pc board. WARNING
There are several different sense lead configurations ELECTRIC SHOCK can kill.
that can be used depending on the application. In
• Do not touch electrically live parts or
extremely sensitive applications it may be necessary
electrodes with your skin or wet
to route cables that contain the sense leads away
clothing.
from the electrode and work welding cables.
• Insulate yourself from the work and
ground.
CAUTION • Always wear dry insulating gloves.
If the remote voltage sensing is enabled but the ------------------------------------------------------------------------
sense leads are missing, improperly connected, or
if the electrode polarity is improperly configured
extremely high welding outputs may occur.
------------------------------------------------------------------------

POWER WAVE® AC/DC 1000 SD

A-14 INSTALLATION A-14

VOLTAGE SENSING CONSIDERATIONS FOR

MULTIPLE ARC SYSTEMS

Special care must be taken when more than one arc • For longitudinal applications, connect all work
is welding simultaneously on a single part. Remote leads at one end of the weldment, and all of the
sensing is required in Multi-arc applications work voltage sense leads at the opposite end of the
weldment. Perform welding in the direction away
• Avoid common current paths. Current from adja- from the work leads and toward the sense leads.
cent arcs can induce voltage into each others cur- See Figure A.12.
rent paths that can be misinterpreted by the power
sources, and result in arc interference. • For circumferential applications, connect all work
leads on one side of the weld joint, and all of the
• Position the sense leads out of the path of the work voltage sense leads on the opposite side, such
weld current. Especially any current paths common that they are out of the current path. See Figure
to adjacent arcs. Current from adjacent arcs can A.13
induce voltage into each others current paths that
can be misinterpreted by the power sources, and
result in arc interference.

FIGURE A.12 MULTI-ARC LONGITUDINAL WELDS

CONNECT ALL SENSE

LEADS AT THE END
DIRECTION OF THE WELD.
OF TRAVEL

CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.

POWER WAVE® AC/DC 1000 SD

A-15 INSTALLATION A-15

FIGURE A.13 MULTI-ARC CIRCUMFIRENTIAL WELDS

POWER
SOURCE
#1

POWER
SOURCE
#2

POWER
POWER SOURCE
SOURCE #2
#1

POWER
SOURCE
#1

POWER
SOURCE
#2

POWER WAVE® AC/DC 1000 SD

A-16 INSTALLATION A-16

CONTROL CABLE CONNECTIONS Connections Between Power Source and Optional

DeviceNet Programmable Logic Controller(PLC).
General Guidelines
It is sometimes more practical and cost effective to
Genuine Lincoln control cables should be used at use a custom PLC interface to control a multi-arc sys-
all times (except where noted otherwise). tem (refer to the "DeviceNet Configuration" section for
interface information). The Power Wave AC/DC 1000
Lincoln cables are specifically designed for the com- is equipped with a 5-pin DeviceNet mini style recepta-
munication and power needs of the Power Wave / cle for this purpose. The receptacle is located on the
MAXsa systems. Most are designed to be connected rear panel of the machine See Figure B.3 The
end to end for ease of extension. However, it is rec- DeviceNet cable is keyed and polarized to prevent
ommended that the total length not exceed 100 feet improper connection.
(30.5 m). The use of non-standard cables, especially
in lengths greater than 25 feet, can lead to communi- NOTE: DeviceNet cables should not be routed in
cation problems (system shutdowns), poor motor the same channel as the weld cables.
acceleration (poor arc starting), and low wire driving
force (wire feeding problems). Always use the shortest In a typical system, a DeviceNet connection is made
length of control cable possible, and DO NOT coil between the master power source of each arc, and
excess cable. Best results will be obtained when con- the PLC interface. For best results, route DeviceNet
trol cables are routed separate from the weld cables. cables away from weld cables, wire drive control
This minimizes the possibility of interference between cables, or any other current carrying device that can
the high currents flowing through the weld cables, and create a fluctuating magnetic field. DeviceNet cables
the low level signals in the control cables. These rec- must be sourced locally by the customer. For addition-
ommendations apply to all communication cables al guidelines refer to the "DeviceNet Cable Planning
including optional DeviceNet and Ethernet connec- and Installation Manual" (Allen Bradley publication
tions. DN-6.7.2).

