Lincoln Electric Power Wave AC/DC 1000 MC04-216 Manual de usuario

Description

Output Input

Power Wave®AC/DC 1000™

Increase Productivity, Quality and Flexibility

AUTOMATED SOLUTIONS

The Power Wave AC/DC 1000 is the first power source to introduce Waveform Control

Technology™ to submerged arc welding. Variable frequency and amplitude AC, DC

positive or DC negative output allows the user to control the deposition rate and penetra-

tion. An operator can increase weld speeds, yield higher quality welds and improve effi-

ciencies in a single or multi-arc environment. The phase angle and frequency of different

machines can also be synchronized to balance the interactions between multiple arcs and

minimize arc blow. Depending on the output, a welding arc may be driven by a single

machine or multiple machines in parallel for applications that require more than 1000

amps of continuous operation.

Advantage Lincoln

Order

TECHNICAL SPECIFICATIONS

Recommended General Options

Recommended Wire Feeders

• Eliminate downtime with easy polarity switching –– no hardware

reconfiguration required.

• Stable and independent arc controls for multiple arc applications.

• Improved efficiency and reliability with cooler operation through

patented Coaxial Transformer Technology™.

• 95% power factor correction enables connection of more

machines on the same plant infrastructure for lower installation

costs compared to other machines.

• Remote process monitoring and control through ArcLink,

Ethernet, and DeviceNet communication.

• Consistent operation over ± 10% input voltage variation through

built-in line voltage compensation and reliable input voltage

connection.

• Manufactured under a quality system certified to ISO 9001

requirements and ISO 14001 environmental standards.

•Three-year warranty on parts and labor.

PHASE

Power Feed 10A Controller K2362-1 (requires either the K2312-1

Power Feed 10SF Wire Feed Head for fixed hard automation, or

the K2370-1 Power Feed 10S Head for mounting a Lincoln TC-3

Travel Carriage), Power Feed 10SM Motor Conversion Kit K2311-1

(Other options may apply).

K2344-1 Power Wave AC/DC 1000 460/500/575/3/60

K2344-2 Power Wave AC/DC 1000 400/460/500/575/3/50/60

System Interface, Interface Control Cable (22-pin), ArcLink Cable (5-pin),

Feeder Control Cable (14-pin), TC-3 Self-Propelled Travel Carriage,

CE Filter(1)

Rated Output Dimensions Net

Product Product Input Current/Voltage/ Input Current Output H x W x D Weight

Name Number Voltage Duty Cycle @Rated Output Range in (mm) lbs (kg)

Power Wave AC/DC 1000 K2344-1 460/500/575/3/60 1000/44/100% 68/62/54 100-1000A 43.5 x 19.2 x 33 600

(1105 x 488 x 838) (272)

Power Wave AC/DC 1000(1) K2344-2(1) 380/400/460/500/575/3/50/60 1000/44/100% 82/79/69/62/55 100-1000A 43.5 x 19.2 x 33 650

(1105 x 488 x 838) (295)

Submerged Arc

Processes

(1) External Filter is required to meet CE conducted emission requirements. The K2444-1 must be used with the K2344-2.

Publication E10.96 1/05

Web Update 1/06

www.lincolnelectric.com

Power Wave AC/DC 1000

A CLOSER LOOK

[2] www.lincolnelectric.com

WHAT IS NEXTWELD®?

Nextweld integrates Lincoln’s technologies, process-

es and products to create a comprehensive, flexible,

user-friendly welding system that can increase

efficiency and reduce fabrication costs. Waveform

Control Technology™ and digital communications

provide the foundation for Nextweld innovations like Pulse-On-

Pulse™, Power Mode™, STT®and ArcLink®.Look for Nextweld

products for ultimate arc control, high efficiency/reliability and

seamless system integration.

Waveform Control Technology™

Driving Superior Welding Performance

Lincoln’s Waveform Control Technology controls and shapes the output waveforms (or weld

modes) to adapt to virtually any application, material or weld position. In addition, you can

have our Application Engineering department add or customize standard waveform programs.

For more information see Nextweld Document NX-1.10

Waveform Control Technology

• Ultimate arc control — Many aspects of the waveform may be varied

as a function of time in order to customize the arc exactly to your

specifications.

• Dynamically controlled output — Arc Current, Voltage or Power

may be controlled and regulated automatically so adjustments and

corrections are made as they arise.

• Different parts of the waveform and wire feed speed may be

modulated at varying rates to accomplish a constant average

condition (Constant Voltage, Constant Current, etc.).

