Mechanized Solutions Basic Automation Solutions Integrated Solutions Robotic Solutions

Digital Submerged Arc Welding Systems

Advanced Control
Enhanced Deposition
Faster Travel Speeds

E9.181 Subarc Solutions Rev6-12.indd 1 8/28/12 1:21 PM

 THE LINCOLN ELECTRIC COMPANY

About The
Submerged Arc Welding Platforms
Lincoln Electric Company
Lincoln Electric is the world’s leading Lincoln Electric’s advanced submerged arc systems couple the
industry’s most advanced power source with mobile, hard
manufacturer of welding equipment automation or robotic feeding equipment to achieve new levels
and consumables. Our focus is of welding performance and operational efficiency.

helping companies make their welding Whether your application is bridge decking, pressure vessels,
panel line, seamer, pipe mill integrator solutions or submerged
operations more effective, more arc robotic welding, the software-driven Power Wave® AC/DC
1000® SD and your choice of integrated feeding equipment can
efficient, and more profitable. help your operations improve weld quality, reduce welding and
operational costs and increase weld team productivity.
We are dedicated to two equally Advanced Control
important goals: • Our 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
Exceptional quality and extended-range pendant. It is no longer necessary to reverse
exceptional service electrode and work cables.

Our field support team –– with Energy Savings

• With input current requirements reduced by up to 50%
hundreds of field sales engineers and for our inverter-based system, customers consistently report
significant energy savings over traditional submerged arc
thousands of knowledgeable and welding equipment.
responsive Lincoln Electric distributors Modular Components
in countries all over the world –– is the • Power Wave® and MAXsa® controller and feed
head components are engineered to readily adapt the
largest in the industry. system for use in almost any indoor or outdoor heavy wall
thickness submerged arc welding application.
Innovative thinking Rugged Reliability
For a quality, service-first attitude; • Power source, controller and feed heads are reliability
tested to meet IP23 standards. Each is designed to
innovative design, manufacturing, and withstand harsh environments and outdoor storage.
packaging; and worldwide strength — Lincoln Electric technical teams are standing by to assist
you with set up, customized welding mode development
Choose Lincoln Electric. optimized for your application, and welding consumables
testing and selection.

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 INTRODUCTION

Power Source M
Power Wave® AC/DC 1000® SD . . . . . . 4-5 Po
Cr

Mechanized Solution
Power Wave® AC/DC 1000® SD
Cruiser® Tractor . . . . . . . . . . . . . . . . . . . 6-7

Ba
Po
MA
MA

Basic Automation Solution

Power Wave® AC/DC 1000® SD
MAXsa® 10 Controller . . . . . . . . . . . . . . 8-9
MAXsa® 22Feed Head . . . . . . . . . . . . 10-11

In
Po
Integrated and Robotic Solutions MA
Power Wave® AC/DC 1000® SD MA
MAXsa® 19 Controller
and MAXsa® 29 Feed Head . . . . . . . . 12-14
Modified Series Arc™ . . . . . . . . . . . . . . . 15 Ro
Po
Robotic Submerged Arc Solutions . . . . . 16 MA
MA

Appendix . . . . . . . . . . . . . . . . . . . . . 17-27

Submerged Arc Equipment Systems | [ 3 ]

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 THE LINCOLN ELECTRIC COMPANY

® ®
Power Wave AC/DC 1000 SD
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 AC
constant voltage operation and set variable frequency and amplitude. DC
Software-driven AC, DC positive or DC negative output allows the user to
control the deposition rate and penetration. The result over conventional Input
power sources is increased weld speeds, consistently higher quality
welds and improved efficiencies in a single or multi-arc environment. 3
PHASE

50
60
Hz

Processes
DC+ Submerged Arc
DC- Submerged Arc
Balanced AC Submerged Arc
Variable AC Submerged Arc

COMMUNICATIONS PROTOCOL

Key Features www.lincolnelectric.com/green

• 380 - 575 VAC, 50/60Hz Voltage Input – Offers the ability to be • True Energy™ – Measures, calculates and displays instantaneous
connected anywhere in the world. energy in the weld for critical heat input calculations.
• Voltage Compensation and Reliable Input Voltage Connection – • CheckPoint™ and Production Monitoring™ 2.2 – Use your server or our
Provides consistent operation over ± 10% input voltage variation. cloud-based server to view or analyze your welding data on almost any
• No Hardware Reconfiguration Required with Easy Polarity device – desktop, laptop, iPhone® or iPad®, Blackberry® and others. Track
Switching – Eliminates downtime. equipment usage, store weld data, configure fault limits and more.
• 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. • iARC™ Digital Control - 90 times faster than the previous generation,
delivering a responsive arc.
• 95% Power Factor Correction – Enables connection of multiple
machines on the same plant infrastructure for lower installation costs. • Factory Burn-In Tested – At maximum output for 2 hours
to ensure quality and reliability.
• Severe Duty – Can be stored outdoors. IP23 Rated.
• ArcLink®, Ethernet, and DeviceNet™ Communication – Offers
remote process monitoring, control and troubleshooting.

