Lincoln Electric K2803, Operator'S Manual

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English English 4
CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the
correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which
can cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another
person. Lifting may be dangerous for your physical health.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
General Description
The Power Wave
®
AC/DC 1000 SD CE is a high
performance, digitally controlled inverter welding power
source. It is capable of producing a variable frequency
and amplitude AC output, DC positive output, or DC
negative output without the need for external
reconnection. It utilizes complex, high-speed waveform
control to support a variety of constant current and
constant voltage welding modes in each of its output
configurations.
The Power Wave
®
AC/DC 1000 SD CE 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 different
machines can be synchronized by interconnecting the
units with a control cable to improve performance and
reduce the effects of arc blow.
The Power Wave
®
AC/DC 1000 SD CE is primarily
designed to interface with compatible ArcLink
equipment. However, it can also communicate with other
industrial machines and monitoring equipment via
DeviceNet, or Ethernet. The result is a highly integrated
and flexible welding cell.
Recommended Process
The Power Wave
®
AC/DC 1000 SD CE is designed for
submerged arc welding (SAW). Due to its modular
design the Power Wave AC/DC can operate on either
single arc or in multi-arc applications with up to six arcs.
Each machine is factory preprogrammed with multiple
welding procedures to support all types of submerged
arc welding. The Power Wave
®
AC/DC 1000 SD CE
carries an output rating of 1000 amps, 44 volts (at 100%
duty cycle). If higher currents are required machines can
be easily paralleled for up to 3000 amps on each arc
(see Duty Cycle section)
Process Limitations
The Power Wave
®
AC/DC 1000 SD CE is suitable only
for the Submerged Arc Process (SAW).
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).
Only the MAXsa™ 22 or MAXsa™ 29 Wire Drives and
MAXsa™ 10 or MAXsa™ 19 Controllers may be used
with a K2803-1 PowerWave
®
AC/DC 1000 SD CE in a
Multi Arc system. Other Lincoln or non-Lincoln Wire
Drives can only be used with custom interfaces.
The Power Wave
®
AC/DC 1000 SD CE will support a
maximum average output current of 1000 Amps at 100%
Duty Cycle.
Location and Mounting
Place the welder where clean cooling air can freely
circulate in through the rear louvers and out through the
case sides and front. Dirt, dust, or any foreign material
that can be drawn into the welder should be kept at a
minimum. Failure to observe these precautions can
result in excessive operating temperatures and nuisance
shutdowns. See the Clearance Requirements and Figure
#1 below.
Stacking
WARNING
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface shall
be covered with a steel plate at least 1.6mm thick, which
shall extend not more than 150mm beyond the
equipment on all sides.
The Power Wave
®
AC/DC 1000 SD CE machine cannot
be stacked.
Lifting
WARNING
FALLING EQUIPMENT can cause injury.

Lift only with equipment of adequate lifting capacity.

Be sure machine is stable when lifting.