COMMON EQUIPMENT CONNECTIONS Connections Between Parallel Power Sources

(K1785-xx - Control Cable).
Connection Between MAXsa Controller and
To increase the output capacity for a given arc, the
MAXsa series Wire Drive (K1785-xx)
output studs of multiple Power Wave AC/DC 1000
machines can be connected in parallel. The parallel
The 14 pin Wire Drive Control Cable (K1785-xx) con- machines utilize a master/slave control scheme to dis-
nects the Controller (MAXsa 10 or MAXsa 19) to the tribute the load evenly and to coordinate AC switch-
Wire Drive (MAXsa 22 or MAXsa 29). This cable ing. K1785-xx cables connect the paralleled machines
should be kept as short as possible. via the synchronizing connectors on the back of the
machine. The system is currently limited to a maxi-
Connection Between Power Source and the mum of 2 slaves per master, or a total of 3 machines
MAXsa Controller (K2683-xx - ArcLink Control per arc.
Cable).
Connections Between Power Sources in Multi-Arc
Single and tandem arc systems are typically con- Applications (K1785-xx - Control Cable).
trolled by a MAXsa 10 Controller. In a tandem, or
multi-arc system, each arc requires its own dedicated Synchronizing Connectors are available on the rear
controller. panel of the machine for Multi-Arc applications using
the K1875-xx control cables. The system is currently
The 5-pin ArcLink control cable connects the power limited to six(6) arcs, or a “Lead” and five “Trail” arcs.
source to the MAXsa 10. If there is more than one
power source per arc, it connects from the MAXsa 10
to the power source designated as the Master for that
arc. The control cable consists of two power leads,
one twisted pair for digital communication, and one
lead for voltage sensing (67).

NOTE: Control cables should not be routed in the

same channel as the weld cables.

POWER WAVE® AC/DC 1000 SD

B-1 OPERATION B-1

SAFETY PRECAUTIONS SYNERGIC WELDING MODES

Read this entire section of operating instructions • A Synergic welding mode offers the simplicity of
before operating the machine. single knob control. The machine will select the
correct voltage and amperage based on the wire
WARNING feed speed (WFS) set by the operator.

COMMON WELDING ABBREVIATIONS

ELECTRIC SHOCK can kill.
SAW
• Unless using cold feed feature, when • Submerged Arc Welding
feeding with gun trigger, the
electrode and drive mechanism are
always electrically energized and GRAPHIC SYMBOLS THAT
could remain energized several
seconds after the welding ceases.
APPEAR ON
• Do not touch electrically live parts or electrodes
THIS MACHINE OR IN THIS
with your skin or wet clothing. MANUAL
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
WORK SENSE LEAD
CONNECTOR
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes. MULTI-ARC
• Use ventilation or exhaust to remove CONNECTOR
fumes from breathing zone.

PARALLEL ARC
WELDING SPARKS can cause
CONNECTOR
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
ETHERNET
held combustibles.
CONNECTOR

ARC RAYS can burn.

ARC LINK
• Wear eye, ear, and body protection. COMMUNICATIONS PROTOCOL
CONNECTOR

Observe additional guidelines detailed in the DEVICENET

beginning of this manual. CONNECTOR

DEFINITIONS OF WELDING MODES

15V 10A 115VAC
NON-SYNERGIC WELDING MODES
NEUTRAL BONDED TO FRAME RECEPTACLE
NEUTRE RACCORDE AU BATI
NEUTRO CONECTADO AL CHASIS
• A Non-synergic welding mode requires all welding
process variables to be set by the operator. L15129-4

POWER WAVE® AC/DC 1000 SD

B-2 OPERATION B-2

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

U0 OPEN CIRCUIT
ON
VOLTAGE

OFF U1 INPUT VOLTAGE

HIGH TEMPERATURE U2 OUTPUT VOLTAGE

MACHINE STATUS I1 INPUT CURRENT

CIRCUIT BREAKER I2 OUTPUT CURRENT

PROTECTIVE
WIRE FEEDER
GROUND

POSITIVE OUTPUT

NEGATIVE OUTPUT WARNING or CAUTION

3 PHASE INVERTER Explosion

INPUT POWER
Dangerous Voltage

THREE PHASE
Shock Hazard

DIRECT CURRENT

POWER WAVE® AC/DC 1000 SD

B-3 OPERATION B-3

PRODUCT SUMMARY

The Power Wave® AC/DC 1000 SD is a high Only the MAXsa 22 or MAXsa 29 Wire Drives and
performance, digitally controlled inverter welding MAXsa 10 or MAXsa 19 Controllers may be used with
power source. It is capable of producing a variable a K2803-1 PowerWave AC/DC 1000 SD in a Multi Arc
frequency and amplitude AC output, DC positive system. Other Lincoln or non-Lincoln Wire Drives can
output, or DC negative output without the need for only be used with custom interfaces.
external reconnection. It utilizes complex, high-speed
waveform control to support a variety of constant The Power Wave® AC/DC 1000 SD will support a
current and constant voltage welding modes in each maximum average output current of 1000 Amps at
of its output configurations. 100% Duty Cycle.