Refer to Publication NX-2.30 Nextweld AC/DC submerged arc

process document for more details.

Variable Frequency – Control Arc Stability

The Power Wave AC/DC 1000™ has the widest range of wave fre-

quency adjustment (10 - 100 Hz) in the industry. Adjust frequency

with the turn of a knob to maximize arc stability.

Turn Frequency down

for more penetration

(less energy) with a less

stable arc.

Turn Frequency up for a

more stable arc with less

penetration (more energy

in less time).

Waveforms are easily changed

through graphical interface

System Interface

Power Wave AC/DC 1000

www.lincolnelectric.com

[3]

A CLOSER LOOK

Variable Balance – Control Deposition

By setting the correct wave balance (that is, the ratio between positive and negative waveforms), the operator is able to work faster and fill

the weld joint with fewer passes. The Power Wave AC/DC 1000™ has wave balance range of 25% to 75%.

The more positive the wave,

the more penetration.

The more negative the

wave, the greater the

weld deposition.

DC Offset (Variable Amplitude) – Control Penetration

Wave amplitude and the duration of positive and negative cycles are independently adjustable, so the operator can obtain deep/shallow

penetration and higher/lower deposition rates, depending on the application. The Power Wave AC/DC 1000 has the widest range of vari-

able amplitude, or DC offset, (-25% to 25%) in the industry.

Increasing the negative amplitude

(offset) decreases penetration.

Multi-Arc Environment

In a multiple arc welding, as many as five arcs operate in a single weld puddle. Changes to the positive/negative polarity phases and/or cycle

balances of the AC waveform enable the operator to control deposition rate, penetration and travel speed without a change in voltage or current

settings. Using the Power Wave AC/DC 1000 in a multi-arc system can increase your weld speeds, yield higher quality welds and improve

efficiencies.

Phase Relationship – Controlling Arc Blow

In a multi-arc environment, arc interaction plays an important role in the behavior of the weld. Two positive electrodes pull together, as do

two negative electrodes, while a positive and negative repel each other, causing arc blow. The Power Wave AC/DC 1000 balances the

"push" and "pull" of the multi-arc relationship using phase shifting to prevent arc blow.

By phase shifting the AC

waveforms, the amount of

"push" and "pull" of the arc

interactions can be bal-

anced using alternating

current to avoid arc blow.

Increasing the positive amplitude

(offset) increases penetration.

Applications

Whether it is a cross country pipeline or an offshore platform, the Power Wave AC/DC 1000 is meeting and exceeding expectations

around the world.

Power Wave AC/DC 1000

www.lincolnelectric.com

[4]

A CLOSER LOOK

75% DC NEGATIVE BALANCED AC LEAD ARC

75% DC NEGATIVE BALANCED AC TRAIL ARC

BALANCED AC LEAD ARC

BALANCED AC TRAIL ARC

STANDARD

TECHNOLOGY

75% DC NEGATIVE LEAD ARC

75% DC NEGATIVE TRAIL ARC WITH

30% DC NEGATIVE AMPLITUDE OFFSET

2 ARCS

3 ARCS

2 Arc 2 Arc 3 Arc 3 Arc

2 Arc 2 Arc 3 Arc

Multi-Arc Submerged Arc Welding

AC/DC 1000

Small diameter circumferential welds, pipe double-

ending, storage tanks, seam welders

Large diameter circumferential welds [40”(1m) and up], spiral pipe mills,

bridge girders, pressure vessels, wind mill towers.

Long straight welds, pipe mills, panel lines.

Single Arc

Tandem Arc

Multiple Arcs (3 to 5)

tt t

Lead Arc — DC+

Deep Penetration

Trailing Arcs — AC

Greater negative components

produces greater deposition and

a flattened bead shape

Variable Positive/Negative

Proportions — Optimize Welding

Variable Frequency and Phase Relationship

— Reduce Arc Blow

Arc Performance

The capabilities of the Power Wave AC/DC 1000™ in a multi-arc environment offer digital control over the critical welding variables for

optimum performance whatever your needs require. As shown below, these digital controls can be used for each arc to provide unprece-

dented arc welding characteristics.

Productivity Comparison

The Power Wave AC/DC 1000 delivers optimized productivity through the ability to adjust phase relationships between the arcs. Multiple

arcs can be tuned to work together rather than interfere with each other.

Productivity Improvement

DC +

DC –

[5]

Power Wave AC/DC 1000

www.lincolnelectric.com

A CLOSER LOOK

RECOMMENDED EQUIPMENT

Product Number Product Description

Power Source K2344-1 or K2344-2 Power Wave AC/DC 1000™ Power Source 1

Head K2370-1 Power Feed 10S head for 3/32 to 7/32 in. solid wire 1

or (Includes hopper, wire straightener, cross seam adjuster,

K2312-1 head mounting hardware)

Power Feed 10SF Head for 3/32 to 7/32 in. solid wire

Fixture Builders Head (Insulators not included)

User Interface K2362-1 Power Feed 10A Controller 1

ArcLink Digital K1543-xx ArcLink Cables (5 pin) from Power Feed 10A Controller 1

Communication Cable to Power Source. Can be extended.

Welding Cables K2163-xx or Weld Power Cables from the Power Source to the 4 Cables

K1842-xx Contact Nozzle and from Power Source to Work Per Arc

Power Source to K1785-xx Feeder Control Cable (14 pin) from the 1

Head Control Cable Head to the Power Source. Cannot be extended.

Torch K231-xx Submerged Arc Contact Nozzle Assembly 1

System Identifier Qty. Required

AC/DC Submerged Arc Single Arc

OPTIONAL EQUIPMENT

PLC (customer supplied)

Ethernet Switch (customer supplied).

Required for arcs > 1000A or with

use of the Submerged Arc Software Suite.

Computer (customer supplied).

Required for use of the

Submerged Arc Software Suite.

K325-x TC-3 Travel Carriage

K96 Horizontal Lift Adjuster

K29 Vertical Lift Adjuster

K299 Wire Reel Assembly

K2462-1 Power Feed 10A Mounting

Bracket (K299 cannot be used if the

mounting bracket is attached. A K390 is

recommended instead.)

System Component

Electrode Studs Work Studs

K2362-1

K1543-XX

Arclink Control Cable

Arclink Connection

Flux Hopper Connection

Travel Carriage Connection

Wire Feeder (14 Pin)

Arclink (5 Pin)

Wire Reel

and Mounting

(1)Work Cable(s)

21 Lead

(1)Electrode Cable(s)

67 Lead

Electrode Sense Lead (67)

Work Sense Lead (67)

K1785-XX

Wire Feeder

Control Cable

K231-XXX

Head

Work Piece

14 Pin Connector

(1)Consult wth your Lincoln representative for recommended cable size.

•

A CLOSER LOOK

Power Wave AC/DC 1000

[6] www.lincolnelectric.com

AC/DC Submerged Arc Dual Arc

RECOMMENDED EQUIPMENT

Product Number Product Description

Power Source K2344-1 or Power Wave AC/DC 1000™ Power Source 2

K2344-2

Mounting for Heads K387 Tandem Arc Framework 1

Head K2312-1 or Power Feed 10S head for 3/32 to 7/32 in. solid wire (Includes hopper, 2

K2370-1 wire straightener, cross seam adjuster, head mounting hardware) or

Power Feed 10SF Head for 3/32 to 7/32 in. solid wire

Fixture Builders Head (Insulators not included)

User Interface K2362-1 Power Feed 10A Controller 2

System Interface K2282-1 System Interface 1

ArcLink Digital K1543-xx ArcLink Cables (5 pin). Can be extended. 3

Communication (1) Lead Arc: Power Source to System Interface

Cable (2) System Interface to User Interface

(3) Trail Arc: Power Source to User Interface

Welding Cables K2163-xx or Weld Power Cables from the Power Source to the contact Nozzle 4 Cables

K1842-xx and from the Power Source to the Work Per Arc

Power Source to K1785-xx Feeder Cable (14 pin) from the Head to the Power Source 2

Head Control Cable Cannot be extended.

Torch K231-xxx Submerged Arc Contact Nozzle Assembly 2

System Interface to K1795-xx Control Cable (22 pin) from each Power Wave AC/DC 1000 to 2

Power Source Cable System Interface. Can be extended.

Product Name Qty. Required

OPTIONAL EQUIPMENT

Ethernet Switch (customer supplied).

Required for arcs > 1000A or with

use of the Submerged Arc Software Suite.

Computer (customer supplied).

Required for use of the

Submerged Arc Software Suite.

K325-x TC-3 Travel Carriage

K96 Horizontal Lift Adjuster

K29 Vertical Lift Adjuster

K299 Wire Reel Assembly

K390 Two Wire Reel Mounting for TC-3

K389 Flux Hopper for K387 Mountings

K2462-1 Power Feed 10A Mounting

Bracket (K299 cannot be used if the

mounting bracket is attached. A K390 is

recommended instead.)

System Component

Arcklink (5 Pin)

Wire Feeder (14 Pin)

Master Input (S12)

Connects to System

Interface

K1795-XX Cables

Arclink Input

Arclink Output

K2282-1

K1543-XX Arclink Control Cables

Travel Carriage Connection

Flux Hopper Connection

Arclink Connection

(1)Electrode Cables

Work Sense Lead (21)

Electrode

Sense

Lead (67)

Work Piece

(1)Work Cables

14 Pin Connector

67 Lead

21 Lead

K231-XXX

Head

K1785-XX

Wire Feeder

Control Cables

Wire Reel and

Mountings

Electrode Studs

K2362-1

Work Studs

(1)Consult wth your Lincoln represen-

tative for recommended cable size.

•

A CLOSER LOOK

AC/DC Submerged Arc Multi-Arc

RECOMMENDED EQUIPMENT

Product Number Product Description

Ethernet Network Equipment Customer Supplied Ethernet Switch, Cables, etc. required for arcs >1000A or for use

with Power Wave Submerged Arc Utilities software package As Needed

Personal Computer Customer Supplied IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, 1

or greater) required for use with Power Wave Submerged Arc Utilities software package

Controls Customer Supplied Programmable Logic Controller 1

DeviceNet Cables Automation Department DeviceNet Cable from the Power Source to PLC and

or Customer Supplied System Interface to PLC (Cables, Tees, and Terminators as required) As Needed

Ethernet Switch Customer Supplied Ethernet Switch 1

Power Source K2344-1 or K2344-2 Power Wave AC/DC 1000™ Power Source 3+

Head K2312-1 or K2370-1 Power Feed 10S head for 3/32 to 7/32 in. solid wire(Includes hopper, wire, straightener 3+

cross seam adjuster, head mounting hardware) or Power Feed 10SF Head for 3/32 to 7/32 in.

solid wire Fixture Builders Head (Insulators not included)

System Interface K2282-1 System Interface 1

Welding Cables K2163-xx or Weld Power Cables from the Power Source to the Contact Nozzle 4 Cables

K1842-xx and from the Power Source to the Work Per Arc

Power Source to K1785-xx Feeder Cable (14 pin) from the Head to the Power Source 3+

Head Control Cable Cannot be extended.

Torch K231-xxx Submerged Arc Contact Nozzle Assembly 3+

System Interface to K1795-xx Control Cable (22 pin) from each Power Wave AC/DC 1000 to 3+

Power Source Cable System Interface. Can be extended.

Product Name Qty. Required

PLC Controller

User

Interface

DeviceNet Cable

Network

Electrode Studs

Wire Reel and

Mountings

(1)Work Cables

Head

K231-XXX

K1543-XX Arclink

Control Cable

K1795-XX Cables K2282-1 DeviceNet

Arclink Input

Work Studs

(1)Electrode Cables

K1785-XX Wire Feeder

Control Cables

Electrode Sense Lead (67)

67 Lead

14 Pin Connector

21 Lead

Work Piece Work Sense Leads (21)

DeviceNet (5 Pin)

Arclink (5 Pin)

Wire Feeder (14 Pin)

Master Input (S12)

Connects to

System

Interface

(1)Consult wth your Lincoln representative for recommended cable size. Power Wave AC/DC 1000

www.lincolnelectric.com

[7]

•

Power Wave AC/DC 1000

www.lincolnelectric.com

[8]

A CLOSER LOOK

What is Coaxial Transformer Technology™?

To transform large amounts of power as is needed for welding, the

power source transformer is a critical factor. Traditional transformers

become more inefficient the larger they become. This becomes a

problem especially for large power sources (i.e. submerged arc power

sources). If the transformer becomes inefficient, it requires more

power to be dissipated in all of the components before the trans-

former. This results in a drastically reduced overall efficiency, compo-

nents that run at higher temperatures, and reduced reliability.

Coaxial Transformer Technology eliminates these problems. Regardless

of the size (power level) a coaxial transformer has superior coupling and

efficiency. This is obtained through the coaxial orientation of the primary

and secondary windings.

The benefits for the customer include:

• Higher power capabilities (submerged arc inverters)

• Higher efficiency (reduced energy costs)

• Higher reliability (lower stresses on components)

Impeller Cooling Technology™

High Efficiency Cooling

Conventional-cooling mechanisms for welders rely on a fan to blow

through the machine, while Lincoln’s patented Impeller Cooling

Technology uses an impeller fan to create a high-pressure chamber.

This high-pressure chamber forces airflow across the heated

components in the machine cooling the Power Wave AC/DC 1000™

transformer and power switchgear.

Power Input Amps

Technology Volts Amps Efficiency Factor @ 460 Volt

Miller Electric®

Summit Arc 1000™ 44 1000 0.84 0.54 122

Power Wave AC/DC 1000 44 1000 0.86 0.95 68

Industry-leading Efficiency, Power Factor and Input Current Draw

Reduce Energy Spending!

The Power Wave® AC/DC 1000 has better efficiency and a

higher Power Factor than the Summit Arc 1000™. Two

Power Wave® AC/DC 1000 machines can be installed for

the same capacity that it takes to install one Summit Arc 1000™.

NOTE: Summit Arc 1000™ is not a trademark of the Lincoln Electric Company.

Power Wave AC/DC 1000

[9]

A CLOSER LOOK

www.lincolnelectric.com

FEATURES

• Machines can be easily configured for multiple arc applications.

• Fully programmable AC or DC wave shape.

• Ethernet capability gives the user the ability to monitor, control

and troubleshoot from remote locations.

• All system components communicate and transfer information.

• Arc performance independent of input power variations.

• Utilizes digital signal processing and microprocessor control.

•Constant current or constant voltage capability.

Key Controls

1. Power Switch

2. Thermal Light

3. Status Light

4. Electrode Stud

5. 10 Amp Wire Feeder Circuit Breaker

6. Auxiliary Power Circuit Breaker

7. Wire Feeder Interface Connector

8. Work Sense Lead Connector

9. RS232 Connector

10. Arclink Connector

11. DeviceNET Connector

12. Ethernet Connector

13. Auxiliary Output

14. Work Stud

15. I/O Connector

11 10 987

QUALITY AND RELIABILITY

• Lincoln’s design philosophy adds an extra factor of safety in all

components and construction to maximize reliability and service.

• Open construction for preventative maintenance.

• Thermostatically protected against overheating.

• Electronic output over-current protection and electronic input

over-voltage protection.

• Operating Temperature Range: -20˚C (-37.7ºF) to +40˚C (-22.2ºF);

Storage Temperature Range: -40˚C (-40ºF) to +40˚C (-22.2ºF).

• Designed to the IEC 60974-1 standards.

• F.A.N. (Fan As Needed). Cooling fan runs during output and for five

minutes after output is turned off.

• Manufactured under a quality system certified to ISO 9001

requirements and ISO 14001 environmental standards.

• Three-year warranty on parts and labor.

• Printed circuit boards are environmentally-shielded using Lincoln's

engineered potting and protective frame trays.

• 100% software controlled – Software based controls can be

upgraded as new features become available.

• Easy access for serviceability.

• Modular construction allows for easy service/maintenance.

Power Wave AC/DC 1000

[10]

A CLOSER LOOK

www.lincolnelectric.com

Real-time welding data is

automatically recorded and saved

Operator Screen Communication

Set Points

Remote Monitoring and Control

Monitor performance from anywhere in the world!

Waveforms are easily changed

through graphical interface

System Interface

The Power Wave AC/DC 1000™ includes software products to

assist with the installation and operation of the equipment. From

an intelligent configuration utility that allows you to automatically

sense and verify the system has been configured properly to a

tool capable of high-level monitoring, control, and data logging

for the system these packages were designed for ease of use

and convenience for the operators and the administrators.

Provides monitoring and control of each arc in a multiple arc system, presenting master/slave relationships and configuration of the arcs in

the system, as well as weld mode selection, parameters of weld states, and diagnostics.

Command Center

Effortlessly change welding

parameters for all arc states

Remotely monitor and diagnose

machine status and system

information

Diagnostics

Digital Communications

Fast, Reliable, System-Wide

ArcLink is the leading digital communications protocol for the arc welding industry. It integrates all welding components for seamless,

time-critical data transfer. The strength of ArcLink lies in the ability to communicate with each system component in a pre-defined welding

language. In addition, ArcLink is an open communications protocol, meaning that Lincoln Electric publishes how it works and encourages

other companies to adopt it.

DeviceNet is a communications protocol widely used throughout the automotive, semiconductor, and packaging industries. In its typical

application, DeviceNet works in conjunction with a programmable Logic Controller (PLC) and several system devices to provide a framework

for data trafficking and monitoring.

Ethernet is a specification for networking that provides the ability to pull large amounts of information into monitoring and supervisory applications.

For more information see Nextweld Document NX-1.30

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