Technical Specifications
Dimensions
Product Product Input Rated Output Input Current Output HxWxD Net Weight
Name Number Voltage Current/Voltage/Duty Cycle @ Rated Output Range in. (mm) lbs. (kg)

Power Wave® AC/DC 1000® SD K2803-1(1) 380/400/460/500/ 1000A/44V/100% 82/79/69/62/55 100-1000A 49.2 x 19.2 x 46.2 800
575/3/50/60 (1250 x 488 x 1174) (363)

(1)
Filter is required to meet CE conducted emission requirements. The K2444-3 must be used with the K2803-1.

[ 4 ] | Submerged Arc Equipment Systems

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 POWER SOURCE

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

6 7 8 9 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. Easy-access Reconnect Panel
• Connect the Power Wave®
AC/DC 1000® SD to an electrical 2
connection almost anywhere in the
world (380 up to 575 Volt input power).

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RC
THE LINCOLN ELECTRIC COMPANY

® ®
Cruiser and Tandem Cruiser Tractors
For Extended Decking Welds Output
The self propelled, modular Cruiser® and Tandem Cruiser™
travel carriages, used with the Power Wave® AC/DC 1000®
SD power source, can deliver deposition rates up to 30 lbs per
arc, per hour for butt and fillet joints on lengthy plate welding
applications common in bridge or barge decking, large tank
fabrication or shipbuilding. Input
40
Processes VDC

Submerged Arc

Shown: K3048-1 Cruiser®

COMMUNICATIONS PROTOCOL

Shown: K3083-1
Tandem Cruiser® What’s Included
• Conduit Tubing – 5 feet (1.5 m)
Key Features • 5/32 in. 600 Amp Contact Nozzle Assembly
• 5/32 in. Contact Tip
• Reliable Operation – Strong, rigid and stiff especially where you need it most.
• Nozzle Extension – 5 in. (127 mm)
• Advanced Control Pendant – Removable, lightweight, impact resistant aluminum user • Curved Nozzle Extension, 45º
interface can be used to save procedures, apply limits and lockouts for any or all controls.
• Nozzle Extension Insulator
• Common Expendable Parts – All drive rolls, nozzles, contact tips and wire straighteners are • Flux Tubing
shared with the MAXsa® submerged arc wire drives. • Flux Hose Clamps
• Multiple Configurations – Flexible system allows set up with or without a track • Wire Reel Assembly
and three or four wheel operation. Tandem model not recommended for three • Wheels for Track Operation
wheel operation.
• Front and Rear Outriggers
• Enclosed Wire Reel (2 for Tandem)
Note: Does not include a control cable.

Technical Specifications
Rated Travel Wire Feed Wire Size Range Dimensions
Product Product Input Output Current/ Duty Speed Speed Range in. (mm) HxWxD Net Weight
Name Number Power Cycle in/min (m/min) Gearing ipm (m/min) Solid in. (mm) lbs. (kg)
Cruiser® K3048-1 40 VDC 1000A / 100% 10 - 100 142:1 15 - 200 1/16 - 7/32 29 x 23 x 36 207
Tractor (0.25 - 2.5) (0.4 - 5.0) (1.6 - 5.6) (736 x 584 x 914) (94)
95:1 15 - 300 1/16 - 3/32
Tandem K3083-1 (0.4 - 7.5) (1.6 - 2.4) 36.5 x 45.5 x 41.5 300
Cruiser® 57:1 50 - 500 1/16 - 3/32 (927 x 1156 x 1054 (136)
Tractor (1.3 - 12.5) (1.6 - 2.4)

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 MECHANIZED SOLUTION

KEY CONTROLS
CRUISER ®
TANDEM CRUISER ®

20 19 1 1
20 19 18 17 16 20 19 18
18 2 2

1
2 17
17
3
3
16 16
4 15
4 15
14
5 5 14
13
6 6 13
7 12 7
8 11 8

9 10 10 11 12 13 14 15 4 5 9 10 11 12

1. WFS LED 6. Travel Menu (Left Button) 13. Arc End Options (Right 19. Voltage Display and
2. AMPS LED 7. Travel Direction Button) Control
3. Auto / OFF / Manual 8. Jog 14. Arc Start Options (Right 20. WFS/Amps Display and
Travel Switch 9. Memories Button) Control
4. Weld Mode Selection 10. Mode Select Display 15. Set-Up Menu
(Left Button) and Control 16. Stop Pushbutton
5. Frequency and Balance 11. Inch Down 17. Start Pushbutton
(Left Button) 12. Inch Up 18. Volts LED

RUGGED DESIGN & FLEXIBLE ADJUSTMENT FOR ANY CONFIGURATION

1. Improved Rigidity and

Stiffness
2. Heavy Duty Cross Slides
3. New Rugged Wheels
4. Modified Mast and Boom
3
Clamping System 1 2

5. Proven Industrial Wire

Drive
6. Cable Rack
7. Laser Pointer and Improved
Steering
8. Tandem Cruiser® for
greater weld deposition
4 5 6

7 8

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 THE LINCOLN ELECTRIC COMPANY
C

®
MAXsa 10 Controller
ArcLink®-enabled Controller for Output
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 Input
welding parameters and easy PLC interfacing to control
fixture travel, timers and other system commands.