The Power Wave® AC/DC 1000 SD power source is COMMON EQUIPMENT PACKAGES
designed to be a part of a modular welding system.
Each welding arc may be driven by a single machine, BASIC PACKAGE
or by a number of machines in parallel. In multiple arc
applications the phase angle and frequency of K2803-1 Power Wave® AC/DC 1000 SD
different machines can be synchronized by
interconnecting the units with a control cable to K2370-2 MAXsa 22 Wire Drive
improve performance and reduce the effects of arc
blow. K2814-1 MAXsa 10 Controller / User Interface

The Power Wave® AC/DC 1000 SD is primarily K2683-xx Control Cable (5 pin – 5 pin) - power
designed to interface with compatible ArcLink source to controller.
equipment. However, it can also communicate with
other industrial machines and monitoring equipment K1785-xx Control Cable (14 pin – 14 pin) -
via DeviceNet, or Ethernet. The result is a highly Controller to Wire Drive.
integrated and flexible welding cell.
OPTIONAL KITS
RECOMMENDED PROCESSES
K1785-xx Control Cable (14 pin – 14 pin) - for
The Power Wave® AC/DC 1000 SD is designed for paralleling / multiple arc applications.
submerged arc welding (SAW). Due to its modular
design the Power Wave AC/DC can operate on either K2312-2 MAXsa 29 Wire Drive (for fixture
single arc or in multi-arc applications with up to six builders).
arcs. Each machine is factory preprogrammed with
multiple welding procedures to support all types of K2311-1 Motor Conversion Kit (to convert
submerged arc welding. The Power Wave® AC/DC existing NA-3/NA-4/NA-5 wire feeder
1000 SD carries an output rating of 1000 amps, 44 gear boxes).
volts (at 100% duty cycle). If higher currents are
required machines can be easily paralleled for up to K2444-1 CE, C-Tick Filter Kit
3000 amps on each arc.
K2626-2 Wire Drive Controller (for fixture
PROCESS LIMITATIONS builders that do not require the
MAXsa 10 Controller).
The Power Wave® AC/DC 1000 SD is suitable only
for the Submerged Arc Process (SAW). RECOMMENDED EQUIPMENT
(See Installation Section)

EQUIPMENT LIMITATIONS

The Power Wave® AC/DC 1000 SD can be used in

outdoor environments. The Operating Temperature
Range is 14°F to 104°F(0°C to +40°C).

POWER WAVE® AC/DC 1000 SD

B-4 OPERATION B-4

CASE FRONT CONTROLS FIGURE B.1 - CASE FRONT

1. Power Switch: Controls input power to the Power

Wave® AC/DC 1000 SD and any auxiliary
equipment that may be connected to it.

2. Status Light: A two color LED that indicates

2
system errors. Normal operation is steady green.
Flashing green or red/green indicates a system
error. See the Troubleshooting Section.

NOTE: The Power Wave Status Light will flash 3

green for up to 60 seconds at power up as
the machine runs through a self test
routine, and then go to steady green. 1
3. Thermal Light: A yellow light that comes ON when
an over temperature situation occurs. The machine
output is disabled until the machine cools down
and the thermal light goes OFF

FIGURE B.2 - INPUT SECTION (LEFT SIDE)

1 3
5

INPUT POWER SECTION

1. Input Contactor: Connection point for incoming 3

phase power. See the Installation Section for
input wiring and fusing information.
2 4
2. Case Ground: Used to provide an “earth ground”
for the frame of the welder. Consult your local and
national electrical codes for proper grounding
information.

3. Auxiliary Reconnect: Select the proper tap based

L15129-2
on the supply voltage.

4. Fuse (F1): Protection for the primary side of the

auxiliary transformer 380-
415V 440-
460V
5. Cord Connector: Input power cord strain relief.

500V 550-
575V

POWER WAVE® AC/DC 1000 SD

B-5 OPERATION B-5

CASE BACK COMPONENTS (See Figure B.3)

1. 10 Amp Circuir Breaker (CB1): Protects the 40VDC wire feeder power supply.

2. 10 amp Circuit Breaker (CB-2): Protects the 115VAC Auxiliary Power Receptacle.

