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Lincoln Electric
Power Wave AC/DC 1000 SD

Power Wave AC/DC 1000 SD

Product catalog summary

Introduction
This document provides an overview of Lincoln Electric's advanced submerged arc welding systems, specifically the Power Wave® AC/DC 1000® SD, MAXsa™, and Cruiser™ systems. These systems are designed to enhance welding performance and efficiency in applications such as bridge decking, pressure vessels, and robotic welding.

Specifications
The Power Wave® AC/DC 1000® SD features advanced Waveform Control Technology® for precise AC and DC welding parameter control. It supports constant current or voltage operation with variable frequency and amplitude settings, designed for high productivity, quality, and flexibility. Key features include easy polarity switching, 95% power factor correction, and an IP23 rating for outdoor storage.

Mechanized Solution
The Cruiser™ Tractor is a versatile wire feeding system for heavy plate submerged arc welding, capable of high deposition rates up to 30 lbs/hr. It includes digital meters, travel mode switches, and memory buttons for saving procedures.

Basic Automation Solution
The MAXsa™ 10 Controller offers a single control point for hard automation welding systems, with user-friendly controls and eight procedure memories. It supports both AC and DC welding parameters and is designed for severe duty environments.

Feed Head
The MAXsa™ 22 Feed Head is designed for hard automation applications, providing accurate wire feeding for large diameter wires. It features a high torque motor, closed loop speed control, and multi-axis rotation for flexible setup.

Key Features
- Advanced waveform control for precise welding.
- Energy-efficient design with reduced input current requirements.
- Modular components for adaptability in various applications.
- IP23 rating for durability in harsh environments.
- Software-based controls for easy upgrades and monitoring.

Conclusion
Lincoln Electric's submerged arc welding systems are engineered to improve weld quality, reduce costs, and increase productivity. The systems are supported by a global network of technical teams for setup and customization.

Overview
This document provides detailed specifications and configurations for Lincoln Electric's submerged arc welding systems, focusing on various components and their applications in high-current welding processes.

Specifications

Electrode sizes range from 5/64 to 3/16 inches (2.0 to 4.8 mm) with currents generally below 600 amps, but rated up to 650 amps.
Contact assemblies are designed for single arc welding at high currents, with specific assemblies for different wire diameters.
ESO (Extended Stick-Out) extensions and narrow gap deep groove nozzles are available for specific welding techniques.

Components

MAXsa™ 19 Controller: Compact, designed for integration with third-party systems, featuring fast digital communication and IP23 rating for harsh environments.
MAXsa™ 29 Feed Head: Offers closed-loop speed control, high torque motor, and adjustable wire straightener, suitable for wire diameters up to 7/32 inches (5.6 mm).
TC-3 Tractor: Allows mounting of feed heads and wire reels for automation installations.

Technical Specifications

MAXsa™ 19 Controller and MAXsa™ 29 Feed Head both operate at 40 VDC with a 1000A/100% duty cycle.
Gear ratios for the feed head can be adjusted to match application requirements.

Recommended Equipment

Power Wave® AC/DC 1000® SD, MAXsa™ 10 Controller, and MAXsa™ 22 Wire Drive are recommended for various configurations.
Specific cables and leads are required for system integration and operation.

Accessories and Options

Drive roll kits, control cables, and sense lead kits are available for different wire sizes and types.
Additional accessories include flux hoppers, wire straighteners, and contact nozzle assemblies.

Waveform Control Technology®
Provides software-driven control over penetration, deposition rate, and travel speed, allowing for precise adjustments to welding parameters.

Specifications and Procedures
The document discusses the balance and offset in submerged arc welding systems, focusing on the percentage of time in the positive polarity portion of one cycle and the positive/negative amplitude. It highlights productivity improvements achievable through enhanced control in single arc and Twinarc® submerged arc welding systems.

Productivity Improvement
Graphs illustrate productivity improvements in percentage terms for various welding configurations, including DC+ lead arc, balanced AC trail arcs, and 75% DC- square wave AC lead and trail arcs. The data suggests greater productivity through enhanced control.