Processes
Submerged Arc

COMMUNICATIONS PROTOCOL

Key Features

• Severe Duty Ready – The controller is IP23 rated and ready for operation • User-Friendly Controls – Clear digital display and controls make it easy
in harsh environments. to set weld modes, AC operation, strike/start/end options, travel stop/
• Pendant Box – Mount the controller in the standard protective box or start, timers and other parameters.
remove the pendant for hand-held operation. Extend hand-held operation • Limit Control – Apply operator procedure limits or lockout on any or all
from 4 feet (1.2 m) up to 100 feet (30.5 m) with an ArcLink® extension parameters.
cable. • Waveform Control Technology® – Allows the user to choose from a
• Eight Procedure Memories – Pre-set and save your optimal library of pre-programmed weld modes. Parameters for each mode can
welding parameters for repeating applications and recall later for be adjusted within a limited range to achieve optimal balance between
fast changeovers. deposition rate and penetration.

Technical Specifications

Dimensions Net
Product Product Input HxWxD Weight
Name Number Power in. (mm) lbs. (kg)

MAXsa® 10 Controller K2814-1 40 VDC 15 x 13 x 4 25

(381 x 259 x 102) (11.3)

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 BASIC AUTOMATION SOLUTION

KEY CONTROLS

1 15
2
14
3

13

5 12
11
6 10
7

8 9

16 17 18 19 20 21

1. AMPS/WFS Control 6. Weld Mode Selector 9. Feed Reverse/Feed Forward 15. Volts Control
2. AMPS/WFS Display • Weld Mode Indicator Light Buttons 16. User Interface/Pendant
• AMPS Indicator Light • Frequency/Balance Indicator 10. Arc Start/End Options Selector Connector
• WFS Indicator Light Light • Start Options Indicator Light 17. Status LED
3. Travel Switch 7. Mode Select Panel Control Knob • End Options Indicator Light
18. Wire Drive Connector
• Auto/Off/Manual 8. Eight Memory Buttons: 11. Set-Up Menu Indicator
• Save common procedures 19. Power Source Connector
4. Flux Hopper Switch 12. Arc Established Indicator
• Apply operator range or limits 20. Flux Hopper Connector
5. Mode Select Panel (MSP) • Lockout changes for procedure 13. Stop/Start Buttons
Display 21. Travel Carriage Connector
control 14. Volts Display
• Volts Indicator Light

RUGGED DESIGN, FLEXIBLE CONNECTION

1. IP23 Rated – Tested and approved to 1 2

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 3
protects the controller. To get closer to the
work, detach the controller for hand-held
operation.

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 THE LINCOLN ELECTRIC COMPANY

®
MAXsa 22 Feed Head
Submerged Arc Hard Output
Automation Feed Head
Designed specifically for hard automation
applications, the MAXsa® 22 Feed Head
delivers accurate wire feeding of large
diameter submerged arc wires. Based Input
on Lincoln’s proven gearbox and cast
aluminum feedplate, the MAXsa® 22
model features a 40VDC 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
Submerged Arc

COMMUNICATIONS PROTOCOL

Key Features
• Flexible Configuration – Can be used in single, tandem, Twinarc® • Multi-Axis Rotation – Rotational feed head adjustment in two planes
or multiple arc applications. allows flexible, accurate setup for fixturing or arc locating. Additional
• Closed Loop Speed Control – Facilitates full control over starting, positioning flexibility can be achieved with optional horizontal and vertical
running and stopping wire feed speed. lift adjusters.
• IP23 Rated – Tested to withstand harsh environments. • Standard Accessories – Including an adjustable wire straightener,
cross-seam adjuster and electrical valve flux hopper and mounting
• Additional Gear Sets included – Used to change the speed ratio to bracket for TC-3 carriage.
match the requirements of your application.

Technical Specifications

Wire Feed Wire Size Range (1) Dimensions Net

Product Product Input Rated Output Gear Speed Range (1) in. (mm) HxWxD Weight
Name Number Power Current / Duty Cycle Box ipm (m/min) Solid in. (mm) lbs. (kg)

MAXsa™ 22 Feed Head K2370-2 40 VDC 1000A/100% 142:1(1) 15 - 200 1/16 - 7/32 23.5 x 17 x 20 80
(includes flux hopper) (.25 - 5.08) (1.6 - 5.6) (597 x 432 x 508) (36.3)
95:1(1) 15 - 300 1/16 - 3/32
(.25 - 7.62) (1.6 - 2.4)

57:1(1) 50 - 500 1/16 - 3/32

(1-12.7) (1.6 - 2.4)

(1) 142:1 gear set is standard. Additional gears supplied for conversion to 95:1 with Wire Drive (K2370-2, K2312-2, or K2311-1)

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 BASIC AUTOMATION SOLUTION

KEY CONTROLS
1 2 3 4 5
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 9 8 7 6

OPTIONAL TC-3 TRAVEL CARRIAGE

TC-3 Travel Carriage Beam Profile

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

CONTACT NOZZLES (ONE REQUIRED)

1 5

1. Submerged Arc Contact Nozzle Assembly (K231-1)

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 (K148A + K148B)

For single arc welding at high currents. 2 6

3. Contact Jaw Assembly (K226R)

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 (K149-5/32)

Linc-Fill long stickout extension for K148A Single Arc Positive Contact Nozzle Assembly.
Required for long stickout technique. 3 7

5. Narrow Gap Deep Groove Nozzle (K386)

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 (K225)

Feeds two 5/64 in. (2.0 mm), 3/32 in. (2.4 mm) or 1/8 in. (3.2 mm) wires for submerged 4
arc welding on “Fast-Fill” joints or hardfacing beads.

7. Tiny Twinarc® Contact Assemblies (K129-XX)

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.

