AUTOMATED SOLUTIONS
Power Wave® AC/DC 1000™
Increase Productivity, Quality and Flexibility
The Power Wave AC/DC 1000 is the first power source to introduce Waveform Control
™
Technology to submerged arc welding. Variable frequency and amplitude AC, DC
positive or DC negative output allows the user to control the deposition rate and penetra-
tion. An operator can increase weld speeds, yield higher quality welds and improve effi-
ciencies in a single or multi-arc environment. The phase angle and frequency of different
machines can also be synchronized to balance the interactions between multiple arcs and
minimize arc blow. Depending on the output, a welding arc may be driven by a single
machine or multiple machines in parallel for applications that require more than 1000
amps of continuous operation.
Processes
Description
AC
DC
50
Hz
CC
CV
Submerged Arc
3
Output
Input
60
PHASE
Advantage Lincoln
Recommended General Options
System Interface, Interface Control Cable (22-pin), ArcLink Cable (5-pin),
Feeder Control Cable (14-pin), TC-3 Self-Propelled Travel Carriage,
CE Filter(1)
• Eliminate downtime with easy polarity switching –– no hardware
reconfiguration required.
• Stable and independent arc controls for multiple arc applications.
• Improved efficiency and reliability with cooler operation through
patented Coaxial Transformer Technology™.
Recommended Wire Feeders
• 95% power factor correction enables connection of more
machines on the same plant infrastructure for lower installation
costs compared to other machines.
Power Feed 10A Controller K2362-1 (requires either the K2312-1
Power Feed 10SF Wire Feed Head for fixed hard automation, or
the K2370-1 Power Feed 10S Head for mounting a Lincoln TC-3
Travel Carriage), Power Feed 10SM Motor Conversion Kit K2311-1
(Other options may apply).
• Remote process monitoring and control through ArcLink,
Ethernet, and DeviceNet communication.
• Consistent operation over 10% input voltage variation through
built-in line voltage compensation and reliable input voltage
connection.
Order
K2344-1 Power Wave AC/DC 1000 460/500/575/3/60
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
K2344-2 Power Wave AC/DC 1000 400/460/500/575/3/50/60
• Three-year warranty on parts and labor.
TECHNICAL SPECIFICATIONS
Rated Output
Current/Voltage/
Duty Cycle
Dimensions
H x W x D
in (mm)
Net
Weight
lbs (kg)
Product
Name
Product
Number
Input
Voltage
Input Current
@Rated Output
Output
Range
Power Wave AC/DC 1000
K2344-1
460/500/575/3/60
1000/44/100%
68/62/54
100-1000A
43.5 x 19.2 x 33
(1105 x 488 x 838)
600
(272)
(1)
(1)
Power Wave AC/DC 1000
K2344-2
380/400/460/500/575/3/50/60 1000/44/100%
82/79/69/62/55
100-1000A
43.5 x 19.2 x 33
650
(1105 x 488 x 838)
(295)
(1)
External Filter is required to meet CE conducted emission requirements. The K2444-1 must be used with the K2344-2.
Publication E10.96 1/05
Web Update 1/06
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A CLOSER LOOK
Variable Balance – Control Deposition
By setting the correct wave balance (that is, the ratio between positive and negative waveforms), the operator is able to work faster and fill
the weld joint with fewer passes. The Power Wave AC/DC 1000™ has wave balance range of 25% to 75%.
The more positive the wave,
the more penetration.
The more negative the
wave, the greater the
weld deposition.
DC Offset (Variable Amplitude) – Control Penetration
Wave amplitude and the duration of positive and negative cycles are independently adjustable, so the operator can obtain deep/shallow
penetration and higher/lower deposition rates, depending on the application. The Power Wave AC/DC 1000 has the widest range of vari-
able amplitude, or DC offset, (-25% to 25%) in the industry.
Increasing the positive amplitude
(offset) increases penetration.
Increasing the negative amplitude
(offset) decreases penetration.
