PW Acdc 1000

Mechanized Solutions
Robotic Solutions
Integrated Solutions
Basic Automation Solutions
Power Wave AC/DC 1000 SD, MAXsa and Cruiser

Submerged Arc Equipment Systems
Bigger Welds, Faster.
www.lincolnelectric.com/subarc
THE LINCOLN ELECTRIC COMPANY
About The Lincoln

Electric Company
Lincoln Electric is the worlds 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 is the
largest in the industry. Innovative
thinking. For a quality, service-first
attitude; innovative design,
manufacturing, and packaging; and
worldwide strengthChoose Lincoln.
Submerged Arc Welding Platforms

Lincolns advanced submerged arc systems couple the
industrys most advanced power source with mobile, hard
automation or robotic feeding equipment to achieve new levels
of welding performance and operational efficiency. Whether
your application is bridge decking, pressure vessels, panel line,
seamer, pipe mill integrator solutions or submerged arc robotic
welding, the software-driven Power Wave AC/DC 1000 SD
and your choice of integrated feeding equipment can help your
operations improve weld quality, reduce welding and operational
costs and increase weld team productivity.
Our advanced Waveform Control Technology allows
operators to set all AC and DC arc and PLC-based fixture
motion control parameters from a single mountable or
hand-held extended-range pendant. It is no longer
necessary to reverse electrode and work cables.
With input current requirements reduced by up to 50%
for our new inverter-based system, customers consistently
report significant energy savings over traditional submerged
arc welding equipment.
Modular Power Wave and MAXsa controller and feed
head components are engineered to readily adapt the
system for use in almost any indoor or outdoor heavy wall
thickness submerged arc welding application.
Power source, controller and feed heads are reliability
tested to meet IP23 standards. Each is designed to
withstand harsh environments and outdoor storage.
Lincoln Electric technical teams are standing by to assist
you with set up, customized welding mode development
optimized for your application, and welding consumables
testing and selection.
[ 2 ] | Submerged Arc Equipment Systems
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

MAXsa 10
Controller . . . . . . . . . . . . . . . . . . . . . . . .8-9
MAXsa 22
Feed Head . . . . . . . . . . . . . . . . . . . . . 10-11
Integrated Solution and Robotic Solution

MAXsa 19 Controller
and MAXsa 29 Feed Head . . . . . . . 12-14
Appendix . . . . . . . . . . . . . . . . . . . . 15-23
Submerged Arc Equipment Systems | [ 3 ]
Increase Productivity, Quality and Flexibility
Output
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 environment.
AC
DC
Input
3
PHASE
50
60
Hz
Processes
DC+ Submerged Arc
DC- Submerged Arc
Balanced AC Submerged Arc
Variable AC Submerged Arc
Key Features
www.lincolnelectric.com/green
380 - 575 VAC, 50/60Hz Voltage Input Offers the ability to be

connected anywhere in the world.
ArcLink, Ethernet, and DeviceNet Communication Offers

remote process monitoring, control and troubleshooting.
Voltage Compensation and Reliable Input Voltage Connection

Provides consistent operation over 10% input voltage variation.
True Energy Measures, calculates and displays instantaneous

energy in the weld for critical heat input calculations.
No Hardware Reconfiguration Required with Easy Polarity

Switching Eliminates downtime.
Production Monitoring 2 Track equipment usage, store weld

data and configure limits to assist in welding efficiency analysis.
Easy to Parallel Machines or Run Multiple Arcs.
Software Based Controls Can be upgraded as new features

become available.
3-Phase Voltage Input Eliminates the imbalance associated with

transformer-based AC welding machines.
95% Power Factor Correction Enables connection of multiple
machines on the same plant infrastructure for lower installation costs.
Severe Duty Can be stored outdoors. IP23 Rated.
iARC Digital Control - 90 times faster than the previous generation,

delivering a responsive arc.
Each Unit is Factory burn-in tested at maximum output for 2 hours
to ensure quality and reliability.
Technical Specifications
Product
Name
Product
Number
Input
Voltage
Rated Output
Current/Voltage/Duty Cycle
Input Current
@ Rated Output
Output
Range
Dimensions
HxWxD
in. (mm)
Net Weight
lbs. (kg)
K2803-1(1)
380/400/460/500/
575/3/50/60
1000A/44V/100%
82/79/69/62/55
100-1000A
49.2 x 19.2 x 46.2

(1250 x 488 x 1174)
800
(363)
(1)
Filter is required to meet CE conducted emission requirements. The K2444-3 must be used with the K2803-1.
POWER SOURCE
KEY CONTROLS
4
1. Power Switch
3
2
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
Front Top View
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
Bottom Rear View