Submerged Arc Equipment Systems | [ 11 ]

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 THE LINCOLN ELECTRIC COMPANY

®
MAXsa 19 and ®
MAXsa 19 MSA Controller
Submerged Arc Controllers for MAXsa® 19 Output
Fabrication Integrators and Controller
Robotic Applications

The MAXsa® 19 or MAXsa® 19 MSA (Modified Series Arc)

controllers are specifically designed to relay wire feed commands
Input
to the MAXsa® 29 when a customer-supplied user interface
is used in place of the MAXsa® 10 controller. Typically, this
occurs in third party fabrication integrator solutions that include
integration hardware like turning rolls, panel lines, seamers and
pipe mills fixturing.
Modified Series Arc is a single pass, one-sided process
developed for plate joining, typically in gantry-mounted
applications. New digital solutions based on the use of the MAXsa® 19 MSA
Power Wave® AC/DC 1000® SD advanced submerged arc welding Controller
power source provide a number of advantages over conventional
Modified Series Arc systems.

Processes COMMUNICATIONS PROTOCOL

Submerged Arc
Key Features
MAXsa® 19 Controller - Weld plates up to 3/4 in. thick vs. 5/8 in. thick with conventional
• Compact size is easy to position in custom integrator solutions. systems.
• Fast digital communication with the Power Wave® AC/DC 1000® SD via - Presettable welding parameters, all set through the PLC
Arclink® cable and to the wire drive via a 14 pin control cable. - Eight user procedure memories
• Standard I/O connector block for start/stop, forward/reverse feed and - Fast, reliable digital system communication
shutdown input interfacing with external accessories. - Run the third wire on CC or CV
• Standard Status indicator aids diagnostic system troubleshooting. - Three phase operation, compared to single phase for conventional
• IP23 Rated – Tested to withstand harsh environments. systems.
- Weld production and quality monitoring through Lincoln Electric
Modified Series Arc™ process with MAXsa® 19 MSA Controller CheckPoint™, Production Monitoring™ and WeldScore™ software.
Compared to conventional MSA systems: • Increased Productivity
• Greater Control - Travel Speeds increase up to 28%, depending on plate thickness.
- Direct control of the series wire and ground current, resulting in - Weld faster on thinner plate with lower heat inputs and reduced
added stability, improved and consistent back bead appearance and distortion.
independent control of the heat input and deposition rate. • IP23 Rated – Tested to withstand harsh environments.

Technical Specifications

Dimensions Net
Product Product Input Rated Output HxWxD Weight
Name Number Power Current / Duty Cycle in. (mm) lbs. (kg)

MAXsa® 19 Controller K2626-2 40 VDC 1000A / 100% 9 x 10.5 x 3 7

(229 x 267 x 76) (3.2)

MAXsa® 19 MSA Controller K3172-1 40 VDC 1000A / 100% 9 x 10.5 x 3 7

(229 x 267 x 76) (3.2)

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 INTEGRATED AND ROBOTIC SOLUTIONS

KEY CONTROLS

MAXsa® 19 Controller

1. Mounting Holes
2. Power Source 5-Pin
ArcLink® Input Connector
3. Status LED
4. Wire Feeder Connector
5. I/O Connector

Bottom View

5 4 3 2 1

MAXsa® 19 MSA Controller

1. Mounting Holes
2. Status LED
3. Power Source 5-Pin
ArcLink® Input Connector
4. Arclink® Output Connector
5. Wire Feeder Connector
6. Cold Feed up/down

Bottom View

1
6 5 4 3 2

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 THE LINCOLN ELECTRIC COMPANY

®
MAXsa 29 Feed Head
Submerged Arc Feed Head for
Fabrication Integrators and Output
Robotic Applications

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
[email protected] for more information on robotic Input
applications.

Processes
Submerged Arc
MAXsa® 29
Feed Head

COMMUNICATIONS PROTOCOL

KEY CONTROLS

1. Wire Straightener 6. Idle Roll Arm

2. Mounting Bracket 7. Guide Tubes
1
3. Fuse 8. 5/32 in. (4.0 mm)
4. 14-Pin Connector Drive Rolls
2 5. Lead (67) 9. Tension Indicator

9 8 7 6 5 4

Wire Feed Wire Size Range (1) Dimensions Net

Product Product Input Rated Output Gear Speed Range (2) in. (mm) HxWxD Weight
Name Number Power Current / Duty Cycle ipm (m/min) Solid in. (mm) lbs. (kg)
Box
15 - 200 1/16 - 7/32
142:1
(.25 - 5.08) (1.6 - 5.6)
MAXsa® 29 K2312-2 40 VDC 1000A / 100% 15 - 300 1/16 - 3/32 13 x 16 x 10 35
95:1 (330 x 406 x 254)
Feed Head (.25 - 7.62) (1.6 - 2.4) (15.9)
50 - 500 1/16 - 3/32
57:1
(1-12.7) (1.6 - 2.4)
(1) 142:1 gear set is standard. Additional gears supplied for conversion to 95:1 + 57:1 with Wire Drive (K2370-2, K2312-2, or K2311-1)

[ 14 ] | Submerged Arc Equipment Systems

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 MECHANIZED SOLUTION
INTEGRATED AND ROBOTIC SOLUTIONS

Modified Series Arc™ System

Greater Control. Increased Productivity MAXsa® 19 MSA
Controller
Modified Series Arc™ is a single pass, one-sided process developed
for plate joining, typically in gantry-mounted applications. New
digital solutions based on the use of the Power Wave® AC/DC
1000® SD advanced submerged arc welding power source provide
a number of advantages over conventional Modified Series Arc™
systems.