Multi-Arc Environment
In a multiple arc welding, as many as five arcs operate in a single weld puddle. Changes to the positive/negative polarity phases and/or cycle
balances of the AC waveform enable the operator to control deposition rate, penetration and travel speed without a change in voltage or current
settings. Using the Power Wave AC/DC 1000 in a multi-arc system can increase your weld speeds, yield higher quality welds and improve
efficiencies.
Phase Relationship – Controlling Arc Blow
In a multi-arc environment, arc interaction plays an important role in the behavior of the weld. Two positive electrodes pull together, as do
two negative electrodes, while a positive and negative repel each other, causing arc blow. The Power Wave AC/DC 1000 balances the
"push" and "pull" of the multi-arc relationship using phase shifting to prevent arc blow.
By phase shifting the AC
waveforms, the amount of
"push" and "pull" of the arc
interactions can be bal-
anced using alternating
current to avoid arc blow.
Power Wave AC/DC 1000
[3]
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A CLOSER LOOK
Arc Performance
The capabilities of the Power Wave AC/DC 1000™ in a multi-arc environment offer digital control over the critical welding variables for
optimum performance whatever your needs require. As shown below, these digital controls can be used for each arc to provide unprece-
dented arc welding characteristics.
+
–
DC
DC
t
t
t
Trailing Arcs — AC
Lead Arc — DC+
Deep Penetration
Greater negative components
produces greater deposition and
a flattened bead shape
Variable Frequency and Phase Relationship
— Reduce Arc Blow
Variable Positive/Negative
Proportions — Optimize Welding
Productivity Comparison
The Power Wave AC/DC 1000 delivers optimized productivity through the ability to adjust phase relationships between the arcs. Multiple
arcs can be tuned to work together rather than interfere with each other.
Multi-Arc Submerged Arc Welding
AC/DC 1000
2 ARCS
3 ARCS
3 Arc
2 Arc
3 Arc
2 Arc
2 Arc
2 Arc
3 Arc
75% DC NEGATIVE BALANCED AC LEAD ARC
75% DC NEGATIVE BALANCED AC TRAIL ARC
STANDARD
TECHNOLOGY
BALANCED AC LEAD ARC
BALANCED AC TRAIL ARC
75% DC NEGATIVE LEAD ARC
75% DC NEGATIVE TRAIL ARC WITH
30% DC NEGATIVE AMPLITUDE OFFSET
Applications
Whether it is a cross country pipeline or an offshore platform, the Power Wave AC/DC 1000 is meeting and exceeding expectations
around the world.
Single Arc
Small diameter circumferential welds, pipe double-
ending, storage tanks, seam welders
Tandem Arc
Large diameter circumferential welds [40”(1m) and up], spiral pipe mills,
bridge girders, pressure vessels, wind mill towers.
Long straight welds, pipe mills, panel lines.
Multiple Arcs (3 to 5)
Power Wave AC/DC 1000
[4]
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A CLOSER LOOK
AC/DC Submerged Arc Single Arc
OPTIONAL EQUIPMENT
RECOMMENDED EQUIPMENT
System Component
Qty. Required
Product Number
System Identifier
Product Description
PLC (customer supplied)
Power Source
Head
K2344-1 or K2344-2
Power Wave AC/DC 1000™ Power Source
1
1
Ethernet Switch (customer supplied).
Required for arcs > 1000A or with
use of the Submerged Arc Software Suite.
K2370-1
or
K2312-1
Power Feed 10S head for 3/32 to 7/32 in. solid wire
(Includes hopper, wire straightener, cross seam adjuster,
head mounting hardware)
or
Computer (customer supplied).
Required for use of the
Submerged Arc Software Suite.
Power Feed 10SF Head for 3/32 to 7/32 in. solid wire
Fixture Builders Head (Insulators not included)
User Interface
K2362-1
Power Feed 10A Controller
1
1
K325-x TC-3 Travel Carriage
K96 Horizontal Lift Adjuster
K29 Vertical Lift Adjuster
K299 Wire Reel Assembly
ArcLink Digital
Communication Cable
K1543-xx
ArcLink Cables (5 pin) from Power Feed 10A Controller
to Power Source. Can be extended.