6
10
11
12
Top Rear View
15
14
13
FEATURE LOADED, RUGGED CONSTRUCTION AND EASY MAINTENANCE

11
1. Easy Maintenance designed for

Extreme Environments
Pull-out back panel provides fast
access to heat sinks and other
components
Re-Usable filter prevents particulate
matter from entering the machine.
2. Production Monitoring 2
Web-based Production Monitoring 2
allows fabricators to analyze and
improve their welding operations
and processes.
3. Easy-access Reconnect Panel
Connect the Power Wave
AC/DC 1000 SD to an electrical
connection almost anywhere in the
world (380 up to 575 Volt input power).
Cruiser Tractor
For The Long Haul
Output
The Cruiser is a flexible wire feeding tractor for heavy

plate submerged arc welding in field and yard
applications. Designed for big joints on big jobs.
Weld butt joints and fillet joints at deposition rates
up to 30 lbs./hr. Comes ready to weld with
joint tracking kits and drive rolls for 5/32 in.
(4.0 mm) solid wire.
Input
40
VDC
Processes
Submerged Arc
Key Features
K2607-1 Includes
Designed for Welding Big Joints on Big Jobs Ideal for welding heavy plate on barges, ships,
large tanks, bridges, and offshore platforms.
Pendant Control
High Deposition Rates Up to 30 lbs/hr. Rated output of 1000 amps at 100% duty cycle.
50-60 Lb. (22.7 - 27.2 kg) Coil Adapter
Versatile Travel Capabilities 3 or 4 wheel configuration for use with or without track.
Wire Straightener
Lightweight Pendant Control with Digital Meters Save procedures, apply procedure limits,
and lockout any or all controls.
Drive Roll/Guide Tube Kit for

5/32 in. (4.0 mm) solid wire
Rugged Mast and Arm Keeps the wire drive in a steady position and allows flexible
adjustment.
Contact Nozzle Assembly
Proven Industrial Wire Drive Design Rotates on two axes and is attached to heavy duty
cross slides for any torch angle. Feed up to 7/32 in. (5.6 mm) diameter wire.
Butt, Fillet and Lap Joint Tracker
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)
Cruiser
Tractor
K2607-1
40 VDC
1000A / 100%
10 - 100
(0.25 - 2.5)
Gearing
142:1
Wire Feed
Speed Range
ipm (m/min)
Wire Size Range

in. (mm)
Solid
Dimensions
HxWxD
in. (mm)
Net Weight
lbs. (kg)
15 - 200
(0.4 - 5.0)
1/16 - 7/32
(1.6 - 5.6)
29 x 23 x 36
(737 x 584 x 914)
140
(63.5)
MECHANIZED SOLUTION
KEY CONTROLS
4
5
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
9. 4 Memory Buttons:
Save common procedures.
(including travel)
Apply operator range or limits
Lockout changes for procedure
control
8. Feed Reverse/Feed Forward Buttons
RUGGED DESIGN & FLEXIBLE ADJUSTMENT FOR ANY CONFIGURATION

1. Mast and Frame
Heat treated aluminum alloy tubing
Creates a rigid frame for steady position
Mast and boom completely separates from the base for mobility
2. Heavy Duty Cross Slides

Easy adjustment of electrode stick-out and position
Accurate positioning of the electrode in joint
5
3. Hardened Base Construction

Stainless steel to reduce corrosion
Heat shield to withstand preheated plate
Environmentally hardened (IP23 Rated)
4. Stable Travel and Tracking
3 or 4 wheel configuration on same model
Easy to use clutch
Factory ready for use with or without track
Patent Pending wheel design that endures impacts, is high
temperature resistant and excellent traction
5. Proven Industrial Wire Drive
Feeds wire up to 7/32 in. (5.6 mm) diameter
Changeable gears for a wide range of wire feed speed range
Rotation in two directions for any torch angle
1000A, 100% Duty Cycle
MAXsa 10 Controller
ArcLink-enabled Controller for
Systems
Output
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.
Input
Processes
Submerged Arc
Key Features
Severe Duty Ready The controller is IP23 rated and ready for operation
in harsh environments.
Pendant Box Mount the controller in the standard protective box or
remove the pendant for hand-held operation. Extend hand-held operation
from 4 feet (1.2 m) up to 100 feet (30.5 m) with an ArcLink extension
cable.
Eight Procedure Memories Pre-set and save your optimal
welding parameters for repeating applications and recall later for
fast changeovers.
User-Friendly Controls Clear digital display and controls make it easy

