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POWER WAVE 405M
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED 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
RETURN TO MAIN MENU
For use with machines Code 11142, 11490
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OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
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Copyright © Lincoln Global Inc.
IM846-A
December, 2010
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Related Manuals for Lincoln Electric POWER WAVE IM846-A
Summary of Contents for Lincoln Electric POWER WAVE IM846-A
- Page 1 POWER WAVE 405M For use with machines Code 11142, 11490 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 thoughtful operation on your part.
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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 SAFETY...
- Page 4 SAFETY...
- 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 SAFETY...
- Page 7 SAFETY...
- 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
viii Installation ...Section A Technical Specifications ...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 Cable Inductance, Negative Electrode Polarity ...A-3 Voltage Sensing ... A-4 Power Feed Wire Feeder Interconnections, System Decription ...A-4 Configuring the System ...A-5 System Set-Up, Alternate &... -
Page 10: Installation
TECHNICAL SPECIFICATIONS - INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Name Information Voltage Power 200-220/ Wave K 2369-1 380-400/ 405M 50/60 Hz * Overall Length Including Handle, 21.6” (549mm) without handle. Insulation Class 180 (H) POWER WAVE 405M INPUT CURRENT Recommended Fuse Sizes based On The U.S. -
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
OUTPUT CAbLES, CONNECTIONS AND LIMITATIONS Connect a work lead of sufficient size and length (per table A.1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. -
Page 13: Voltage Sensing
Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age 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 14: 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 welder output will be disabled. If a system is not “Auto-mappable”, then consult the instruction manual for the accessory being used for configuration infor- mation about DIP switch settings, or consult your local... -
Page 15: Alternate Hard Automatic Application
ALTERNATE HARD AUTOMATIC APPLICATION (using a User Interface, Wire Drive Module, and POWER FEED-10R) COMbINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto Feeder, Wire Drive Module, and POWER FEED-10R) DUAL HEAD System that is NOT "Auto Mappable" DUAL HEAD bOOM FEEDER (using two single heads) POWER WAVE 405M In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE 405M... -
Page 16: 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 17 INSTALLATION MULTIPLE ARC UNSYNCHRONIzED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 405M...
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Page 18: I / O Receptacle Specifications
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 19: Operation
SAFETY PRECAUTIONS 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 20: Required Equipment
POWER WAVE 405M – Semi-Automatic Operation Power Wave 405M can only be used with ArcLink compatible Power Feed M semi-automatic wire feed- ers. In addition, the Power Feed M 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 21: 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 22: Constant Voltage Welding
• ARC CONTROL Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from "soft" to "harsh" in all weld modes. It is adjustable from -10.0 to +10.0, with a nominal setting of 00.0 (The nominal set- ting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels). -
Page 23: Pulse Welding
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. -
Page 24: Arc Gouging
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 25: 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 26: 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 Any ArcLink compatible semi-automatic wire feeding... -
Page 27: 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 28: 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 29 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 feed head) has a status light, and when a problem occurs it is important to note the condition of each.
- Page 30 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 / 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 31: 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 32 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 33 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 34 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) General degradation of the weld per- formance Excessively long and erratic arc. If Wire Feed Speed is in Question. Inch Per Minute = (IPM) 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 35 WIRING DIAGRAMS POWER WAVE 405M...
- Page 36 DIAGRAMS POWER WAVE 405M...
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Page 37: Connection Diagram
Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE C O N T R O L C A B L E K 1 5 4 3 W O R K F E E D E R W I R E P O W E R W A V E WORK CONNECTION DIAGRAM... - Page 38 DIMENSION PRINT POWER WAVE 405M...
- Page 39 NOTES POWER WAVE 405M...
- Page 42 • 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...