•
•
Welding Cables
K2163-xx or
K1842-xx
Weld Power Cables from the Power Source to the
Contact Nozzle and from Power Source to Work
4 Cables
Per Arc
Power Source to
Head Control Cable
K1785-xx
Feeder Control Cable (14 pin) from the
Head to the Power Source. Cannot be extended.
1
K2462-1 Power Feed 10A Mounting
Bracket (K299 cannot be used if the
mounting bracket is attached. A K390 is
recommended instead.)
Torch
K231-xx
Submerged Arc Contact Nozzle Assembly
1
Arclink (5 Pin)
Work Studs
Wire Feeder (14 Pin)
Electrode Studs
Travel Carriage Connection
Flux Hopper Connection
Arclink Connection
K1543-XX
Arclink Control Cable
K2362-1
K1785-XX
Wire Feeder
Control Cable
(1)
Work Cable(s)
Electrode Cable(s)
(1)
Wire Reel
and Mounting
21 Lead
Head
K231-XXX
Electrode Sense Lead (67)
Work Sense Lead (67)
67 Lead
Work Piece
14 Pin Connector
(1)
Consult wth your Lincoln representative for recommended cable size.
Power Wave AC/DC 1000
[5]
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A CLOSER LOOK
AC/DC Submerged Arc Dual Arc
RECOMMENDED EQUIPMENT
OPTIONAL EQUIPMENT
System Component
Qty. Required
Product Number
Product Name
Product Description
Ethernet Switch (customer supplied).
Required for arcs > 1000A or with
Power Source
K2344-1 or
K2344-2
Power Wave AC/DC 1000™ Power Source
2
use of the Submerged Arc Software Suite.
Mounting for Heads
Head
K387
Tandem Arc Framework
1
2
Computer (customer supplied).
Required for use of the
Submerged Arc Software Suite.
K2312-1 or
K2370-1
Power Feed 10S head for 3/32 to 7/32 in. solid wire (Includes hopper,
wire straightener, cross seam adjuster, head mounting hardware) or
Power Feed 10SF Head for 3/32 to 7/32 in. solid wire
K325-x TC-3 Travel Carriage
K96 Horizontal Lift Adjuster
Fixture Builders Head (Insulators not included)
User Interface
K2362-1
K2282-1
K1543-xx
Power Feed 10A Controller
System Interface
2
1
3
K29 Vertical Lift Adjuster
System Interface
K299 Wire Reel Assembly
ArcLink Digital
Communication
Cable
ArcLink Cables (5 pin). Can be extended.
(1) Lead Arc: Power Source to System Interface
(2) System Interface to User Interface
•
K390 Two Wire Reel Mounting for TC-3
K389 Flux Hopper for K387 Mountings
(3) Trail Arc: Power Source to User Interface
Welding Cables
K2163-xx or
K1842-xx
Weld Power Cables from the Power Source to the contact Nozzle
and from the Power Source to the Work
4 Cables
Per Arc
K2462-1 Power Feed 10A Mounting
Bracket (K299 cannot be used if the
mounting bracket is attached. A K390 is
recommended instead.)
Power Source to
Head Control Cable
K1785-xx
Feeder Cable (14 pin) from the Head to the Power Source
Cannot be extended.
2
•
•
Torch
K231-xxx
K1795-xx
Submerged Arc Contact Nozzle Assembly
2
2
System Interface to
Power Source Cable
Control Cable (22 pin) from each Power Wave AC/DC 1000 to
System Interface. Can be extended.
Wire Feeder (14 Pin)
Master Input (S12)
Connects to System
Interface
Arcklink (5 Pin)
Work Studs
K1795-XX Cables
Electrode Studs
Wire Reel and
Mountings
Arclink Input
Arclink Output
K2282-1
K1785-XX
Wire Feeder
Control Cables
K1543-XX Arclink Control Cables
Travel Carriage Connection
(1)
Work Cables
Flux Hopper Connection
K2362-1
14 Pin Connector
Electrode
Sense
Lead (67)
(1)
Arclink Connection
Consult wth your Lincoln represen-
Head
tative for recommended cable size.