to set weld modes, AC operation, strike/start/end options, travel stop/start,
timers and other parameters.
Limit Control Apply operator procedure limits or lockout on any or all
parameters.
Waveform Control Technology Allows the user to choose from a
library of pre-programmed weld modes. Parameters for each mode can
be adjusted within a limited range to achieve optimal balance between
deposition rate and penetration.
Product
Name
Product
Number
Input
Power (1)
Dimensions
HxWxD
in. (mm)
Net
Weight
lbs. (kg)
MAXsa 10 Controller
K2814-1
40 VDC
15 x 13 x 4
(381 x 259 x 102)
25
(11.3)
(1)
When not driving a motor.
BASIC AUTOMATION SOLUTION
KEY CONTROLS
1
15
14
3
13
4
5
12
11
10
6
7
16
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
10. Arc Start/End Options Selector

Start Options Indicator Light
End Options Indicator Light
7. Mode Select Panel Control Knob
11. Set-Up Menu Indicator
8. Eight Memory Buttons:

Save common procedures
Apply operator range or limits
Lockout changes for procedure control
12. Arc Established Indicator
9. Feed Reverse/Feed Forward Buttons
13. Stop/Start Buttons

14. Volts Display
Volts Indicator Light
17 18
19
20
21
16. User Interface/Pendant Connector

17. Status LED
18. Wire Drive Connector
19. Power Source Connector
20. Flux Hopper Connector
21. Travel Carriage Connector
15. Volts Control
RUGGED DESIGN, FLEXIBLE CONNECTION

1. IP23 Rated Tested and approved to
withstand rain, humidity, dust and other
environmental conditions. When placed
vertically, the unit can be stored outdoors.
2. Hard Automation Connection Motion

control, limit switches, PLC inputs and
other auxiliary equipment are easily
added to control device starting, stopping
and other functions.
3. Hand-held Options The protective base
unit shell facilitates fixed mounting and
protects the controller. To get closer to the
work, detach the controller for hand-held
operation.
MAXsa 22 Feed Head

Submerged Arc Hard
Automation Wire Drive
Output
Designed specifically for hard automation

applications, the MAXsa 22 Wire Drive
delivers accurate wire feeding of large
diameter submerged arc wires. Based
on Lincolns 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.
Input
Processes
Submerged Arc
Key Features
Multi-Axis Rotation Rotational feed head adjustment in two planes allows flexible, accurate setup for fixturing or arc locating. Additional
positioning flexibility can be achieved with optional horizontal and vertical
lift adjusters.
Flexible Configuration Can be used in single, tandem, Twinarc

or multiple arc applications.
Closed Loop Speed Control Facilitates full control over starting,
running and stopping wire feed speed.
Standard Accessories Including an adjustable wire straightener,

cross-seam adjuster and electrical valve flux hopper and mounting
bracket for TC-3 carriage.
IP23 Rated Tested to withstand harsh environments.

Standard Conversion Kits Used to change the speed ratio to
match the requirements of your application.
Includes Drive Rolls - 1/16, 5/64 and 3/32 (1.6, 2.0 and 2.4 mm)
Product
Name
MAXsa 22 Head
(includes flux hopper)
Product
Number
K2370-2
Input
Power
40 VDC
Rated Output
Current / Duty Cycle
1000A/100%
Wire Feed
Speed Range (1)
imp (m/min)
Wire Size Range (1)

in. (mm)
Solid
142:1(1)
10 - 200
(.25 - 5.08)
5/32 - 7/32
(4.0 - 5.6)
95:1(1)
10 - 300
(.25 - 7.62)
1/8 - 5/32
(3.2 - 4.0)
57:1(1)
40 - 500
(1-12.7)
.045 - 1/16
(1.1 - 1.6)
Gear
Box
(1)
Dimensions
HxWxD
in. (mm)
Net
Weight
lbs. (kg)
23.5 x 17 x 20
(597 x 432 x 508)
80
(36.3)
142:1 gear box is standard. Conversion Kit supplied for conversion to 95:1 with Wire Drive (K2370-2, K2312-2, or K2311-1)
BASIC AUTOMATION SOLUTION

A CLOSER LOOK
1
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
11
10
OPTIONAL TC-3 TRACTOR

TC-3 Tractor
The TC-3 travel carriage allows the
mounting of up to two feed heads/
controllers and wire reels to a
beam for basic hard automation
installations.
Beam Profile
Recommended for the TC-3
carriage. (See manual for
more precise dimensions.)
8 in. (203 mm)
10 in. (254 mm)
12 in. (305 mm)
CONTACT NOZZLES (ONE REQUIRED)

