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AC-DC Power Wave 1000A

Key Features I
Modular System with 1000A units @ 100% Duty Cycle Easy Paralleling of up to five 1000A units to achieve necessary Currents Same Hardware can be used for AC, DC+ or DC- Process with CC or CV characteristic. Even Phase Generator has same hardware than Power Wave PC.-Board Less Spare Parts

Hardware Overview

Key Features II
In Multi-Arc Environment all arcs are synced by an external Phase Generator The Phase Generator allows infinitely variable Frequency and Phase Shift between different Arcs or different Frequencies for each arc Square Wave Process can use Wave Form Control Technology to adjust Balance or DC-Offset

Wave Form Control Technology

Independent Wave Form Parameters for each Arc

Phase Angle: Stepless changeable Frequency: Stepless changeable (10Hz to 90Hz - upper frequency can change with inductance of welding cable) DC Offset: Positive vs. Negative Amplitude Balance: Positive vs. Negative Cycle Time Slope: Fixed within Wave Form description

Idea of Wave Form Control

Stepless change of Melt of Rate vs. Penetration with no effect on the Heat Input Calculation
60 U i I i

HI = Heat Input [kJ/cm] U, I = Voltage and Current Workpoint of each Arc v = welding speed [cm/min]

HI =

1000 vs

Usage of Wave Form Control

Comparison to Standard Equipment

Power Wave AC-DC DC+, DC-, Sinus, Square Wave or Custom Wave Form Variable Frequency Variable Phase Shifting Transformer or Rectifier Only DC or Sinus Wave Forms Frequency fixed to Power Supply Phase Shifting limited to 60, 90 or 120

Comparison to Standard Equipment

Power Wave AC-DC Power Factor 95% Transformer or Rectifier Typical Power Factor 65-95% Rectifier or 40-80% Transformer Typical Efficiency Rating 70-80% Rectifier or 80-85% Transformer

Efficiency Rating 86%


Standard SAW Processes

DC+ or DC- (CC or CV) Square Wave with Wave Form Controls (CC and CV) Sinus Wave Form fixed at 50Hz and 60Hz only (only CC) to emulate standard Transformers Additional Wave Forms possible at Customer Request

Networking with Power Wave


Network Overview
Daisy Chain Connection of Digital Bus runs from Phase Generator to Master to Slave Power Waves Device Net Interface adds possibility of easy PLC connection Ethernet Network between all Power Sources, Phase Generator and Control Center

PLC Interface
Device Net Interface to Allan Bradley PLC (or Siemens with additional Gateway) Independent control of each Arc On the fly changes of Welding Work Points Report of Power Wave and Arc Status (Current, Voltage, WFS, Diagnose Bits)


Command Center
Detailed Set up of Power Wave Parameters including Strike, Start, Burnback and Crater Fill


Command Center
Detailed Diagnose of every single Power Wave