K231-XXX
(1)
67 Lead
21 Lead
Electrode Cables
Work Piece
Work Sense Lead (21)
Power Wave AC/DC 1000
[6]
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A CLOSER LOOK
AC/DC Submerged Arc Multi-Arc
RECOMMENDED EQUIPMENT
Qty. Required
Product Number
Product Name
Product Description
Ethernet Network Equipment
Customer Supplied
Customer Supplied
Customer Supplied
Ethernet Switch, Cables, etc. required for arcs >1000A or for use
with Power Wave Submerged Arc Utilities software package
As Needed
1
Personal Computer
IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP,
or greater) required for use with Power Wave Submerged Arc Utilities software package
Controls
Programmable Logic Controller
1
DeviceNet Cables
Automation Department
or Customer Supplied
DeviceNet Cable from the Power Source to PLC and
System Interface to PLC (Cables, Tees, and Terminators as required)
As Needed
Ethernet Switch
Power Source
Head
Customer Supplied
K2344-1 or K2344-2
K2312-1 or K2370-1
Ethernet Switch
1
Power Wave AC/DC 1000™ Power Source
3+
3+
Power Feed 10S head for 3/32 to 7/32 in. solid wire(Includes hopper, wire, straightener
cross seam adjuster, head mounting hardware) or Power Feed 10SF Head for 3/32 to 7/32 in.
solid wire Fixture Builders Head (Insulators not included)
System Interface
Welding Cables
K2282-1
System Interface
1
K2163-xx or
K1842-xx
Weld Power Cables from the Power Source to the Contact Nozzle
and from the Power Source to the Work
4 Cables
Per Arc
Power Source to
Head Control Cable
K1785-xx
Feeder Cable (14 pin) from the Head to the Power Source
Cannot be extended.
3+
•
•
Torch
K231-xxx
K1795-xx
Submerged Arc Contact Nozzle Assembly
3+
3+
System Interface to
Power Source Cable
Control Cable (22 pin) from each Power Wave AC/DC 1000 to
System Interface. Can be extended.
K2282-1
K1795-XX Cables
K1543-XX Arclink
Control Cable
DeviceNet
PLC Controller
Arclink Input
User
Interface
Master Input (S12)
Connects to
System
Interface
DeviceNet Cable
Network
Wire Feeder (14 Pin)
Wire Reel and
Mountings
Arclink (5 Pin)
DeviceNet (5 Pin)
Electrode Studs
(1)
Work Cables
Head
Work Studs
(1)
K231-XXX
Electrode Cables
K1785-XX Wire Feeder
Control Cables
21 Lead
67 Lead
14 Pin Connector
Work Piece
Electrode Sense Lead (67)
Work Sense Leads (21)
(1)
Consult wth your Lincoln representative for recommended cable size.
Power Wave AC/DC 1000
[7]
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A CLOSER LOOK
Impeller Cooling Technology™
High Efficiency Cooling
Conventional-cooling mechanisms for welders rely on a fan to blow
through the machine, while Lincoln’s patented Impeller Cooling
Technology uses an impeller fan to create a high-pressure chamber.
This high-pressure chamber forces airflow across the heated
components in the machine cooling the Power Wave AC/DC 1000™
transformer and power switchgear.
What is Coaxial Transformer Technology™?
To transform large amounts of power as is needed for welding, the
power source transformer is a critical factor. Traditional transformers
become more inefficient the larger they become. This becomes a
problem especially for large power sources (i.e. submerged arc power
sources). If the transformer becomes inefficient, it requires more
power to be dissipated in all of the components before the trans-
former. This results in a drastically reduced overall efficiency, compo-
nents that run at higher temperatures, and reduced reliability.
Coaxial Transformer Technology eliminates these problems. Regardless
of the size (power level) a coaxial transformer has superior coupling and
efficiency. This is obtained through the coaxial orientation of the primary
and secondary windings.