1
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 arc contact jaw assembly for 1/8 - 7/32 in. (3.2 - 5.6 mm) diameter wire.
Maximum life at currents over 600 amps.
4. ESO (Extended Stick-Out) Extension
Linc-Fill long stickout extension for K148A Single Arc Positive Contact Nozzle Assembly.
Required for long stickout technique.
5. Narrow Gap Deep Groove Nozzle
For single arc 3/32 in. (2.4 mm) diameter wire welding on thick walled steel plate with
nearly parallel-sided, narrow gap joint preparations.
6. Large Wire Twinarc Contact Assemblies
Feeds two 5/64 in. (2.0 mm), 3/32 in. (2.4 mm) or 1/8 in. (3.2 mm) wires for submerged
arc welding on Fast-Fill joints or hardfacing beads.
7. Tiny Twinarc Contact Assemblies
Feeds two electrodes for high speed submerged arc welds. Includes contact nozzle, wire
guides, drive rolls and guides, and a second wire reel and mounting bracket.
MAXsa 19 Controller and

MAXsa 29 Feed Head
Submerged Arc Systems for

Fabrication Integrators and
Robotic Applications
Output
MAXsa 19
Controller
The MAXsa 19 controller is specifically designed to relay wire

feed commands to the MAXsa 29 when a customer-supplied user
interface is used in place of the MAXsa 10 controller. Typically,
this occurs in a variety of third party fabrication integrator solutions
that include integration hardware like turning rolls, panel lines,
seamers and pipe mills fixturing.
Input
The compact MAXsa 29 Feed Head is intended for integrator

solutions as well as the latest submerged arc robotic applications.
Contact Lincoln Electric Automation Division via email at
automation@lincolnelectric.com for more information on robotic
applications.
MAXsa 29
Feed Head
Processes
Submerged Arc
Key Features
MAXsa 29 Feed Head
MAXsa 19 Controller
Compact size is easy to position in custom integrator solutions.
Closed Loop Speed Control Facilitates full control over starting, running
and stopping wire feed speed.
Fast digital communication with the Power Wave AC/DC 1000 SD

via Arclink cable and to the wire drive via a 14 pin control cable.
32VDC permanent magnet, high torque motor that delivers plenty

of traction to push up to 7/32 in. (5.6 mm) diameter solid wire. Top
speed of up to 500 ipm (11.43 m/min) can be achieved by changing
the gear ratio.
Standard I/O connector block for start/stop, forward/reverse feed

and shutdown input interfacing with external accessories.
Standard Status indicator aids diagnostic system troubleshooting.
Standard conversion kits Used to change the speed ratio to match

the requirements of your application.
Rotational feed head adjustment in one plane allows flexible, accurate
setup for fixturing.
Standard adjustable wire straightener.
Includes drive rolls for 1/16, 5/64 and 3/32 (1.6, 2.0 and 2.4 mm)
Product
Name
Product
Number
Input
Power (1)
Rated Output
Current / Duty Cycle
MAXsa 19 Controller
K2626-2
40 VDC
1000A / 100%
Wire Feed
Speed Range (2)
imp (m/min)
Gear
Box
Not Applicable
95:1(1)
10 - 200
(.25 - 5.08)
10 - 300
(.25 - 7.62)
5/32 - 7/32
(4.0 - 5.6)
1/8 - 5/32
(3.2 - 4.0)
57:1(1)
40 - 500
(1-12.7)
.045 - 1/16
(1.1 - 1.6)
142:1(1)
MAXsa 29
Feed Head
K2312-2
40 VDC
1000A / 100%
(1)
Wire Size Range (2)

in. (mm)
Solid
When not driving a motor.
(2)
Dimensions
HxWxD
in. (mm)
Net
Weight
lbs. (kg)
9 x 10.5 x 3
(229 x 267 x 76)
7
(3.2)
13 x 16 x 10
(330 x 406 x 254)
35
(15.9)
142:1 gear box is standard. Conversion Kit supplied for conversion to 95:1 with Wire Drive (K2370-1, K2312-2, or K2311-1)
INTEGRATED AND ROBOTIC SOLUTIONS

KEY CONTROLS
MAXsa 19 Controller
1. Mounting Holes
2. Power Source 5-Pin
ArcLink Connector
3. Status LED
4. Wire Feeder Connector
5. I/O Connector
Bottom View
MAXsa 29 Feed Head