3. Work Sense Lead Connector(4 Pin): Connection point for the #21 lead.

4. Arclink Connector (5 Pin): Provides power and communication to the controller.

5. Devicenet Connector: Provides Devicenet communication to remote equipment.

6. Output Studs (2) (WORK): Connection point for welding cable(s) to the work piece.

7. Output Studs (2) (ELECTRODE): Connection point for welding cables to the Wire Drive.

8. Auxilary Output Receptacle: Provides 10 amps of 115VAC power.

9. Ethernet Connector (RJ-45): Provides Ethernet communication to remote equipment.

10. Master Input: From Lead or previous trail arc in a Multi-arc system

11. Master Output: To subsequent trail arc in a Multi-arc system.

12. Parallel Input: From Master or previous Slave in a parallel machine set up.

13. Parallel Output: To Slave in a parallel machine set up

POWER WAVE® AC/DC 1000 SD

B-6 OPERATION B-6

FIGURE B.3 - CASE BACK COMPONENTS

10 11 9 2 1
3

115V AC 10 A 40V

- 10 A

F1
COMMUNICATIONS PROTOCOL
10A NEUTRAL BONDED TO FRAME
600V NEUTRE RACCORDE AU BATI
L15129-3 NEUTRO CONECTADO AL CHASIS

- L15129-4

L15129-1

12 13 4 5 8

9 2 1
3

10
8
11

12

13
4
5

Stud Cover Doors Removed

for Clarity

POWER WAVE® AC/DC 1000 SD

B-7 OPERATION B-7
POWER-UP SEQUENCE Consult the User Interface documentation for more
detailed set up information. (MAXsa 10, Command
When power is applied to the Power Wave AC/DC Center, PLC, Robot etc..)
1000, the status lights will flash green for up to 60
seconds. During this time the Power Wave® AC/DC First, consider the desired welding procedures and
1000 SD is performing a self test, and mapping the part to be welded. Choose an electrode material,
(identifying) each component in the local ArcLink diameter, and flux.
system. The status lights will also flash green as a
result of a system reset or configuration change Second, find the program in the welding software that
during operation. When the status lights become best matches the desired welding process. The
steady green the system is ready for use standard software shipped with the Power Wave®
AC/DC 1000 SD encompasses a wide range of
If the status lights do not become steady green common processes and will meet most needs. If a
consult the troubleshooting section of this manual for special welding program is desired, contact the local
further instruction. Lincoln Electric sales representative.

DUTY CYCLE To make a weld, the Power Wave® AC/DC 1000 SD

needs to know the desired welding parameters.
The Power Wave® AC/DC 1000 SD is capable of Waveform Control Technology™ allows full
welding 1000Amps, @ 44 Volts, at a 100% duty cycle. customization of Strike, Run-in, Crater and other
parameters for exacting performance.
COMMON WELDING PROCEDURES
OVERVIEW OF THE AC/DC SUBMERGED
MAKING A WELD ARC PROCESS

The serviceability of a product or structure The Power Wave® AC/DC 1000 SD combines the
utilizing the welding programs is and must be the advantages of AC and DC Submerged Arc Welding
sole responsibility of the builder/user. Many (SAW) into a single power source. The limiting factor
variables beyond the control of The Lincoln of AC-SAW welding has traditionally been the time it
Electric Company affect the results obtained in takes to transition from positive to negative polarity.
applying these programs. These variables This lag through the zero crossing can cause arc
include, but are not limited to, welding procedure, instability, penetration, and deposition problems in
plate chemistry and temperature, weldment certain applications. The Power Wave® AC/DC 1000
design, fabrication methods and service SD utilizes the speed of an inverter based power
requirements. The available range of a welding source, and the flexibility of Waveform Control
program may not be suitable for all applications, Technology™ to address this issue.
and the build/user is and must be solely
responsible for welding program selection. By adjusting the Frequency, Wave Balance and Offset
of the AC waveform the operator can now control the
The steps for operating the Power Wave® AC/DC balance (relationship) between the penetration of DC
1000 SD will vary depending upon the user interface positive and the deposition of DC negative while
of the welding system. The flexibility of the system lets taking full advantage of the reduction in arc blow
the user customize operation for the best associated with AC.
performance.
FIGURE B.4 - AC/DC SUBMERGED ARC PROCESS

TM
Output waveform variations made possible by Waveform Control Technology
Transi tion Rate
di/dT
PulseWidth

Frequency
Positive
Current

Current Time

Negative
Current

Depending on the process, different parts of the output waveform and wire feed
speed may be modulated at varying rates to achieve a smooth and stable arc.

POWER WAVE® AC/DC 1000 SD

B-8 OPERATION B-8
MULTIPLE ARC SYSTEM BASIC MODES OF OPERATION
CONSIDERATIONS
CONSTANT CURRENT (CC)
Large scale SAW applications often employ multiple • Operator presets Current and desired Voltage.
arcs to increase deposition rates. In multiple arc • The Power Source:
systems, magnetic forces created by like and - Goal is to maintain a constant arc length.
opposing weld currents of adjacent arcs can result in - Drives a constant Current.
arc interaction that can physically push or pull the arc - Synergically Controls WFS to Maintain Voltage
columns together. See Figure B.5. To counteract this at the desired Set point.
effect, the phase relationship between adjacent arcs • Arc Length is proportional to Voltage.
can be set to alternate and equalize the duration of • Traditionally used for larger diameter wires and
magnetic push and pull forces. This is accomplished slower travel speeds.
through the synchronizing cables (K1785-xx). Ideally, FIGURE B.7 - CONSTANT CURRENT
the net result is a cancellation of the interacting
forces. See Figure B.6.