Processes
DC+ Submerged Arc
DC- Submerged Arc
Balanced AC Submerged Arc
Variable AC Submerged Arc MAXsa® 29
Feed Head
Multiple Wire Applications
• Single Pass, One-Sided Plate Welding
• Gantry Mounted Systems

What’s Included
Modified Series Arc One-Pak® (K3124-2)
• Power Wave® AC/DC 1000® SD (K2803-1) Qty 3
• MAXsa® 29 Feed Head (K2312-2) Qty 3
MAXsa® 10
• MAXsa® 10 Controller (K2814-1) Qty 2
• MAXsa® 19 MSA Controller (K3172-1) Qty 1 Controller

Key Features
• Greater Control
- Direct control of the series wire and ground current, resulting in
added stability, improved and consistent back bead appearance and
independent control of the heat input and deposition rate.
• Weld plates up to 3/4 in. thick.
• Increased Productivity
- Travel speeds increase up to 28%, depending on plate thickness. Power Wave®
- Weld faster on thinner plate with lower heat inputs and reduced AC/DC 1000® SD
distortion.

Wire Feed Wire Size Range (2) Dimensions Net

Product Product Input Rated Output Gear Speed Range (2) in. (mm) HxWxD Weight
Name Number Power (1) Current / Duty Cycle ipm (m/min) Solid in. (mm) lbs. (kg)
Box
(1) 15 - 200 1/16 - 7/32
142:1
(.25 - 5.08) (1.6 - 5.6)
Power Source:
Modified Series Arc™ K3124-2 380/400/460/500/575/3/50/60 1000A / 100%
(1) 15 - 300 1/16 - 3/32 NA NA
95:1
One-Pak® Controllers & Feed Head: (.25 - 7.62) (1.6 - 2.4)
40 VDC (1) 50 - 500 1/16 - 3/32
57:1
(1-12.7) (1.6 - 2.4)
(1) When not driving a motor. (2) 142:1 gear box is standard. Conversion Kit supplied for conversion to 95:1 with Wire Drive (K2370-2, K2312-2, or K2311-1)

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 THE LINCOLN ELECTRIC COMPANY

Robotic Submerged Arc Solutions

Faster Arc Time. Consistent Quality.
/

Building on the digital component platform of the

Power Wave® AC/DC 1000® SD power source and MAXsa®
controllers and feed heads, the team at Lincoln Electric
Automation developed an advanced robotic submerged arc
welding system to enhance productivity for many heavy
industry applications.
With robotic automation, operations can be moved to the
next level with robot features such as touch sensing, path
follow and vision-based arc guidance along with automated
flux recovery.

Processes
DC+ Submerged Arc
DC- Submerged Arc
Balanced AC Submerged Arc
Variable AC Submerged Arc

Applications
• Structural Steel
• Process and Power Generation
• Wind Tower Fabrication
• Heavy Equipment
• Offshore
• Pipe Fabrication

Key Features
Robotic Submerged Arc Solutions
• Higher deposition rates at faster travel speeds
• Increased productivity and arc-on time
• Patented flux delivery system
• Engineered cable management system
• Fast digital system component communication

Contact Lincoln Electric Automation Solutions at 888.935.3878 or [email protected]

[ 16 ] | Submerged Arc Equipment Systems

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 APPENDIX

DIGITAL COMMUNICATIONS AND SEAMLESS INTEGRATION

Production Monitoring™

Production Monitoring™
Turning Rolls(1)

PC Computer

Intranet and/or Internet

connection over a VPN
(Virtual Private Network)

Robot and
Robot Controller
MAXsa® 19 MAXsa® 19 MSA
Controller Controller Pipe Mills

Power Wave®
AC/DC 1000® SD
MAXsa® 22 MAXsa® 29
Feed Head Feed Head

Seamers

Column and Boom

Panel Lines(2) Flux Recycling

Systems(3)

(1) 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.

Submerged Arc Equipment Systems | [ 17 ]

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 THE LINCOLN ELECTRIC COMPANY

SINGLE ARC MOBILE CONFIGURATION

RECOMMENDED EQUIPMENT
Product Number Product Description Qty. Required

K2803-1 Power Wave® AC/DC 1000® SD 1

K3048-1 Cruiser® Tractor 1

K2683-xx Heavy Duty ArcLink® Control Cable 1

K1811-xx Work Sense Lead 1

Connection Diagram - Cruiser™ Tractor System

K2803-1
Power Wave®
AC/DC 1000® SD

K1811-XX
Sense Lead

K2683-XX
K2607-1 ArcLink® Cable
Cruiser®

Electrode
Weld Cable

Work
Work
Weld Cable

[ 18 ] | Submerged Arc Equipment Systems

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 APPENDIX

SINGLE ARC CONFIGURATION

RECOMMENDED EQUIPMENT
Product Number Product Description Qty. Required
®
K2803-1 Power Wave AC/DC 1000® SD 1

K2814-1 MAXsa® 10 Controller 1

K2370-2 MAXsa® 22 Feed Head 1

K148A Positive Contact Nozzle Assembly 3/32 - 1/8 2

K148B Positive Contact Nozzle Assembly 5/32 - 3/8 1

K2683-XX Heavy Duty ArcLink® Control Cable 1

K1785-XX 14-pin Control Cable 1

K1811-XX Work Sense Lead 1

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
67 Lead
14-Pin Cable

K231-XX Electrode
Contact Nozzle Weld Cable

Work
Work Weld Cable

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 THE LINCOLN ELECTRIC COMPANY

DUAL ARC CONFIGURATION (For paralleling or more than two arcs, please contact your local Lincoln Electric Office.)