1. Wire Straightener
2. Mounting Bracket
1
3. Fuse
4. 14-Pin Connector
5. Lead (67)
6. Idle Roll Arm

7. Guide Tubes
8. 5/32 in. (4.0 mm)
Drive Rolls
9. Tension Indicator
DIGITAL COMMUNICATIONS AND SEAMLESS INTEGRATION
Production Monitoring
Turning Rolls(1)
Computer
Intranet and/or Internet

connection over a VPN
(Virtual Private Network)
Robot and
Robot Controller
MAXsa 19
Controller
Pipe Mills
Power Wave
AC/DC 1000 SD
MAXsa 29
Feed Head
Seamers
Column and Boom
Panel Lines(2)
(1)
Flux Recycling
Systems(3)
Photo used with permission of Pandjiris, Inc.
(2)
Photo used with permission of Ogden Welding Systems, Inc.
(3)
Photo used with permission of Weld Engineering Co., Inc.
APPENDIX
SINGLE ARC MOBILE CONFIGURATION
RECOMMENDED EQUIPMENT
Product Number
Product Description
Qty. Required
K2803-1
K2607-1
Cruiser Tractor
K2683-xx
Heavy Duty ArcLink Control Cable
K1811-xx
Work Sense Lead
Connection Diagram - Cruiser Tractor System

K2803-1
Power Wave
AC/DC 1000 SD
K1811-XX
Sense Lead
K2607-1
Cruiser
K2683-XX
ArcLink Cable
Electrode
Weld Cable
Work
Work
Weld Cable
SINGLE ARC CONFIGURATION
Product Number
Product Description
Qty. Required
K2803-1
K2814-1
MAXsa 10 Controller
K2370-2
MAXsa 22 Wire Drive
K231-1
Submerged Arc Contact Nozzle Assembly

[3/32 in. (2.4 mm), 1/8 in. (3.2 mm), 5/32 in. (4.0 mm)]
K2683-XX
Heavy duty ArcLink Control Cable
K1785-XX
14-pin Control Cable
K1811-XX
Work Sense lead
Contact Lincoln Electric Automation Division via email at automation@lincolnelectric.com for more information on robotic applications.
Connection Diagram - Single Arc System
K2803-1
Power Wave
AC/DC 1000 SD
K1811-XX
Sense Lead
K2683-XX
ArcLink Cable
K2814-1
MAXsa 10
K2370-2
MAXsa 22
K1785-XX
14-Pin Cable
67 Lead
K231-XX
Contact Nozzle
Work
Electrode
Weld Cable
Work
Weld Cable
APPENDIX
DUAL ARC CONFIGURATION (For paralleling or more than two arcs, please contact your local Lincoln Electric Office.)
Product Number
Product Description
Qty. Required
K2803-1
K2814-1
MAXsa 10 Controller
K2370-2
MAXsa 22 Wire Drive
K231-1
Submerged Arc Contact Nozzle Assembly

[3/32 in. (2.4 mm), 1/8 in. (3.2 mm), 5/32 in. (4.0 mm)]
K2683-XX
Heavy duty ArcLink Control Cable
K1785-XX
14-pin Control Cable (controller to wire drive)
K1785-XX
14-pin Control Cable (machine to machine)
K1811-XX
Work Sense lead
Contact Lincoln Electric Automation Division via email at automation@lincolnelectric.com for more information on robotic applications.
Connection Diagram - Tandem Arc System

K2683-XX
ArcLink Cable
K1785-XX 14-Pin Cable
K1811-XX
Sense Lead
K2814-1
MAXsa 10
K2814-1
MAXsa 10
K2683-XX
ArcLink Cable
K1785-XX
14-Pin Cable
K2803-1
Power Wave
AC/DC 1000 SD
K1785-XX
14-Pin Cable
K2370-2
MAXsa 22
67 Lead
K2370-2
MAXsa 22
K231-XX
Contact Nozzle
Work
K2803-1
Power Wave
AC/DC 1000 SD
Electrode
Weld Cable
Work Weld Cable
Electrode Weld Cable
Mild Steel SAW Wire Feeding Capability

142:1
gear ratio
(standard*)
SOLID WIRE DIAMETER (INCHES/mm)
7/32
5.6
3/16
4.8
5/32
4.0
95:1
gear ratio
(optional)
1/8
3.2
57:1
gear ratio
(optional)
3/32
2.4
5/64
2.0
1/16
1.6
.052
1.3
.045
1.1
.035
0.9
15
50
100
200
300
400
500
.4
1.25
2.5
7.6
10
12.7
WIRE FEED SPEED (IPM/MPM)
DC+ SINGLE ARC

DC
DC- SINGLE ARC
DC+ TWINARC
* On MAXsa Feed Heads
RECOMMENDED ACCESSORIES AND OPTIONS
RECOMMENDED ACCESSORIES AND OPTIONS
14-PIN CONTROL CABLE