FIG. B.5 - ARC INTERFERENCE AMPS

+ - + +
CURRENT HELD
CONSTANT
- + - - AND

WIRE FEED Extension

SPEED VARIED Heating= Vir
Total Electrical
TO
Stick out
V= Vir+Varc
MAINTAIN CONSTANT Arc Length= Varc
ARC LENGTH
WIRE FEED SPEED

PUSH PULL

CONSTANT VOLTAGE (CV)

• Operator presets Wire Feed Speed and desired
FIG. B.6 SYNCHRONIZED ARCS Voltage
• The Power Source:
- Goal is to maintain a constant arc length.
Lead Arc - Commands constant wire feed speed
- Synergically Controls Current to Maintain
Voltage at the desired Set point
Trail Arc
• Arc Length is proportional to Voltage
• Traditionally used for smaller diameter wires and
Positive Negative

Negative Negative
Positive Negative
Positive Positive

faster travel speeds.

Positive Negative

FIGURE B.8
PULL

PULL
PUSH
PUSH
PUSH

AMPS

CURRENT VARIED

AND

CAUTION WIRE FEED SPEED

HELD CONSTANT
Extension
Heating= Vir
Total Electrical
Never simultaneously touch electrically "hot" TO Stick out
V= Vir+Varc
parts in the electrode circuits of two different MAINTAIN CONSTANT
ARC LENGTH
Arc Length= Varc

welders. The electrode to electrode no load WIRE FEED SPEED

voltage of multiple arc systems with opposite

polarities can be double the no load voltage of
each arc. Consult the Safety information located
at the front of the Instruction Manual for additional
information.
------------------------------------------------------------------------

POWER WAVE® AC/DC 1000 SD

B-9 OPERATION B-9

WELD SEQUENCE: END OPTIONS

The weld sequence defines the weld procedure from The Downslope, Crater, and Burnback parameters
beginning to end. The Power Wave® AC/DC 1000 SD are used to define the end of the weld sequence.
not only provides adjustment of basic welding
parameters, but also allows the operator to fine tune • Downslope determines the amount of time it takes
the start and finish of each weld for superior to ramp from the Weld parameters to the Crater
performance. parameters. The transition is linear and may be up
or down depending on the relationship between the
All adjustments are made through the user interface. Weld and Crater settings.
Because of the different configuration options, your
system may not have all of the following adjustments. • Crater parameters are typically used to fill the crater
Regardless of availability, all controls are described at the end of the weld, and include both time and
below. output settings.

START OPTIONS • Burnback defines the amount of time the output

remains on after the wire has stopped. This feature
The Strike, Start, and Upslope parameters are used at is used to prevent the wire from sticking in the weld
the beginning of the weld sequence to establish a puddle, and condition the end of the wire for the
stable arc and provide a smooth transition to the next weld. A Burnback time of 0.4 sec is sufficient in
welding parameters. most applications. The output level for Burnback is
generally set to the same level as the last active
• Strike settings are valid from the beginning of the weld sequence state (either Weld or Crater).
sequence (Start Button Pressed) until the arc is
established. They control Run-in (speed at which RE-STRIKE TIMER
the wire approaches the workpiece), and provide
the power to establish the arc. If the arc goes out for any reason (short circuit or open
Typically output levels are increased and circuit), the Power Wave® AC/DC 1000 SD will enter
WFS is reduced during the Strike portion of a Re-strike state. During this state the system will
the weld sequence automatically manipulate the WFS and output in an
attempt to re-establish the arc. The Re-strike timer
• Start values allow the arc to become stabilized once determines how long the system will attempt to re-
it is established. establish the arc before it shuts down.
Extended Start times or improperly set
parameters can result poor starting • Used to protect the welding system and/or work
piece being welded.
• Upslope determines the amount of time it takes to • A Re-strike time of 1 to 2 sec is sufficient in most
ramp from the Start parameters to the Weld applications.
parameters. The transition is linear and may be up • A Re-Strike setting of “OFF” allows for infinite
or down depending on the relationship between the restriking attempts until a shutdown occurs.
Start and Weld settings.
FIGURE B.9 WELD SEQUENCE

Arc Start
Delay Strike Start Upslope Weld Downslope Crater Burnback
Output

Time
Wire Touches
Start Button

Wire Begins

End of Start

Downslope

End of Crater
Stop Button
Pressed

Upslope

Burnback
to Feed

End of

End of
Pressed
Plate

Timer

End of
Timer

POWER WAVE® AC/DC 1000 SD

B-10 OPERATION B-10

WELD PROCESS ADJUSTMENTS DC OFFSET

Depending on the weld mode, there are a number of • Refers to +/- shift of the current waveform with
adjustments that can be made, including but not respect to the zero crossing.
limited to Current, Voltage and WFS. These FIGURE B.11 - DC OFFSET
adjustments apply to either AC or DC processes, and
control the basic parameters of the weld.
Positive Offset
More Penetration
1000 Less Deposition
Nominal Offset Negative Offset
Less Penetration
AC ADJUSTMENTS 500
More Deposition

In addition to the basic weld parameters, there are a

0
number of unique adjustments related to the AC
waveform of the Power Wave® AC/DC 1000 SD.
These adjustments enable the operator to balance the -500

relationship between penetration and deposition to

tailor the output for specific applications. -1000

WAVE BALANCE

• Refers to amount of time the waveform spends in • Use Offset to control the penetration and deposition
DC+ portion of the cycle. of a given process. See Figure B.11.

