For over 50 years, Lincoln Electric has offered its Submerged Arc Welding (SAW) customers high deposition rates, reliable penetration, and smooth bead appearance.

Now, Lincoln brings you the first advance in SAW technology that provides the option of variable polarity. Changes in the balance of positive and negative polarity of the AC waveform enable the operator to change penetration and deposition, without changing the current or voltage settings.

Lincoln???s AC/DC Submerged Arc process with the Power Wave power source gives the operator real-time control. Instead of making a weld, stopping and re-programming the new parameters, and running a test weld to make sure they worked, changing the face of a weld is as easy as turning a knob.

The Power Wave?? AC/DC 1000??? takes Submerged Arc Welding to the next level. In addition to conventional benefits of SAW, such as high deposition rates and good penetration, heightened control and faster responses to the arc are unique to the design of the Power Wave?? AC/DC 1000???.

a d v a n t a g e s

MODULAR

The Power Wave AC/DC1000 is designed for easy paralleling, overcoming the problems typically associated with synchronization of AC waveforms for increased amperage applications.

MULTI-ARC

AC/DC welding is designed for applications that require up to five independently controlled welding arcs.

EASY INTEGRATION

Digital Communications provide a simple solution for the integration of the welding power source to the motion controlling Programmable

Logic Controller (PLC).

INCREASED PROCESS CONTROL

Digital Communications also enable the use of software tools to record the actual welding values for each weld as well as monitoring the status of the welding system.

WAVEFORM CONTROL TECHNOLOGY

The Power Wave AC/DC 1000 is equipped with factory-programmed procedures for fast setup.

Patented. This product is protected by one or more of the following United States patents: 6,809,292; 6,795,778; 6,700,097; 6,697,701; 6,683,278; 6,660,966; 6,600,134; 6,683,278; 6,596,570; 6,570,130; 6,536,660; 6,489,952; 6,472,634; 6,636,776; 6,486,439; 6,441,342; 6,365,874; 6,291,798; 6,207,929; 6,111,216; 4,927,041; 4,861,965 and other pending U.S. patents. Similar patents are maintained in other countries.

What

Is AC/DC Submerged Arc?

A Submerged Arc Welding (SAW) option that combined the advantages of AC and DC SAW welding was not possible until now.

A Lincoln inverter power source coupled with Waveform Control Technology provides control over the ratio of positive to negative amplitude, as well as the amount of time spent at each polarity.

The AC/DC Submerged Arc Process

The above waveform represents the possible variations of an AC/DC waveform with Waveform Control Technology.

Different parts of the waveform and wire feed speed may be

modulated at varying rates to achieve a smooth, stable arc.

The limiting factor for SAW AC welding has always been that it takes too long to cross from electrode positive (EP) to electrode negative (EN). This lag can cause arc instability, penetration, and deposition problems in certain applications.

The Lincoln Power Wave AC/DC 1000 with Waveform

Control was designed specifically to solve this problem, allowing the operator to take full advantage of the reduction in arc blow experienced with AC, while maintaining the penetration advantages of DC positive and the advantageous deposition rate of DC negative. Using these controls, the shape of the output waveform is changed, and in turn the welding characteristics are controlled.

With the Power Wave AC/DC 1000, you get the best of both worlds: the speed, deposition rate, and penetration that DC SAW offers, and the resistance to arc blow that AC SAW offers. In single arc processes, the Power Wave AC/DC 1000 provides flexibility with Waveform Control Technology. In multiple arc processes, that same flexibility is achieved through control of phase shifting between arcs.

W A V E F O R M C O N T R O L T E C H N O L O G Y ??

AC/DC Submerged Arc Welding

Using AC/DC

The AC/DC SAW process is the ideal choice for high-deposition, high-speed welds that can be made in the 1G position. Whether your applications demands a single arc or up to five synchronized arcs, AC/DC SAW with the Power Wave will increase weld speeds and yield higher quality welds.

In multiple arc welding, as many as 5 arcs operate in a single weld puddle. The positive and negative polarity phases of the AC waveform can be independently adjusted, as well as the cycle balance. Changes to the combination of any of these values will change the deposition rate, penetration, and travel speed, without changing the voltage or current settings.

Typical DC-AC two-arc combinations can be replaced with AC/DC Power Waves for either AC/DC or AC/AC welding applications.

PROCESS

3/6

Interfacing

with Power Wave AC/DC 1000

Hard Automation

For repeatable, high-deposition, quality welds, the Power Wave AC/DC 1000 coupled with a PLC provides a reliable hard automation welding solution. The Power Wave AC/DC 1000 can easily be connected to a PLC with the standard Ethernet/DeviceNet gateway board (which is included in the Power Wave AC/DC 1000). The Ethernet/DeviceNet gateway board also allows the system to be tracked and monitored from a remote location, over a network.

Customer Supplied

Programmable Logic Controller (PLC) ??? and ??? Allen-BradleyTM PanelView User Interface

24 Volt Power Supply

Power Wave AC/DC 1000 with

Ethernet/DeviceNet Gateway

Typical Hard Automation Welding System Configuration

Power Electronics

Power Wave AC/DC 1000 uses inverter technology, not SCR or cyclo-conversion, which limits control options.

Control

Choice of AC frequency (from 10 Hz to 100 Hz) standard, balance of positive and negative half-cycles, and amplitudes.

Efficiency

Inverter power sources operate at 87% efficiency and a power factor of 95%.

Stability

Increased stability of phase-shifting of multiple arcs due to the capability of

any degree of shift to create equal ratios Power Wave AC/DC 1000 of magnetic push and pull.

Waveform Control

Waveform Control and infinite phase shifting stabilize imbalanced waveforms. The operator achieves full control of penetration and deposition without changing heat input levels.

Communications between ArcLink and Ethernet enable equipment tracking via Lincoln Electric's Production Monitoring??? software utility.

Lincoln Welding Systems featuring AC/DC

Power Wave?? AC/DC 1000???

The Power Wave AC/DC 1000 is equipped with Waveform Control Technology and Inverter Power Source design, to provide the highest reliability and weld quality the welding industry has to offer.

Power Wave AC/DC 1000 operates at a 95% power factor with low harmonic distortion, and is 87% efficient. It draws equally matched currents from a three-phase line and can produce both sine and square waves, for compatibility with older equipment or better penetration and greater deposition with new processes.

Power Feed??? 10A Controller

The Power Feed 10A Controller is the next generation in automatic submerged arc feeding. Designed for use with the Power Wave AC/DC 1000 power source, the Power Feed 10A eliminates the need for a separate AC and DC controller, making this powerful hard automation system controllable, adaptable and easy to use. The user-friendly control panel offers a single-point of control over the entire welding cell, including the

Power Wave's Waveform Control Technology???, delivering an unprecedented level of control over wave balance, amplitude and

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 customer 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 requirement.

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.

WHAT IS NEXTWELD?

The challenges facing industrial fabricators today are growing in number and complexity. Rising labor, material and energy costs, intense domestic and global competition, a dwindling pool of skilled workers, more

stringent and specific quality demands all contribute to a more difficult welding environment today.

Through our commitment to extensive research and investments in product development, Lincoln

Electric has established an industry benchmark for applying technology to improve the quality, lower the cost and enhance the performance of arc welding processes. Advancements in power electronics, digital communications and Waveform Control TechnologyTM are the foundation for many of the improvements.

NEXTWELD brings you a series of Process, Technology, Application and Success Story documents like this one. NEXTWELD explains how technologies, products, processes and applications are linked together to answer the important questions that all businesses face:

???How can we work faster, smarter, more efficiently?

???How can we get equipment and people to perform in ways they???ve never had to before?

???How do we stay competitive?

NEXTWELD is the future of welding but its benefits are available to you today. Ask your Lincoln Electric representative how to improve the flexibility, efficiency and quality of your welding operations to reduce your cost of fabrication.

THE LINCOLN ELECTRIC COMPANY www.lincolnelectric.com 1.216.481.8100