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POWER WAVE
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
All manuals and user guides at all-guides.com
For use with machines Code 11379, 11491
W A
R N
IN
G
R E
M O
T E
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
®
405M
P O
W
E R
O N
O F
F
Copyright © Lincoln Global Inc.
IM917-A
June, 2009
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Related Manuals for Lincoln Electric 11379
Summary of Contents for Lincoln Electric 11379
- Page 1 ® IM917-A POWER WAVE 405M June, 2009 For use with machines Code 11379, 11491 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
- Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
- Page 3 All manuals and user guides at all-guides.com SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
- Page 4 All manuals and user guides at all-guides.com SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 All manuals and user guides at all-guides.com SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
- Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
- Page 7 All manuals and user guides at all-guides.com SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-...
- Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 9: Table Of Contents
All manuals and user guides at all-guides.com viii viii TABLE OF CONTENTS Page Installation .......................Section A Technical Specifications - POWER WAVE® 405M ..........A-1 Safety Precautions....................A-2 Select Suitable Location ..................A-2 Stacking ......................A-2 Tilting.......................A-2 Input and Grounding Connections ..............A-2 Power Cord Connection ..................A-2 Undercarriage Mountings................A-2 Output Cables, Connections and Limitations............A-3 Negative Electrode Polarity ...................A-3... -
Page 10: Installation
All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® 405M INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD 5 5 0 0 / / 6 6 0 0 H H z z (continuous) 3 3 5 5 0 0 A A / / 3 3 4 4 V V / / 6 6 0 0 % % 1 1 4 4 . -
Page 11: Safety Precautions
All manuals and user guides at all-guides.com INSTALLATION SAFETY PRECAUTIONS • Initial 200VAC - 230VAC operation will require an Input voltage panel setup. WARNING • Open the access panel on the rear of the machine. • For 200 or 230: Position the large switch to 200- ELECTRIC SHOCK can kill. -
Page 12: Output Cables, Connections And Limitations
All manuals and user guides at all-guides.com INSTALLATION OUTPUT CABLES, CONNECTIONS AND Output connections on some POWER WAVE®s are LIMITATIONS made via 1/2-13 threaded output studs located Connect a work lead of sufficient size and length (per beneath the spring loaded output cover at the bottom table A.1) between the proper output terminal on the of the case front. -
Page 13: Voltage Sensing
All manuals and user guides at all-guides.com INSTALLATION VOLTAGE SENSING ELECTRODE VOLTAGE SENSING The best arc performance occurs when the Enabling or disabling electrode voltage sensing is PowerWaves have accurate data about the arc condi- automatically configured through software. The 67 tions. -
Page 14: Power Wave® To Semi-Automatic Power Feed Wire Feeder Interconnections
All manuals and user guides at all-guides.com INSTALLATION POWER WAVE® TO SEMI-AUTOMATIC POWER FEED WIRE FEEDER INTERCON- NECTIONS The POWER WAVE® 405M and semi-automatic Power Feed family communicate via a 5 conductor control cable (K1543). The control cable consists of two power leads, one twisted pair for digital communi- cation, and one lead for voltage sensing. - Page 15 All manuals and user guides at all-guides.com INSTALLATION CONFIGURING THE SYSTEM If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the The power source will “Auto Map” the system eliminat- welder output will be disabled.
- Page 16 All manuals and user guides at all-guides.com INSTALLATION ALTERNATE HARD AUTOMATIC APPLICATION (using a User Interface, Wire Drive Module, and POWER FEED-10R) POWER WAVE® 405M PF-10R WIRE DRIVE MODULE (FH1) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto Feeder, Wire Drive Module, and POWER FEED-10R) POWER WAVE®...
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Page 17: Welding With Multiple Power Waves
All manuals and user guides at all-guides.com INSTALLATION WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS WAVES ® It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically CAUTION designed for the communication and power needs of the POWER WAVE ®... - Page 18 All manuals and user guides at all-guides.com INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE® 405M...