(CANNOT BE EXTENDED)
WELD POWER CABLES

Part No.
Length
Part No.
4 ft. (1.2 m)
K1785-4
16 ft. (4.9 m)
K1785-16
25 ft. (7.6 m)
K1785-25
Required
For Up to 250 ft. (75 m) @ 80% Duty Cycle
50 ft. (15.2 m)
K1785-50
100 ft. (30.5 m)
K1785-100
35 ft. - 2x4/0
K2163-35
60 ft. - 2x4/0
K2163-60
110 ft. - 1x4/0
K2163-110
For Up to 250 ft. (75 m) @ 100% Duty Cycle

10 ft. - 1x3/0
K1842-10
35 ft. - 1x3/0
K1842-35
60 ft. - 1x3/0
K1842-60
5-PIN HEAVY DUTY ARCLINK CONTROL CABLE

[CAN BE EXTENDED UP TO
200 FT. (61 M) TOTAL LENGTH]
Length
Part No.
Heavy Duty
MAXsa DRIVE ROLL KIT INFORMATION

25 ft. (7.6 m)
K2683-25
50 ft. (15.2 m)
K2683-50
100 ft. (30.5 m)
K2683-100
Drive Roll
Kit Number
Wire Sizes
and Types
KP1899-1
3/32 - 7/32 in. Wires
KP1899-2
1/16 - 3/32 in. Wires
KP1899-3
.035 - .052 in. Solid Wire
KP1899-4
.045 - .052 in. Cored Wire
SENSE LEAD KIT

Length
Part No.
50 ft. (15.2 m)
K1811-50
75 ft. (23 m)
K1811-75
100 ft. (30.5 m)
K1811-100
POWER WAVE
AC/DC 1000 SD
CE Filter
This high power filter that
enables Power Wave
AC/DC 1000 CE ready
machine to conform to the
EMC standards of Europe
and Australia.
Order K2444-3
MAXsa 22 and
MAXsa 29 HEADS
MAXsa 10
Mounting Bracket
Allows for mounting the
MAXsa 10 to the TC-3
Travel Carriage. Cannot
be used with K299.
Order K2462-1
TC-3 Self-Propelled
Travel Carriage
The TC-3 travel carriage
allows the mounting of up
to two feed heads/
controllers and wire reels
to a beam for basic hard
automation installations.
Order K325 HCS
(for 5-75 ipm)
Order K325 HCF
(for 15-270 ipm)
(Made to order)
Large Wire Twinarc

Contact Assemblies
Feeds two 5/64 in. (2.0 mm),
3/32 in. (2.4 mm) or 1/8 in.
(3.2 mm) wires for
submerged arc welding
on "Fast-Fill" joints or
hardfacing beads.
Order K225
Twinarc Solid Wire
Straightener
Straightens wire diameters
.045 thru 3/32 in.
(1.2 thru 2.4 mm).
Particularly valuable on
longer electrical stickout
procedures.
Order K281
Tiny Twinarc Contact

Assemblies
Feeds two electrodes for
high speed submerged arc
welds. Includes contact
nozzle, wire guides, drive
rolls and guides, and a
second wire reel and
mounting bracket.
Order K129-xx
Automatic Flux Hopper

Assembly
Flux Hopper for MAXsa 29
Heads (included standard
on the MAXsa 22 Heads)
Order K219
MAXsa 22 and
MAXsa 29 HEADS
and TC-3 TRACTOR
Tandem Reels
Two Wire Reel Mounting
for TC-3.
Order K390
Tandem Arc Framework
Provides mountings with
desired positioning
adjustments for two
standard Automatic Wire
Feed Heads. Includes
insulation and hardware to
permit direct mounting to
a high capacity TC-3
Carriage, or to the user's
gantry or fixture for either
direction of travel.
Order K387
Flux Hopper for

Tandem Arc
Flux Hopper for
K387 mountings.
Order K389
Vertical Lift Adjuster

Provides 4 in. (102 mm)
hand crank adjustment of
vertical head position. It
also includes up to 3-3/4 in.
(95.2 mm) in-and-out
horizontal adjustment with
stops that can be preset for
simple repetition of the
same adjustment.
Order K29
Horizontal Adjuster
Provides crank adjustment
of head position. Has 2 in.
(51 mm) horizontal travel.
Order K96
Wire Reel Assembly for