FIGURE B.10 - WAVE BALANCE

FREQUENCY
1000 Increased Balance
Nominal Balance More Penetration
Less Deposition Decreased Balance • Power Wave® AC/DC 1000 SD can produce Output
Less Penetration
More Deposition
Frequencies from 10 - 100Hz
500
FIGURE B.12 - FREQUENCY

1000 Use Frequency to fin e tune stability of

imb alanced waveform s and multipl e arc syst ems
-500

500

-1000

-500

• Use Wave Balance to control the penetration and -1000 Decrease Increase
deposition of a given process. See Figure B.10.

• Use Frequency to help provide stability.

• Higher frequencies in multiple arc setups can help

reduce arc interaction.

• Lower frequencies will help overcome output limita-

tions due to inductance in the Weld Circuit. See
Figure B.12.

POWER WAVE® AC/DC 1000 SD

B-11 OPERATION B-11

PHASE ADJUSTMENT FOR MULTIPLE

ARC SYSTEMS
Arc Start
Delay Strike Start Upslope Weld
Phase
• The phase relationship between the arcs helps to
Output

minimize the magnetic interaction between adjacent

arcs. It is essentially a time offset between the
waveforms of different arcs, and is set in terms of an
angle from 0 to 360°, representing no offset to a full
period offset. The offset of each arc is set
independently with respect to the lead arc of the
Wire Touches
Start Button

Wire Begins

End of Start

system (ARC 1).

Pressed

Upslope
to Feed

End of
Plate

Timer

Recommendations:

• For balanced waveforms a phase relationship of 90°

should be maintained between adjacent arcs.

TABLE B.1 - PHASE RELATIONSHIP

ARC 1 ARC 2 ARC 3 ARC 4 ARC 5 ARC 6
Lead Trail Trail Trail Trail Trail
2 Arc
System
0° 90° X X X X
3 Arc
System
0° 90° 180° X X X
4 Arc
System
0° 90° 180° 270° X X
5 Arc
System
0° 90° 180° 270° 0° X
6 Arc
System
0° 90° 180° 270° 0° 90°

• For unbalanced waveforms:

– Avoid switching at same time.
– Break up long periods of unchanged polarity
relative to adjacent arcs.

Phase Relationship
Use Phase Relation ship to minimize arc blo w
in multip le arc systems.
(Balanced two arc syst em shown)

0° 90° 180°
(PULL) (PUSH/PULL ) (PUSH)

500
ARC 1
ARC 2

-500

BAD GOOD BAD

Best results obtained by alternating and equalizing the duration of
magnetic for ces between adjacent arcs.

POWER WAVE® AC/DC 1000 SD

C-1 ACCESSORIES C-1
OPTIONS AND ACCESSORIES are
available at www.lincolnelectric.com

Follow these steps:

1. Go to www.lincolnelectric.com

2. In the Search field type E9.180 and click on the

Search icon (or hit ‘Enter’ on the keyboard).

3. On the Results page, scroll down to the

Equipment list and click on E9.180.

All of the information for the PowerWave System

accessories can be found in this document.

SOFTWARE TOOLS

The Power Wave® AC/DC 1000 SD is shipped with a CD including software tools and other documents related
to the integration, configuration, and operation of the system. The Power Wave Submerged Arc Utilities CD
includes the following items and all of the documentation to support them.
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 power
source (more than one Power Wave per arc) systems.

Diagnostics Utility Utility to diagnose Power Wave problems, read system information,
calibrate output voltage and current, test sense leads, and diagnose
feed head issues. Can also setup and verify DeviceNet operation.

POWER WAVE® AC/DC 1000 SD

D-1 MAINTENANCE D-1

SAFETY PRECAUTIONS
CALIBRATION SPECIFICATION
WARNING
Output Voltage and Current are calibrated at the
factory. Generally speaking the machine
ELECTRIC SHOCK can kill. calibration will not need adjustment. However, if
• Only Qualified personnel should the weld performance changes, or the yearly
perform this maintenance. calibration check reveals a problem, use the
calibration section of the Weld Manager Utility
• Turn the input power OFF at the disconnect
to make the appropriate adjustments.
switch or fuse box before working on this
equipment.
The calibration procedure itself requires the use
• Do not touch electrically hot parts. of a grid (Resistive Load Bank), and certified
ROUTINE MAINTENANCE actual meters for voltage and current. The
accuracy of the calibration will be directly
affected by the accuracy of the measuring
Routine maintenance consists of periodically
equipment you use. The Weld Manager Utility
blowing out the machine, using a low-pressure
includes detailed instructions, and is available on
airstream, to remove accumulated dust and dirt
the Power Wave Submerged Arc Utilities CD.
from the intake and outlet louvers, and the
It is also available on the internet at power-
cooling channels in the machine.
wavesoftware.com under Power Wave
The rear portion of the machine that contains the filter, Utilities.
the cooling fans and many of the heat sinks slides out
for easy access. Removing the four(4) clips and
pulling back on the rear portion of the machine will
provide access for cleaning the machine and checking
the filter. The filter may be removed from the right side
of the machine. See Figure A.1.

PERIODIC MAINTENANCE
Calibration of the Power Wave® AC/DC 1000 SD
is critical to its operation. Generally speaking the
calibration will not need adjustment. However,
neglected or improperly calibrated machines may
not yield satisfactory weld performance. To
ensure optimal performance, the calibration of
output Voltage and Current should be checked
yearly.

POWER WAVE® AC/DC 1000 SD

E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
Step 1. LOCATE PROBLEM (SYMPTOM). This column provides a course of action for the
This column describes possible symptoms that the Possible Cause, generally it states to contact your
machine may exhibit. Find the listing that best local Lincoln Authorized Field Service Facility.
describes the symptom that the machine is exhibiting.
If you do not understand or are unable to perform the
Step 2. POSSIBLE CAUSE. Recommended Course of Action safely, contact your
The second column labeled “POSSIBLE CAUSE” lists local Lincoln Authorized Field Service Facility.
the obvious external possibilities that may contribute
to the machine symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000 SD

E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual

USING THE STATUS LED TO TROUBLESHOOT

SYSTEM PROBLEMS
The POWER WAVE® AC/DC 1000 SD is equipped with an externally
mounted status light. If a problem occurs it is important to note the
condition of the status lights. Therefore, prior to cycling power to
the system, check the power source status light for error
sequences as noted below.

Included in this section is information about the power source and

Wire Drive Module Status LED’s, and some basic troubleshooting
charts for both machine and weld performance.

The STATUS LIGHTS are dual-color LED’s that indicate system

errors. Normal operation for each is steady green. Error conditions
are indicated in the following Table E.1.

TABLE E.1
Light Meaning
Condition

Steady Green System OK. Power source is operational, and is communicating normally with all healthy
peripheral equipment connected to its ArcLink network.

Blinking Green Occurs during power up or a system reset, and indicates the POWER
WAVE® is mapping (identifying) each component in the system. Normal for
first 1-10 seconds after power is turned on, or if the system configuration is
changed during operation.

Fast Blinking Green Under normal conditions indicates Auto-mapping has failed.
Also used by the Diagnostics Utility (included on the POWER WAVE® Utilities
and Service Navigator CD’s or available at www.powerwavesoftware.com) to
identify the selected machine when connecting to a specific IP address.

Alternating Green and Red Non-recoverable system fault. If the Status lights are flashing any combination
of red and green, errors are present. Read the error code(s) before the
machine is turned off.

Error Code interpretation through the Status light is detailed in the Service
Manual. Individual code digits are flashed in red with a long pause between
digits. If more than one code is present, the codes will be separated by a
green light. Only active error conditions will be accessible through the Status
Light.

Error codes can also be retrieved with the Diagnostics Utility (included on the
POWER WAVE® Utilities and Service Navigator CD’s or available at
www.powerwavesoftware.com). This is the preferred method, since it can
access historical information contained in the error log.

To clear the active error(s), turn power source off, and back on to reset.

Steady Red Not applicable.

Blinking Red Not applicable.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® AC/DC 1000 SD

E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWER WAVE®
The following is a partial list of possible error codes for the Power Wave® AC/DC 1000 SD. For a complete listing
consult the Service Manual for this machine.

POWER SOURCE–––WELD CONTROLLER

Error Code # LECO Indication
(FANUC#)
31 Primary (Input) overcurrent error. 49 Excessive Primary current present. May be related to a
switch board or output rectifier failure.

32 Capacitor “A” under voltage 50 Low voltage on the main capacitors. May be caused by
(right side facing the Switch PC Board) improper input configuration, or an open/short circuit in the
33 Capacitor bank "B" under voltage 51 primary side of the machine.
(left side facing the Switch PC Board)
34 Capacitor "A" over voltage Excess voltage on the main capacitors. May be caused by
(right side facing the Switch PC Board) 52
improper input configuration, excessive line voltage, or
35 Capacitor "B" over voltage improper capacitor balance (see Error 43)
(left side facing the Switch PC Board) 53

36 Thermal error Indicates over temperature. Usually accompanied by

54 Thermal LED. Check fan operation. Be sure process does
not exceed duty cycle limit of the machine.

37 Softstart (pre-charge) error 55 Capacitor precharge failed. Usually accompanied by

codes 32 and 33.

39 Misc. hardware fault 57 Unknown glitch has occurred on the fault interrupt circuit-
ry. Sometimes caused by primary over current fault, or
intermittent connections in the thermostat circuit.

43 Capacitor delta error 67 The maximum voltage difference between the main capac-
itors has been exceeded. May be accompanied by errors
32-35. May be caused by an open or short in the primary
or secondary circuit(s).

54 Secondary (output) over current 84 The long term average secondary (weld) current limit has
been exceeded. This error will immediately turn off the
machine output.

NOTE: The long term average secondary current limit is

450 amps.

A complete list of error codes is available in the

Diagnostics Utility (included on the POWER WAVE®
Utilities and Service Navigator CD’s or available at
see com- www.powerwavesoftware.com).
Other plete
listing Error codes that contain three or four digits are defined as
fatal errors. These codes generally indicate internal errors
on the Power Source Control Board. If cycling the input
power on the machine does not clear the error, contact the
Service Department

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE® AC/DC 1000 SD
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual

ERROR CODES FOR THE POWER WAVE®

The following is a partial list of possible error codes for the Power Wave® AC/DC 1000 SD. For a complete listing
consult the Service Manual for this machine.

WIRE DRIVE MODULE

Error Code # LECO Indication
(FANUC#)
81 Motor Overload 129 Long term average motor current limit has been exceeded. Typically
indicates mechanical overload of system. If problem continues con-
sider higher torque gear ratio (lower speed range).

82 Motor Overcurrent Absolute maximum motor current level has been exceeded. This is a
130
short term average to protect drive circuitry.

83 Shutdown #1 131 The Shutdown inputs on the POWER WAVE® AC/DC 1000 SD have
been disabled. The presence of these errors indicates the Feed
Head Control PCB may contain the wrong operating software.
84 Shutdown #2 132

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE® AC/DC 1000 SD
E-5 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
BASIC MACHINE PROBLEMS

Major physical or electrical damage None 1. Contact your local authorized

is evident when the sheet metal Lincoln Electric Field Service
covers are removed. facility for technical assis-
tance.

Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly
sized. See installation section
of this manual for recom-
mended sizes.

2. Improper Weld Procedure 2. Reduce output current, duty

requiring output levels in cycle, or both.
excess of machine rating.

3. Major physical or electrical 3. Contact your local authorized

damage is evident when the Lincoln Electric Field Service
sheet metal covers are facility for technical assis-
removed. tance.

Machine will not power up (no 1. No Input Power. 1. Make sure input supply dis-
lights) connect has been turned ON.
Check input fuses. Make cer-
tain that the Power Switch
(SW1) on the power source is
in the “ON” position.

2. Fuse F1 (in reconnect area) 2. Power Down and replace the

may have blown. fuse.

3. Circuit breaker CB1 (on the 3. Power Down and reset CB1.
control panel) may have
tripped.

4. Improper input voltage selec- 4. Power down, check input volt-

tion (multiple input voltage age reconnect according to
machines only). diagram on reconnect cover.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE® AC/DC 1000 SD
 F-1
DIAGRAMS

POWER WAVE® AC/DC 1000 SD

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
 F-2
DIAGRAMS

POWER WAVE® AC/DC 1000 SD

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
 F-3

19.71

46.60 19.12

7.94 19.47
9.56 9.56

49.13
45.75

22.63

61.30

WIDTH NEEDED FOR FILTER

MAINTENANCE ACCESS
DIMENSION PRINT

POWER WAVE® AC/DC 1000 SD

33.00

FILTER REMOVAL
FROM SIDE OF MACHINE

A.02
F-3

L15150
 NOTES

POWER WAVE® AC/DC 1000 SD

 • Do not touch electrically live parts or • Keep flammable materials away. • Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

• Insulate yourself from work and
ground.
Spanish
• No toque las partes o los electrodos • Mantenga el material combustible • Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION • Aislese del trabajo y de la tierra.

French • Ne laissez ni la peau ni des vête- • Gardez à l’écart de tout matériel • Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
• Isolez-vous du travail et de la terre.

German • Berühren Sie keine stromführenden • Entfernen Sie brennbarres Material! • Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
• Não toque partes elétricas e electro- • Mantenha inflamáveis bem guarda- • Use proteção para a vista, ouvido e
dos com a pele ou roupa molhada. dos. corpo.
ATENÇÃO • Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE

ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT

ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
• Keep your head out of fumes. • Turn power off before servicing. • Do not operate with panel open or
• Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
• Los humos fuera de la zona de res- Spanish
• Desconectar el cable de ali- • No operar con panel abierto o
piración.
• Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
• Gardez la tête à l’écart des fumées. • Débranchez le courant avant l’entre- • N’opérez pas avec les panneaux French
• Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
• Vermeiden Sie das Einatmen von • Strom vor Wartungsarbeiten • Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öffnen; oder Innenschutzverkleidung in
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Maschine anhalten!) Betrieb setzen! WARNUNG
• Não opere com as tampas removidas. Portuguese
• Mantenha seu rosto da fumaça. • Mantenha-se afastado das partes
• Use ventilação e exhaustão para • Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço.
• Não toque as partes elétricas nuas.
• Não opere com os paineis abertos ATENÇÃO
ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES

DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 • World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com