The benefits for the customer include:
• Higher power capabilities (submerged arc inverters)
• Higher efficiency (reduced energy costs)
• Higher reliability (lower stresses on components)
Industry-leading Efficiency, Power Factor and Input Current Draw
Reduce Energy Spending!
The Power Wave® AC/DC 1000 has better efficiency and a
higher Power Factor than the Summit Arc 1000™. Two
Power Wave® AC/DC 1000 machines can be installed for
the same capacity that it takes to install one Summit Arc 1000™.
Power
Factor
Input Amps
@ 460 Volt
Technology
Volts Amps
Efficiency
0.84
NOTE: Summit Arc 1000™ is not a trademark of the Lincoln Electric Company.
®
Miller Electric
Summit Arc 1000™
44
44
1000
1000
0.54
122
Power Wave AC/DC 1000
0.86
0.95
68
Power Wave AC/DC 1000
[8]
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A CLOSER LOOK
FEATURES
• Arc performance independent of input power variations.
• Utilizes digital signal processing and microprocessor control.
• Constant current or constant voltage capability.
• Machines can be easily configured for multiple arc applications.
• Fully programmable AC or DC wave shape.
• Ethernet capability gives the user the ability to monitor, control
and troubleshoot from remote locations.
• All system components communicate and transfer information.
Key Controls
9
11
3
2
10
8
7
1
1. Power Switch
2. Thermal Light
12
13
3. Status Light
6
5
4. Electrode Stud
5. 10 Amp Wire Feeder Circuit Breaker
6. Auxiliary Power Circuit Breaker
7. Wire Feeder Interface Connector
8. Work Sense Lead Connector
9. RS232 Connector
10. Arclink Connector
11. DeviceNET Connector
12. Ethernet Connector
13. Auxiliary Output
14
15
14. Work Stud
15. I/O Connector
4
QUALITY AND RELIABILITY
• Printed circuit boards are environmentally-shielded using Lincoln's
engineered potting and protective frame trays.
• Lincoln’s design philosophy adds an extra factor of safety in all
components and construction to maximize reliability and service.
• Open construction for preventative maintenance.
• Thermostatically protected against overheating.
• Electronic output over-current protection and electronic input
over-voltage protection.
• Operating Temperature Range: -20˚C (-37.7ºF) to +40˚C (-22.2ºF);
Storage Temperature Range: -40˚C (-40ºF) to +40˚C (-22.2ºF).
• Designed to the IEC 60974-1 standards.
• 100% software controlled – Software based controls can be
upgraded as new features become available.
• F.A.N. (Fan As Needed). Cooling fan runs during output and for five
minutes after output is turned off.
• Easy access for serviceability.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
• Modular construction allows for easy service/maintenance.
• Three-year warranty on parts and labor.
Power Wave AC/DC 1000
[9]
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A CLOSER LOOK
Digital Communications
Fast, Reliable, System-Wide
ArcLink is the leading digital communications protocol for the arc welding industry. It integrates all welding components for seamless,
time-critical data transfer. The strength of ArcLink lies in the ability to communicate with each system component in a pre-defined welding
language. In addition, ArcLink is an open communications protocol, meaning that Lincoln Electric publishes how it works and encourages
other companies to adopt it.
DeviceNet is a communications protocol widely used throughout the automotive, semiconductor, and packaging industries. In its typical
application, DeviceNet works in conjunction with a programmable Logic Controller (PLC) and several system devices to provide a framework
for data trafficking and monitoring.
Ethernet is a specification for networking that provides the ability to pull large amounts of information into monitoring and supervisory applications.
For more information see Nextweld Document NX-1.30
Remote Monitoring and Control
Monitor performance from anywhere in the world!
The Power Wave AC/DC 1000™ includes software products to
assist with the installation and operation of the equipment. From
an intelligent configuration utility that allows you to automatically
sense and verify the system has been configured properly to a
tool capable of high-level monitoring, control, and data logging
for the system these packages were designed for ease of use
and convenience for the operators and the administrators.
Command Center
Provides monitoring and control of each arc in a multiple arc system, presenting master/slave relationships and configuration of the arcs in
the system, as well as weld mode selection, parameters of weld states, and diagnostics.
Data Viewer
Communication
Operator Screen
Real-time welding data is
automatically recorded and saved
Diagnostics
Set Points
System Interface
Waveforms are easily changed
through graphical interface
Effortlessly change welding
parameters for all arc states
Remotely monitor and diagnose
machine status and system
information
Power Wave AC/DC 1000
[10]
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RECOMMENDED OPTIONS
GENERAL OPTIONS
WIRE FEEDER OPTIONS
System Interface
Power Feed 10A Controller
Control box required per arc.
Includes MSP4 User Interface
Panel, inputs/outputs for hard
automation.
External controller required for
multi-arc applications provides
arc-to-arc phase relationship.
Order K2282-1
Order K2362-1
Interface Control Cable (22-pin)
Required to parallel multiple
Power Wave power sources —
one per machine required. Can
be extended.
Power Feed 10S Head
(3/32” to 7/32” solid wire)
Includes wire feeder head with
straightener for solid wire, flux
hopper with automatic valve,
head mounting and cross stream
adjuster. Does not include control
box or wire reel brake and
mounting.
•
Order K1795-XX
ArcLink/Linc-Net Cable (5-pin)
Includes two leads plus two
mating terminals. Connects
Power Feed to Power Wave.
Can be extended.
Order K2370-1
•
•
Order K1543-XX
Power Feed 10SF Head
(3/32” to 7/32” solid wire)
For machinery and fixture
builders. Fixture mount wire drive
assembly includes motor, gear-
box, drive rolls, guidelines,
straightener. Does not include
head mounting, electrode cables,
cross seam adjuster, flux hopper
and pointer.
Feeder Control Cable (14-pin)
Connects Power Wave power
source to wire feeder. Cannot
be extended.
Order K1785-XX
TC-3 Self-Propelled Travel
Carriage
Order K2312-1
Carries head and controls in
either direction on a beam.
Operates manually or automati-
cally with the weld controls.
Requires 115V AC 50 or 60 hertz
input power.
Power Feed 10SM Motor
Conversion Kit
For use with NA Series Gear
Head. ArcLink™ motor retrofit kit.
Used to replace existing motor on
NA3/4 or NA5 wire feed head.
Order K2311-1
Order K325x
CE Filter
The K2444-1 Power Wave AC/DC
1000™ CE Module is a high
power filter that enables the
K2344-2 Power Wave AC/DC
1000 CE "ready" machine to
conform to the EMC standards of
Europe and Australia. Electrically,
the module is connected between
the power line and the input of
the K2344-2 machine. The filter
provides high differential and
common mode attenuation to
reduce conducted emissions on
the power line.
Note: K2344-1 can not be used
with K2444-1 for CE confor-
mance.
Order K2444-1
Power Wave AC/DC 1000
[11]
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POWER WAVE AC/DC 1000 ORDER FORM
PRODUCT DESCRIPTION
ORDER NUMBER
QUANTITY
PRICE
POWER WAVE AC/DC 1000™ (460/500/575/3/60)
POWER WAVE AC/DC 1000™ (380/400/460/500/575/3/50/60)
K2344-1
K2344-2
RECOMMENDED GENERAL OPTIONS
System Interface
K2282-1
K1795-10
K1543-xx
K1785-xx
K325x
Interface Control Cable (22-pin)
ArcLink Cable (5-pin)
Feeder Control Cable (14-pin)
TC-3 Self-Propelled Travel Carriage
(1)
CE Filter
K2444-1
RECOMMENDED WIRE FEEDER OPTIONS
Power Feed 10A Controller
K2362-1
K2370-1
K2312-1
K2311-1
Power Feed 10S Head
Power Feed 10SF Wire Feed Head
Power Feed 10SFM Motor Conversion Kit
TOTAL:
(1)
The K2444-1 must be used with the K2344-2.
C U S T O M E R A S S I S T A N C E P O L I C 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 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 requirements.
THE LINCOLN ELECTRIC COMPANY
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