50-60 lb. Coils
Accommodates 50 lb.
(22.7 kg) or 60 lb. (27.2 kg)
coils of wire on automatic
wire feeders. The unit
includes a wire reel
mounting spindle and
braking system. Cannot be
used with K2462-1.
Order K299
SpreadArc Oscillator
Oscillates head across the
line of travel. Calibrated
dwell time and oscillation
speed controls permit the
SpreadArc to cover large
areas quickly with smooth
beads of minimum
admixture.
Order K278-1
MAXsa 22 and
MAXsa 29 HEADS
and CRUISER
TRACTOR
Wire Straightener (Subarc)
up to 7/32 in. (5.6 mm)
Includes: A three roll wire
straightener with adjustable
pressure. (1 included with
each tractor and MAXsa
Feed Head.)
Order K1733-5
Magnetic Flux Screen

Separator
For submerged arc welding.
Removes foreign magnetic
particles from reused flux.
Order K58
Submerged Arc Contact

Nozzle Assembly for 3/32 in.
(2.4 mm), 1/8 in. (3.2 mm) and
5/32 in. (4.0 mm) electrodes.
For 5/64 in. (2.0 mm), 3/16 in.
(4.8 mm) or 7/32 in. (5.6 mm)
sizes, order additional
appropriate KP1962 tips.
Outer flux cone gives full
flux coverage with minimum
consumption.
(Rated up to 650 amps.)
Order K231-1
K231 nozzle tips

Designed for long life.
Order
KP1962-1B1
for 1/8 in. (3.2mm) wire
KP1962-2B1
for 3/16 in. (4.8 mm) wire
KP1962-3B1
KP1962-4B1
KP1962-5B1
KP2082-2B1
RECOMMENDED ACCESSORIES AND OPTIONS - CONT.

Positive Contact Assembly
For single arc welding at
high currents (optional T12928
water cooling attachment
recommended when
welding over 600 amps).
Order K148A
(for 3/32 to 1/8 in. wire)
Order K148B
(for 5/32 to 3/16 in. wire)
Concentric Flux
Cone Assembly
For use with K148B,
Positive Contact Nozzle
Assembly. Gives concentric
flux coverage around the
electrode.
Order K285
Contact Jaw Assembly

Single arc contact jaw
assembly for 1/8-7/32 in.
(3.2-5.6 mm) diameter wire.
Rugged contact jaws for
maximum life at currents
over 600 amps.
Order K226R
ESO (Extended Stick-Out)

Extension
Linc-Fill long stickout
extension for K148A Single
Arc Positive Contact Nozzle
Assembly. Required for long
stickout technique.
Order
K149-1/8
K149-3/32
K149-5/32
Narrow Gap Deep
Groove Nozzle
For single arc 3/32 in.
(2.4 mm) diameter wire
welding on thick walled
steel plate with nearly
parallel-sided, narrow gap
joint preparations.
Order K386
5 in. Nozzle Extension

Extends the wire for
subarc nozzles by 5 inches
[up to 1/4 in. (6.4 mm)
diameter wire].
Order KP2721-1
CRUISER
TRACTOR
Track Section
Includes: a single section
of 70 in (1.8 m) of track.
Order K396
50-60 lb. Coil Adapter

Adapts 50-60 lb.
(22.7-27.2 kg) coils of
Lincoln Electric electrode
to 2 in. (51 mm) spindle.
Order K1504-1
FOR OLD K2344-X

INSTALLATIONS
ONLY
Interface Control
Cable (22-pin)
Required to parallel
multiple Power Wave
power sources one per
machine required. Can be
extended.
Order K1795-XX
System Interface
External controller required
for multi-arc applications,
provides arc-to-arc phase
relationship.
Order K2282-1
Remote Wire Drive

Module
Designed for the Power
Wave AC/DC 1000
system, the Remote Wire
Drive Module enables you
to remove and remotely
locate your Wire Drive
Module outside of the
power source to support
extended ArcLink cable
lengths. Recommended
for applications where the
MAXsa feed head is
installed at more than
25 ft. (7.6 m) away from
the power source.
Order K2626-1
22 pin to 14 pin Adapter

Cable Assembly
18 in. (457 mm) long cable
adapter from K1785-XX to
K2282-1 system interface.
Order K1805-1
WAVEFORM CONTROL TECHNOLOGY
Waveform Control Technology capability provides

precise control over:
AC Frequency
Balance (Percentage of time in the positive polarity
portion of one Cycle)
Offset (Positive/Negative Amplitude)
The waveform may be varied to:

