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RETURN TO MAIN MENU
IM746
POWER WAVE 405
August, 2004
For use with machines Code 10896
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
W A
R N
IN
G
PRECAUTIONS CONTAINED
R E
M O
T E
THROUGHOUT. And, most
importantly, think before you act
P O
W
E R
and be careful.
O N
O F
F
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• 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
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric POWER WAVE 405 IM746
Summary of Contents for Lincoln Electric POWER WAVE 405 IM746
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Page 1: Power Wave
RETURN TO MAIN MENU IM746 POWER WAVE 405 August, 2004 For use with machines Code 10896 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: California Proposition 65 Warnings
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 ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
- Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 50 199 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 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 recommendations.
- Page 8 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 9: Table Of Contents
viii Installation ...Section A Technical Specifications - POWER WAVE 405 ...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 Voltage Sensing ...A-3, A-4 Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections...A-4 System Description...A-5... -
Page 10: Installation
TECHNICAL SPECIFICATIONS - Product Ordering Input AC Name Information Voltage Power 200-220/ Wave K 2152-2 380-400/ 60/50 Hz * Overall Length Including Handle, 21.6” (549mm) without handle. Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs Input 50/60 Hz Voltage Phases... -
Page 11: Safety Precautions
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS- CONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES. • Only qualified personnel should perform this installation. •... -
Page 12: Output Cables, Connections And Limitations
Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc condi- tions and can have a dramatic effect on performance. -
Page 13: Power Wave To Semi-Automatic Power Feed Wire Feeder Interconnections
Enable the voltage sense leads as follows: TABLE A.1 Process Electrode Voltage Work Voltage Sensing 67 lead * Sensing 21 lead GMAW 67 lead required 21 lead optional GMAW-P 67 lead required 21 lead optional FCAW 67 lead required 21 lead optional GTAW Voltage sense at studs Voltage sense at studs... -
Page 14: System Description
SYSTEM DESCRIPTION The POWER WAVE 405 and Power Feed family of products utilize a digital communication system called Linc-Net. Simply put, Linc-Net allows large amounts of information to be passed at very high speeds between components (nodes) in the system. The system requires only two wires for communication, and because of its bus-like structure, the components may be connected to the network in any order, thus simpli-... -
Page 15: System Set-Up
Basic Rules • Each group is required to have one user interface. No group may have more than one user interface. • Each group can have up to seven Feed Heads. Exception: Group 3 is limited to a maximum of six Feed Heads. - Page 16 INSTALLATION Multiple Group System FIGURE A.3 No “FH0” Alllowed! Single Group Multi-Head System FIGURE A.4 No “FH0” Alllowed! Dual Head option allows the abil- ity to maintain 2 sets of procedures. If more then 2 heads are used, odd #’s use FH1 settings, even #’s use FH2 settings.
- Page 17 INSTALLATION Single Group Multi-Head System (Alternate Method) FIGURE A.5 No “FH0” Alllowed! When a standard User Iterface is used in a group with multi- ple Feed Heads, all of the Feed Heads use a single set of procedures. POWER WAVE 405...
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Page 18: Welding With Multiple Power Waves
WELDING WITH MULTIPLE POWER WAVES CAUTION Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. -
Page 19: I / O Receptacle Specifications
A-10 I / O RECEPTACLE SPECIFICATIONS TABLE A.2 WIRE FEEDER RECEPTACLE LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 0vdc +40vdc TABLE A.3 VOLTAGE SENSE RECEPTACLE LEAD# FUNCTION Work Voltage Sense TABLE A.4 RS232 RECEPTACLE LEAD# FUNCTION RS232 Receive RS232 Transmit Pin5... -
Page 20: Operation
SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the elec- trode and drive mechanism are always electrically energized and could remain energized several sec- onds after the welding ceases. -
Page 21: Required Equipment
POWER WAVE 405 – Semi-Automatic Operation Semi Automatic Power Waves can only be used with Linc-Net compatible Power Feed semi-automatic wire feeders. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non- Lincoln wire feeders, cannot be used. -
Page 22: Nominal Procedures
Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative. To make a weld, the Power Wave needs to know the desired welding parameters. -
Page 23: Constant Voltage Welding
In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the oper- ator must adjust the voltage to compensate for any changes made to the WFS. In constant current modes (stick, TIG) this control adjusts the output current, in amps. - Page 24 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known.
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Page 25: Arc Gouging
BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse-on-Pulse. The welds made to obtain the values in the table were fillet welds in the flat position. -
Page 26: Power Mode
POWER MODE™ The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellent control and the ability to maintain constant arc length. -
Page 27: Accessories
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 COMPATIBLE LINCOLN EQUIPMENT... -
Page 28: Maintenance
Generally speaking the machine calibration will not need adjustment. However, if the weld perfor- mance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and cur- rent. -
Page 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feedhead) has a status light, and when a problem occurs it is important to note the condition of each. - Page 31 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 405 can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006"...
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Page 32: Troubleshooting Guide
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. TROUBLESHOOTING POSSIBLE AREAS OF... - Page 33 Machine won’t weld, can’t get any output. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 34 Auxiliary receptacle is “dead” no auxiliary voltage . 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. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) General degradation of the weld per- formance Excessively long and erratic arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 36 DIAGRAMS POWER WAVE 405...
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Page 37: Connection Diagram
Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WORK CONNECTION DIAGRAM CONTROL CABLE K1543 POWER WAVE 405 Power Feed Family WIRE FEEDER... - Page 38 DIMENSION PRINT POWER WAVE 405...
- Page 39 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 40 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 41 • 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...