Single Arc and Twinarc® Submerged Arc Welding
The document compares single wire DC+, balanced AC, and 75% DC- square wave AC configurations, as well as 2-wire Twinarc® systems, highlighting the advantages of multi-arc submerged arc welding.

Customer Assistance Policy
The Lincoln Electric Company emphasizes its commitment to manufacturing high-quality welding equipment and providing customer assistance. However, it disclaims any liability for information or advice provided, stating that the selection and use of products are the customer's responsibility.

Disclaimer
The document notes that the information is subject to change and advises checking the company's website for updates.

Catalog excerpts

Power Wave® AC/DC 1000® SD, MAXsa™ and Cruiser™ Submerged Arc Equipment Systems Bigger Welds, Faster.™ www.lincolnelectric.com/subarc Mechanized Solutions Basic Automation Solutions Integrated Solutions Robotic Solutions

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[ 2 ] | Submerged Arc Equipment Systems THE LINCOLN ELECTRIC COMPANY About The Lincoln Electric Company Submerged Arc Welding Platforms Lincoln Electric is the world’s leading manufacturer of welding equipment and consumables. Our focus is helping companies make their welding operations more effective, more efficient, and more profitable. We are dedicated to two equally important goals: exceptional quality and exceptional service. Our field support team –– with hundreds of field sales engineers and thousands of knowledgeable and responsive Lincoln distributors in countries all over the world...

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Submerged Arc Equipment Systems | [ 3 ] INTRODUCTION Power Source Power Wave® AC/DC 1000® SD . . . . . . 4-5 Mechanized Solution Power Wave® AC/DC 1000® SD Cruiser™ Tractor . . . . . . . . . . . . . . . . . . 6-7 Basic Automation Solution Power Wave® AC/DC 1000® SD MAXsa™ 10 Controller . . . . . . . . . . . . . . . . . . . . . . . .8-9 MAXsa™ 22 Feed Head . . . . . . . . . . . . . . . . . . . . . 10-11 Integrated Solution and Robotic Solution Power Wave® AC/DC 1000® SD MAXsa™ 19 Controller and MAXsa™ 29 Feed Head . . . . . . . 12-14 Appendix . . . . . . . . . . . . . . . . . . . . 15-23

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[ 4 ] | Submerged Arc Equipment Systems THE LINCOLN ELECTRIC COMPANY Power Wave® AC/DC 1000® SD Increase Productivity, Quality and Flexibility The Power Wave® AC/DC 1000® SD delivers Waveform Control Technology® to submerged arc welding. Choose constant current or constant voltage operation and set variable frequency and amplitude. Software- driven AC, DC positive or DC negative output allows the user to control the deposition rate and penetration. The result over conventional power sources is increased weld speeds, consistently higher quality welds and improved efficiencies in a single or multi-arc...

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Submerged Arc Equipment Systems | [ 5 ] POWER SOURCE KEY CONTROLS Front Top View 3 2 1 Bottom Rear View 4 5 6 7 8 9 10 11 15 14 13 Top Rear View 1. Power Switch 2. Status Lights 3. Thermal Light 4. Electrode Studs 5. Work Studs 6. I/O Connectors for Synchronizing Machines 7. Work Sense Lead Connector 8. Ethernet Connector 9. Auxiliary Power Circuit Breaker 10. 10 Amp Wire Feeder Circuit Breaker 11. Auxiliary Output (115V, 10A AC) 12. Input Cable Location 13. DeviceNET™ Connector 14. Controller ArcLink® Connector 15. I/O Connectors for Paralleling Machines FEATURE LOADED, RUGGED CONSTRUCTION AND...