Control Penetration
Control Bead Shape
Minimize arc interactions which can cause arc blow
Positive Current Level = Penetration
Current, Voltage, or Power
AC Frequency
Cycle Balance = Penetration/Deposition
Negative Current Level = Deposition
Current, Voltage, or Power
SOFTWARE DRIVEN CONTROL OVER PENETRATION, DEPOSITION RATE AND TRAVEL SPEED
Travel
Speed
Travel
Speed
100% DC+
(traditional)
Maximum Penetration
Travel
Speed
50% DC+
Less Penetration
Greater Travel Speed
25% DC+
Less Penetration
More Shallow Bead
Greater Travel Speed
SINGLE ARC AND TWINARC SUBMERGED ARC WELDING
Single
Twinarc
150
PERCENTAGE %
Productivity Improvement
200
100
50
Single Wire DC+
Single Wire
Balanced AC
Single Wire
75% DC-, Square Wave AC
Single Wire
AC EESO
(Extended Electrical
Stickout)
2-Wire Twinarc
DC+
2-Wire Twinarc
Balanced AC
2-Wire
75% DC-, Square Wave AC
MULTI-ARC SUBMERGED ARC WELDING
Greater Productivity
through Enhanced Control
- The Subarc Advantage
2 Arcs
3 Arcs
150
PERCENTAGE %
Productivity Improvement
200
100
50
DC+ Lead Arc

Balanced AC Trail Arcs
Balanced AC Lead Arc

75% DC-, Square Wave AC Lead Arc

75% DC-, Square Wave AC Trail Arcs
30% DC- Amplitude Offset
DC+ Lead Arc

75% DC-, Square Wave AC Lead Arc

75% DC-, Square Wave AC Trail Arcs
30% DC- Amplitude Offset
C USTOME R ASSISTANC E POLIC Y

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 customers and to exceed their expectations.
On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the
knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric
does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied
warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers particular purpose is specifically disclaimed.
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 requirements.
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.
Visit www.lincolnelectric.com/subarc

E9.181 2/10 The Lincoln Electric Co. All Rights Reserved. Printed in the U.S.A.
22801 St. Clair Avenue Cleveland, OH U.S.A. 44117-1199

Phone: +1.216.481.8100 www.lincolnelectric.com

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Mechanized Solutions

Basic Automation Solutions

Power Wave AC/DC 1000 SD, MAXsa and Cruiser

Bigger Welds, Faster.

THE LINCOLN ELECTRIC COMPANY

About The Lincoln

Submerged Arc Welding Platforms

[ 2 ] | Submerged Arc Equipment Systems

Basic Automation Solution

Integrated Solution and Robotic Solution

Submerged Arc Equipment Systems | [ 3 ]

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

380 - 575 VAC, 50/60Hz Voltage Input Offers the ability to be

ArcLink, Ethernet, and DeviceNet Communication Offers

Voltage Compensation and Reliable Input Voltage Connection

True Energy Measures, calculates and displays instantaneous

No Hardware Reconfiguration Required with Easy Polarity

Production Monitoring 2 Track equipment usage, store weld

Easy to Parallel Machines or Run Multiple Arcs.

Software Based Controls Can be upgraded as new features

3-Phase Voltage Input Eliminates the imbalance associated with

iARC Digital Control - 90 times faster than the previous generation,

Power Wave AC/DC 1000 SD

49.2 x 19.2 x 46.2

[ 4 ] | Submerged Arc Equipment Systems

Bottom Rear View

Top Rear View

FEATURE LOADED, RUGGED CONSTRUCTION AND EASY MAINTENANCE

1. Easy Maintenance designed for

Submerged Arc Equipment Systems | [ 5 ]

THE LINCOLN ELECTRIC COMPANY

For The Long Haul

The Cruiser is a flexible wire feeding tractor for heavy

50-60 Lb. (22.7 - 27.2 kg) Coil Adapter

Drive Roll/Guide Tube Kit for

Contact Nozzle Assembly

Butt, Fillet and Lap Joint Tracker

Wire Size Range

[ 6 ] | Submerged Arc Equipment Systems

3. Pushbutton Menu Options

8. Feed Reverse/Feed Forward Buttons

RUGGED DESIGN & FLEXIBLE ADJUSTMENT FOR ANY CONFIGURATION

2. Heavy Duty Cross Slides

3. Hardened Base Construction

Submerged Arc Equipment Systems | [ 7 ]

THE LINCOLN ELECTRIC COMPANY

The MAXsa 10 controller offers a single monitoring

User-Friendly Controls Clear digital display and controls make it easy

[ 8 ] | Submerged Arc Equipment Systems

When not driving a motor.

BASIC AUTOMATION SOLUTION

6. Weld Mode Selector

10. Arc Start/End Options Selector

7. Mode Select Panel Control Knob

11. Set-Up Menu Indicator

8. Eight Memory Buttons: