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Lincoln Electric has launched the Power Wave AC/DC 1000 SD and Maxsa drives and controllers in a move that it says represents a total update of its Power Wave submerged arc welding system solutions.

The equipment components are said to be ideal for rugged work environments and applications, including bridge decking, pressure vessels, panel lines and seamers.

Using the Maxsa 19 controller and Maxsa 29 feed head the system is readily adapted for pipe mill integrator solutions or submerged arc robotic welding.

With a full 380-575VAC, 50/60Hz input voltage capability, the Power Wave AC/DC 1000 SD can be connected anywhere in the world.

The machine’s output is rated at 1000A at 100 per cent duty cycle.

Each welding arc may be driven by a single machine or by a number of machines connected in parallel for additional amperage capacity.

The digital inverter-based power source features Lincoln Electric’s software-driven waveform control technology, resulting in high control of DC positive, DC negative, balanced AC and variable AC submerged arc processes without cumbersome mechanical cable swapping.

Subtle waveform changes can be made for precise control of the submerged arc deposition rate and penetration.

Welding operations are optimised through increased travel speeds, greater deposition, consistently higher quality welds and improved efficiencies in a single- or multi-arc environment.

The new Power Wave machine features Iarc digital controls, delivering processing speeds up to 90 times faster than the previous generation.

The result is faster arc response and greater arc stability.

The Power Wave AC/DC 1000 SD, now housed in a protective, stainless-steel case, is IP23-rated for severe duty outdoor use and storage.

The machine’s efficiency and three-phase operation are said to help reduce electric power consumption.

The unit’s 95 per cent power factor correction allows users to consider connecting more machines on the same plant infrastructure for reduced installation and operating costs compared with traditional submerged arc solutions.

The Power Wave AC/DC 1000 SD is intended for use with the Cruiser and Maxsa controllers and feeders.

The Cruiser is a mechanised travel carriage with a control interface that is said to be able to cut hours from decking weld production time compared with manual or semi-automatic welding.

Maxsa controllers and feeders are intended for beam-mounted hard automation, third-party integrator solutions or robotic submerged arc welding.

The system uses Lincoln Electric’s Arclink digital communications protocol to communicate between components for hard automation and robotic applications.

It is also compatible with Devicenet for additional plant motion control.

As a result, Maxsa controllers can be easily integrated in simple or complex welding and fixturing systems.

These communication features reduce downtime and simplify hardware configuration.

Using embedded Ethernet communication capability, the system can also deliver remote weld process monitoring that allows welding operational efficiency analysis.

Using Lincoln Electric’s Production Monitoring 2 web-based software, managers can track equipment usage; gather and store data by weld, station, shift or date; configure welding process limits; and generate e-mail alerts.

The system also features Lincoln’s True Energy capability, which provides customers with a method for measuring and displaying energy for critical heat-input calculations.

Lincoln Electric Company, The

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