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[ 6 ] | Submerged Arc Equipment Systems THE LINCOLN ELECTRIC COMPANY Output Input 40 VDC • Pendant Control • Butt, Fillet and Lap Joint Tracker • 50-60 Lb. (22.7 - 27.2 kg) Coil Adapter • Wire Straightener • Drive Roll/Guide Tube Kit for 5/32 in. (4.0 mm) solid wire • Contact Nozzle Assembly • Nozzle Extension • Contact Tip for 5/32 in. (4.0 mm) solid wire Product Name Product Number Input Power Rated Output Current/ Duty Cycle Travel Speed in/min (m/min) Gearing Wire Feed Speed Range ipm (m/min) Wire Size Range in. (mm) Solid Dimensions H x W x D in. (mm) Net Weight lbs. (kg) Cruiser™ Tractor...

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Submerged Arc Equipment Systems | [ 7 ] MECHANIZED SOLUTION RUGGED DESIGN & FLEXIBLE ADJUSTMENT FOR ANY CONFIGURATION 2 3 4 5 8 7 6 9 1. Digital Meters 2. Travel Mode Switch • Auto • Off • Manual 3. Pushbutton Menu Options • Weld Mode Select • Frequency and Balance • Travel Options 4. Travel Direction: • Forward • Reverse 5. Jog 6. Start and Stop Pushbutton 7. Arc Start/End Options Selector • Start Options Indicator Light • End Options Indicator Light 8. Feed Reverse/Feed Forward Buttons 9. 4 Memory Buttons: • Save common procedures. (including travel) • Apply operator range or limits • Lockout...

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[ 8 ] | Submerged Arc Equipment Systems THE LINCOLN ELECTRIC COMPANY ArcLink®-enabled Controller for Power Wave® AC/DC 1000® SD Systems The MAXsa™ 10 controller offers a single monitoring and control point for the entire hard automation welding system. Operators have full control over AC and DC welding parameters and easy PLC interfacing to control fixture travel, timers and other system commands. Processes Submerged Arc Output Input Technical Specifications Product Name Product Number Input Power (1) Dimensions H x W x D in. (mm) Net Weight lbs. (kg) MAXsa™ 10 Controller K2814-1 40 VDC 15 x...

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Submerged Arc Equipment Systems | [ 9 ] BASIC AUTOMATION SOLUTION RUGGED DESIGN, FLEXIBLE CONNECTION 3 1. AMPS/WFS Control 2. AMPS/WFS Display • AMPS Indicator Light • WFS Indicator Light 3. Travel Switch • Auto/Off/Manual 4. Flux Hopper Switch 5. Mode Select Panel (MSP) Display 6. Weld Mode Selector • Weld Mode Indicator Light • Frequency/Balance Indicator Light 7. Mode Select Panel Control Knob 8. Eight Memory Buttons: • Save common procedures • Apply operator range or limits • Lockout changes for procedure control 9. Feed Reverse/Feed Forward Buttons 10. Arc Start/End Options Selector • Start...

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[ 10 ] | Submerged Arc Equipment Systems THE LINCOLN ELECTRIC COMPANY MAXsa™ 22 Feed Head Submerged Arc Hard Automation Wire Drive Designed specifically for hard automation applications, the MAXsa™ 22 Wire Drive delivers accurate wire feeding of large diameter submerged arc wires. Based on Lincoln’s proven gearbox and cast aluminum feedplate, the MAXsa™ 22 model features a 32VDC permanent magnet, high torque motor that delivers plenty of traction to push up to 7/32 in. (5.6 mm) diameter solid wire. A top speed of up to 500 ipm (11.43 m/min) can be achieved by changing the gear ratio. Processes...

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Submerged Arc Equipment Systems | [ 11 ] BASIC AUTOMATION SOLUTION A CLOSER LOOK 1. Cross Seam Adjuster 2. Wire Straightener 3. Mounting Bracket 4. Fuse 5. 14-Pin Connector 6. Lead (67) 7. Motor 8. Idle Roll Arm 9. Tension Indicator 10. Flux Hopper 11. Flux Valve Connector 1. Submerged Arc Contact Nozzle Assembly For 5/64 thru 3/16 in. (2.0 thru 4.8 mm) electrode at currents generally below 600 amps. Outer flux cone gives full flux coverage with minimum consumption. (Rated for up to 650 amps.) 2. Positive Contact Assembly For single arc welding at high currents. 3. Contact Jaw Assembly Single...

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