RECOMMENDED EQUIPMENT
Product Number Product Description Qty. Required

K2803-1 Power Wave® AC/DC 1000® SD 2

K2814-1 MAXsa® 10 Controller 2

K2370-2 MAXsa® 22 Feed Head 2

K231-1 Submerged Arc Contact Nozzle Assembly 2

[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 2

K1785-XX 14-pin Control Cable (controller to wire drive) 2

K1785-XX 14-pin Control Cable (machine to machine) 1

K1811-XX Work Sense Lead 1

Connection Diagram - Tandem Arc System

K2683-XX
K1785-XX 14-Pin Cable
ArcLink® Cable

K1811-XX
Sense Lead

K2814-1 K2814-1
MAXsa® 10 MAXsa® 10

K2683-XX
ArcLink® Cable

K1785-XX
14-Pin Cable
K2803-1
K1785-XX
14-Pin Cable Power Wave®
AC/DC 1000® SD

K2370-2
MAXsa® 22 67 Lead

K2370-2
MAXsa® 22 K2803-1
Electrode Power Wave®
K231-XX Weld Cable AC/DC 1000® SD
Contact Nozzle

Work
Work Weld Cable

Electrode Weld Cable

[ 20 ] | Submerged Arc Equipment Systems

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 MECHANIZED SOLUTION
APPENDIX

MODIFIED SERIES ARC CONFIGURATION

RECOMMENDED EQUIPMENT
Product Number Product Description Qty. Required
®
K2803-1 Power Wave AC/DC 1000® SD 3

K2814-1 MAXsa® 10 Controller 2

K2312-2 MAXsa® 29 Feed Head 3

K3172-1 MAXsa® 19 MSA Controller 1

K148A Positive Contact Nozzle Assembly 3/32 - 1/8 2

K148B Positive Contact Nozzle Assembly 5/32 - 3/16 1

K2683-XX Heavy Duty ArcLink® Control Cable 3

K1785-XX 14-pin Control Cable 5

K1811-XX Work Sense Lead 2

K2683-XX
ARCLINK CABLE

K1785-XX
14-PIN CABLE
K1811-XX
SENSE LEAD

K2814-1 K3172-1 K2814-1

MAXsa 10 MAXsa 19 MSA MAXsa 10

K1785-XX
14-PIN CABLE

K2683-XX
ARCLINK CABLE
67 Lead
K2803-1 K2803-1 K2803-1
POWERWAVE POWERWAVE POWERWAVE
AC/DC 1000 SD AC/DC 1000 SD AC/DC 1000 SD
N.A.

WORK
COPPER
BUS BAR

ELECTRODE
WELD CABLE
K148-XX
CONTACT NOZZLE

5°
27°

WORK WELD CABLE

K1811-XX
SENSE LEAD
2.00 2.00
2.00

WORK
.25 BOTTOM EDGE
5.00 OF PLATE

Submerged Arc Equipment Systems | [ 21 ]

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 THE LINCOLN ELECTRIC COMPANY

Mild Steel SAW Wire Feeding Capability

142:1
7/32 gear ratio
5.6 (standard*)

3/16
SOLID WIRE DIAMETER (INCHES/mm)

4.8

5/32
4.0 95:1
gear ratio
(Included)
1/8
3.2
57:1
3/32 gear ratio
(Included)
2.4

5/64
2.0

1/16
1.6

15 50 100 200 300 400 500

.4 1.25 2.5 5 7.6 10 12.7

WIRE FEED SPEED (IPM/MPM)

DC+ SINGLE ARC

DC DC- SINGLE ARC DC+ TWINARC ®

* On MAXsa® Feed Heads

[ 22 ] | Submerged Arc Equipment Systems

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 RECOMMENDED ACCESSORIES ANDAPPENDIX
OPTIONS

14-PIN CONTROL CABLE WELD POWER CABLES

(CANNOT BE EXTENDED)
Product No.
Length Product No.
For Up to 250 ft. (75 m) @ 80% Duty Cycle
4 ft. (1.2 m) K1785-4
35 ft. - 2x4/0 K2163-35
12 ft. (3.7 m) K1785-12
60 ft. - 2x4/0 K2163-60
16 ft. (4.9 m) K1785-16
For Up to 250 ft. (75 m) @ 100% Duty Cycle
25 ft. (7.6 m) K1785-25
10 ft. - 1x3/0 K1842-10
50 ft. (15.2 m) K1785-50
35 ft. - 1x3/0 K1842-35
100 ft. (30.5 m) K1785-100
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 Product No.

25 ft. (7.6 m) K2683-25 MAXsa® DRIVE ROLL KIT INFORMATION

Heavy Duty

Wire Sizes
Product No. and Types
50 ft. (15.2 m) K2683-50

KP1899-1 3/32 - 7/32 in. Wires

100 ft. (30.5 m) K2683-100

KP1899-2 1/16 - 3/32 in. Wires

SENSE LEAD KIT KP1899-3 .035 - .052 in. Solid Wire

Length Product No. KP1899-4 .045 - .052 in. Cored Wire

50 ft. (15.2 m) K1811-50

100 ft. (30.5 m) K1811-100

Submerged Arc Equipment Systems | [ 23 ]

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 THE LINCOLN ELECTRIC COMPANY

RECOMMENDED ACCESSORIES AND OPTIONS

POWER WAVE® Automatic Flux Hopper SpreadArc Oscillator

AC/DC 1000® SD Assembly Oscillates head across the
Flux Hopper for MAXsa® 29 line of travel. Calibrated
CE Filter Heads (included standard dwell time and oscillation
This high power filter that on the MAXsa® 22 Heads) speed controls permit the
enables Power Wave® Order K219 SpreadArc to cover large
AC/DC 1000® CE “ready” areas quickly with smooth
machine to conform to the beads of minimum
EMC standards of Europe admixture.
and Australia.
MAXsa® 22 and Order K278-1
Order K2444-3 MAXsa® 29 HEADS
and TC-3 TRACTOR
MAXsa® 22 and
MAXsa 22 and
® Tandem Reels MAXsa® 29 HEADS
MAXsa® 29 HEADS Two Wire Reel Mounting and CRUISER®
for TC-3.
TRACTOR
MAXsa™ 10 Order K390
Mounting Bracket Wire Straightener (Subarc)
Allows for mounting the Tandem Arc Framework
up to 7/32 in. (5.6 mm)
MAXsa™ 10 to the TC-3 Provides mountings with
Includes: A three roll wire
Travel Carriage. Cannot desired positioning
straightener with adjustable
be used with K299. adjustments for two
pressure. (1 included with
Order K2462-1 standard Automatic Wire
each tractor and MAXsa®
Feed Heads. Includes
Feed Head.)
insulation and hardware to
Order K1733-5
TC-3 Self-Propelled permit direct mounting to
Travel Carriage a high capacity TC-3
The TC-3 travel carriage Carriage, or to the user’s
Submerged Arc Contact
allows the mounting of up gantry or fixture for either
Nozzle Assembly for 3/32
to two feed heads/ direction of travel.
in. (2.4 mm), 1/8 in. (3.2
controllers and wire reels Order K387
mm) and 5/32 in. (4.0 mm)
to a beam for basic hard electrodes.
automation installations. For 5/64 in. (2.0 mm), 3/16
Order K325 HCS Flux Hopper for
in. (4.8 mm) or 7/32 in. (5.6
(for 5-75 ipm) Tandem Arc
mm) sizes, order additional
Flux Hopper for appropriate KP1962 tips.
K387 mountings. Outer flux cone gives full
Large Wire Twinarc® Order K389 flux coverage with minimum
Contact Assemblies consumption.
Feeds two 5/64 in. (2.0 mm), (Rated up to 650 amps.)
3/32 in. (2.4 mm) or 1/8 in. Vertical Lift Adjuster Order K231-1
(3.2 mm) wires for Provides 4 in. (102 mm)
submerged arc welding hand crank adjustment of
on “Fast-Fill” joints or vertical head position. It
hardfacing beads. also includes up to 3-3/4 in.
Order K225 (95.2 mm) in-and-out
horizontal adjustment with
stops that can be preset
Twinarc® Solid Wire for simple repetition of the
Straightener same adjustment.
Straightens wire diameters Order K29
.045 thru 3/32 in.
(1.2 thru 2.4 mm). Horizontal Adjuster
Particularly valuable on Provides crank adjustment
longer electrical stickout of head position. Has 2 in.
procedures. (51 mm) horizontal travel.
Order K281 Order K96

Tiny Twinarc® Contact Wire Reel Assembly for

Assemblies 50-60 lb. Coils
Feeds two electrodes for Accommodates 50 lb.
high speed submerged arc (22.7 kg) or 60 lb. (27.2 kg)
welds. Includes contact coils of wire on automatic
nozzle, wire guides, drive wire feeders. The unit
rolls and guides, and a includes a wire reel
second wire reel and mounting spindle and
mounting bracket. braking system. Cannot be
Order K129-xx used with K2462-1.
Order K299

[ 24 ] | Submerged Arc Equipment Systems

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 MECHANIZED
APPENDIX
SOLUTION

RECOMMENDED ACCESSORIES AND OPTIONS - CONT.

ESO (Extended Stick-Out) Tiny Twin Kit for Cruiser™

K231 Nozzle Contact Tips Extension Includes a second spindle,
Severe Duty Linc-Fill long stickout drive rolls and 95:1 gears.
Order extension for K148A Single Order K3070-1
KP2082-2B1 Arc Positive Contact Nozzle
for 5/64 in. (2.0 mm) wire Assembly. Required for long
KP1962-3B1 stickout technique.
for 3/32 in. (2.4 mm) wire Order K149-1/8 Butt Joint Guide Kit
KP1962-1B1 K149-3/32 (Tandem only)
for 1/8 in. (3.2mm) wire K149-5/32 Used to track the joint and
KP1962-4B1 guide the Tandem Cruiser™
for 5/32 in. (4.0 mm) wire Narrow Gap Deep for plate and decking
Groove Nozzle applications.
KP1962-2B1
For single arc 3/32 in. Order K3154-1
for 3/16 in. (4.8 mm) wire
(2.4 mm) diameter wire
KP1962-5B1 welding on thick walled
for 7/32 in. (5.6 mm) wire steel plate with nearly Nozzle Extension, 45º
parallel-sided, narrow gap Frequently used when
c) Extended Life joint preparations. making horizontal fillet
Order Order K386 welds.
KP3162-3B1 Order KP2721-2
e for 3/32 in. (2.4 mm) wire 5 in. Nozzle Extension
KP3162-1B1 Extends the wire for
for 1/8 in. (3.2 mm) wire subarc nozzles by 5 inches
KP3162-4B1 [up to 1/4 in. (6.4 mm)
for 5/32 in. (4.0 mm) wire diameter wire].
KP3162-2B1 Order KP2721-1
for 3/16 in. (4.8 mm) wire
KP3162-5B1
for 7/32 in. (5.6 mm) wire CRUISER™
TRACTOR
Positive Contact Assembly
For single arc welding Tube and Clamp Kit
at high currents (optional One 30 in. (762 mm)
T12928 water cooling aluminum splined tube; two
l 15 in. (381 mm) aluminum
attachment recommended
when welding over 600 splined tubes; one 30 in.
amps). (762 mm) steel tube; 8
m clamp assemblies with keys;
Order K148A
(for 3/32 to 1/8 in. wire) 2 outrigger assemblies;
hardware.
Order K148B
Order K3090-1
(for 5/32 to 3/16 in. wire)

Concentric Flux Cross Slide Assembly

Cone Assembly Includes: two slides with 4 in.
For use with K148B, (102 mm) of travel. (1 cross
Positive Contact Nozzle slide assembly included with
Assembly. Gives concentric each tractor.)
flux coverage around the Order K3089-1
electrode.
Order K285
Track Section
Contact Jaw Assembly
Includes: a single section
Single arc contact jaw
of 70 in (1.8 m) of track.
assembly for 1/8-7/32 in.
Order K396
(3.2-5.6 mm) diameter wire.
Rugged contact jaws for
maximum life at currents
50-60 lb. Coil Adapter
over 600 amps.
Adapts 50-60 lb.
Order K226R
(22.7-27.2 kg) coils of
Lincoln Electric electrode
to 2 in. (51 mm) spindle.
Order K1504-1

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 THE LINCOLN ELECTRIC COMPANY

®
WAVEFORM CONTROL TECHNOLOGY

The waveform may be varied to: Waveform Control Technology® capability provides
• Control Penetration precise control over:
• Control Bead Shape • AC Frequency
• Minimize arc interactions which can cause arc blow • Balance (Percentage of time in the positive polarity
portion of one cycle)
• Offset (Positive/Negative Amplitude)

Positive Current Level = Penetration

AC Frequency
Current, Voltage, or Power

Cycle Balance = Penetration/Deposition

Negative Current Level = Deposition

SOFTWARE DRIVEN CONTROL OVER PENETRATION, DEPOSITION RATE AND TRAVEL SPEED
Current, Voltage, or Power

Travel Travel
Travel Speed Speed
Greater Travel Speed
Speed 50% DC+ 25% DC+
100% DC+
(traditional)

• Maximum Penetration • Less Penetration • Less Penetration

• Greater Travel Speed • More Shallow Bead
• Greater Travel Speed

[ 26 ] | Submerged Arc Equipment Systems

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 MECHANIZED
APPENDIX
SOLUTION

SINGLE ARC AND TWINARC ® SUBMERGED ARC WELDING

Single Twinarc®
200

150
Productivity Improvement
PERCENTAGE %

100

50

0
Single Wire DC+ Single Wire Single Wire Single Wire 2-Wire Twinarc® 2-Wire Twinarc® 2-Wire
Balanced AC 75% DC-, Square Wave AC AC EESO DC+ Balanced AC 75% DC-, Square Wave AC
(Extended Electrical
Stickout)
MULTI-ARC SUBMERGED ARC WELDING

Greater Productivity
through Enhanced Control
- The Submerged Arc Advantage Twinarc®
1 Arc

2 Arcs 3 Arcs
200

150
Productivity Improvement
PERCENTAGE %

100

50

0
DC+ Lead Arc Balanced AC Lead Arc 75% DC-, Square Wave AC Lead Arc DC+ Lead Arc 75% DC-, Square Wave AC Lead Arc
Balanced AC Trail Arcs Balanced AC Trail Arcs 75% DC-, Square Wave AC Trail Arcs Balanced AC Trail Arcs 75% DC-, Square Wave AC Trail Arcs
30% DC- Amplitude Offset 30% DC- Amplitude Offset

Submerged Arc Equipment Systems | [ 27 ]

3 Arcs
2 Arcs
E9.181 Subarc Solutions Rev6-12.indd 27 8/28/12 1:22 PM
 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 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

THE LINCOLN ELECTRIC COMPANY

22801 St. Clair Avenue • Cleveland, OH • 44117-1199 U.S.A.
Phone: +1.216.481.8100 • www.lincolnelectric.com
E9.181 7/12 © The Lincoln Electric Co. All Rights Reserved. Printed in the U.S.A.

E9.181 Subarc Solutions Rev6-12.indd 28 8/28/12 1:22 PM