Lincoln Electric 11124, 11226 manual Product Summary, Recommended Processes, Process Limitations

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B-3

OPERATION

B-3

 

 

 

PRODUCT SUMMARY

The Power Wave AC/DC 1000 is a high performance, digitally controlled inverter welding power source. It is capable of producing a variable frequency and ampli- tude AC output, DC positive output, or DC negative output without the need for external reconnection. It utilizes complex, high-speed waveform control to sup- port a variety of constant current and constant voltage welding modes in each of its output configurations.

The Power Wave AC/DC 1000 power source is designed to be a part of a modular welding system. Each welding arc may be driven by a single machine, or by a number of machines in parallel. In multiple arc applications the phase angle and frequency of differ- ent machines can be synchronized with the use of an external System Interface to improve performance and reduce the effects of arc blow.

The Power Wave AC/DC 1000 is primarily designed to interface with compatible ArcLink equipment. However, it can also communicate with other industri- al machines and monitoring equipment via DeviceNet, or Ethernet. The result is a highly integrated and flexi- ble welding cell.

RECOMMENDED PROCESSES

The Power Wave AC/DC 1000 is designed for sub- merged arc welding (SAW). Due to its modular design the Power Wave AC/DC can operate on either single arc or multiple arc applications. Each machine is fac- tory preprogrammed with multiple welding procedures to support all types of submerged arc welding. The Power Wave AC/DC 1000 carries an output rating of 1000 amps, 44 volts (at 100% duty cycle). If higher currents are required machines can be easily paral- leled.

PROCESS LIMITATIONS

The Power Wave AC/DC 1000 is suitable only for the processes listed.

Do not use Power Wave AC/DC 1000 for pipe thaw- ing.

EQUIPMENT LIMITATIONS

The Power Wave AC/DC 1000 is not to be used in outdoor environments.

Operating Temperature Range is 32°F to 104°F(0°C to +40°C).

Only the ArcLink Power Feed 10S series wire feeders and Power Feed 10A controller may be used in a standard system. Other Lincoln or non-Lincoln wire feeders can only be used with custom interfaces.

The Power Wave AC/DC will support a maximum average output current of 1000 Amps at 100% Duty Cycle.

COMMON EQUIPMENT PACKAGES

Basic Package

K2344-1 or

Power Wave AC/DC 1000

K2344-2

 

K2370-1

Power Feed 10S Head Wire Feeder

K2362-1

Power Feed 10A Controller / User

 

Interface

K1543-xx

Control Cable (5 pin – 5 pin) - power

 

source to controller.

K1785-xx

Control Cable (14 pin – 14 pin) -

 

power source to wire feeder.

Optional kits

K2282-1 System Interface - for Synchronizing multiple arc applications.

K1795-xx Control Cable (22 pin – 22 pin) - for paralleling / multiple arc applications.

K2312-1 Power Feed 10SF wire feeder (for fix- ture builders).

K2311-1 Power Feed 10SM Motor Conversion Kit (to convert existing NA-3/NA-4/NA-5 wire feeder gear boxes).

K2444-1 CE, C-Tick Filter Kit

RECOMMENDED EQUIPMENT

(See Installation Section)

POWER WAVE® AC/DC 1000

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Contents Power Wave AC/DC Mar ‘95 SafetyElectric Shock can kill Iii Welding and Cutting Sparks can Cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Safety Thank You Table of Contents Table of Contents Specifications Installation Input and Ground Connections Input Fuse and Supply Wire ConsiderationsInput Connection Input Voltage SelectionSystem Overview System ConnectionSystem Description Single Arc Tandem Arc Triple Arc 3,4 Recommended EquipmentSystem Identifier Description Optional EquipmentElectrode Studs Work Studs Arclink 5 Pin Step by Step Installation Checklist Wire Reel Mountings Step by Step Installation Checklist System DeviceNet PLC Controller Installation Connection Diagram- Parallel Machines DeviceNet PLC Controlled Systems PF-10S ConnectionsPF-10A Controlled Systems Connections Electrode and WorkCable INDUCTANCE, and ITS Effects on Welding Remove the front cover from the power sourceRemote Sense Lead Connections Voltage Sensing OverviewVoltage Sensing Considerations for Multiple ARC Systems Voltage Sensing for Slave machinesPower Common Equipment Connections Control Cable ConnectionsInstallation Receptacle Specification External I/O ConnectorTable A.4 RS232 Connector S3 DB-25 style Table A.5 DeviceNet Connector S5 5 pin mini styleTransmit + Table A.7 External I/O S7 12 pin terminal blockTransmit Receive +Ethernet Configuration Wire Drive Gear Ratio SettingInternal Controls Description Devicenet ConfigurationInternal Controls Ethernet Board DIP Switches S1, S2 Control Board DIP Switch S1Feed Head Board DIP Switch S1 Object Instance Off 0defaultTable A.14 Table A.15Devicenet MAC ID Table A.16 Master Master / Slave ConfigSlave Bank S4 Bank S3Common Welding Abbreviations OperationDefinitions of Welding Modes Input Power Three Phase Positive Output Negative Output Phase InverterProtective GroundRecommended Processes Product SummaryProcess Limitations Equipment LimitationsSee Figure B.4 Case Front Control DescriptionsFigure B.5 Power Wave AC/DC Case Rear Components POWER-UP SequenceDuty Cycle Common Welding ProceduresOverview of the AC/DC Submerged ARC Process Making a WeldBasic Modes of Operation Multiple ARC System ConsiderationsConstant Current CC Constant Voltage CVWeld Sequence RE-STRIKE TimerStart Options END OptionsAC Adjustments Weld Process Adjustments DC OffsetWave Balance FrequencyRecommendations PhaseKITS, Options and Accessories AccessoriesOptional Kits and Accessories Software ToolsCalibration Specification MaintenancePeriodic Maintenance HOW to USE Troubleshooting Guide TroubleshootingRecommended SymptomsCourse of Action Qualified person should Perform this operationRecommended Symptoms ARC Quality Problems Weld Tab of the Diagnostics Utility Diagnostics Utility displays Diagnostics Utility, select MonitorDiagnostics Utility, select Changed, select Configure, Power Wave’s passive modeProduced Assembly that Gas Analog In Active Selections From the DeviceNet tabScans Between Updates and I/O Bad Weld Ending Burnback DisabledBetween Updates is 1/4 of I/O Bad Welding Analog Scans Between UpdatesManager utility Utility included on the Power Wave Submerged Arc Present. Read the error codes before the machineUtilities and Service Navigator CD’s. This is the pre Is turned offError Codes Power SOURCE- Weld ControllerError Code # Indication This error will immediately turn off the machine outputWire Drive Module 1000 DiagramsDiagrams AC Switch Wiring Diagram AC Switch Wiring Diagram Dimension Print Power Wave AC/DC Precaucion Warnung