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Page 19: I / O Receptacle Specifications
All manuals and user guides at all-guides.com A-10 A-10 INSTALLATION I / O RECEPTACLE SPECIFICATIONS switch 7 auto mapping TABLE A.2 auto mapping enable-default WIRE FEEDER RECEPTACLE auto mapping disabled LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense switch 8* work sense lead 0vdc... -
Page 20: Operation
All manuals and user guides at all-guides.com OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION The POWER WAVE® 405M semi-automatic power Read this entire section of operating instructions source is designed to be a part of a modular, multi- before operating the machine. process welding system. -
Page 21: Required Equipment
All manuals and user guides at all-guides.com OPERATION POWER WAVE® 405M – Semi-Automatic 3. HIGH TEMPERATURE LIGHT (thermal overload): Operation A yellow light that comes on when an over temper- ature situation occurs. Output is disabled and the POWER WAVE® 405M can only be used with fan continues to run, until the machine cools down. -
Page 22: Nominal Procedures
If a special welding pro- the user can change the Trim setting to adjust the arc gram is desired, contact the local Lincoln Electric length. It is adjustable from 0.500 to 1.500. A Trim set- sales representative. -
Page 23: Constant Voltage Welding
All manuals and user guides at all-guides.com OPERATION • ARC CONTROL Non Synergic CV: Also known as Inductance or Wave Control. Allows This type of CV mode behaves more like a conven- operator to vary the arc characteristics from "soft" to tional CV power source. -
Page 24: Pulse Welding
All manuals and user guides at all-guides.com OPERATION PULSE WELDING (See Figure B.3) PULSE-ON-PULSE™ (GMAW-PP) Pulse welding procedures are set by controlling an Pulse on Pulse™ is a Lincoln process specifically overall "arc length" variable. When pulse welding, the designed for use in welding relatively thin (less than arc voltage is highly dependent upon the waveform. - Page 25 All manuals and user guides at all-guides.com OPERATION BENEFITS OF PULSE ON PULSE FROM SMAW LINCOLN ELECTRIC In SMAW (STICK mode), arc control adjusts the arc force. It can be set to the lower range for a soft and less penetrating arc characteristic (negative numeric •...
- Page 26 All manuals and user guides at all-guides.com OPERATION POWER MODE™ Start by setting the wire feed speed based upon mate- The Power Mode™ process was developed by rial thickness and appropriate travel speed. Then Lincoln to maintain a stable and smooth arc at low adjust the Volts/Trim knob as follows: procedure settings which are needed to weld thin metal without pop-outs or burning-through.
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Page 27: Accessories
All manuals and user guides at all-guides.com ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead Kit K1764-1-Undercarriage* K1838-1-Valet Style Undercarriage K1796-Coaxial Welding Cable-(Requires Adapter K2176-1) K2176-1 Twist-mate to Lug Adapters * Dual Cylinder Kit for K1764-1 is K1702-1 Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE... -
Page 28: Maintenance
However, if the weld perfor- sleeves when servicing. mance changes, or the yearly calibration check ------------------------------------------------------------------------ reveals a problem, contact the Lincoln Electric See additional warning information Company for the calibration software utility. throughout this Operator’s Manual... -
Page 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 30: Using The Status Led To Troubleshoot System Problems
All manuals and user guides at all-guides.com TROUBLESHOOTING charts for both machine and weld performance. USING THE STATUS LED TO The STATUS LIGHT is a two color light that indicates TROUBLESHOOT SYSTEM PROBLEMS system errors. Normal operation is a steady green light. - Page 31 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the POWER WAVE® 405M can output via the status light (see "Troubleshooting the POWER WAVE®...
- Page 32 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE® 405M...
- Page 33 Using the Status LED" section of CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE® 405M...
- Page 34 Authorized Field Service Facility. Reset. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. POWER WAVE® 405M...
- Page 35 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION General degradation of the weld per- 1.Check for feeding problems, bad formance connections, excessive loops in cabling, etc.
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Page 36: Wiring Diagram
All manuals and user guides at all-guides.com WIRING DIAGRAMS POWER WAVE® 405M... - Page 37 All manuals and user guides at all-guides.com DIAGRAMS POWER WAVE® 405M...
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Page 38: Connection Diagram
All manuals and user guides at all-guides.com CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER WORK CONTROL CABLE K1543 POWER WAVE® 405M... - Page 39 All manuals and user guides at all-guides.com DIMENSION PRINT POWER WAVE® 405M...
- Page 40 All manuals and user guides at all-guides.com NOTES POWER WAVE® 405M...
- Page 41 All manuals and user guides at all-guides.com NOTES POWER WAVE® 405M...
- Page 42 All manuals and user guides at all-guides.com Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 43 All manuals and user guides at all-guides.com Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 44 All manuals and user guides at all-guides.com • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...