Lincoln Electric POWER WAVE 405M IM917-A manual

PO WER W A VE ® 405M OPERA TOR’S MANUAL For use with machines Code 11379, 11491 IM917-A June, 2009 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. D O NOT INSTALL, OPERATE OR[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC R A Y S can b urn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your [...]

iii SAFETY iii FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. N[...]

iv SAFETY iv Mar. ‘93 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. Les[...]

v SAFETY v Electro magnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements[...]

vi SAFETY vi Electro magnetic 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 ma[...]

vii vii Thank Y ou for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference[...]

viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® 405M ..............................................A-1 Safety Precautions.............................................................................[...]

A-1 INST ALLA TION POWER WAVE® 405M A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® 405M INPUT AC VOL T AGE & DC OUTPUT OUTPUT CABLES, CONNECTIONS AND LIMIT A TIONS 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 [...]

A-2 INST ALLA TION POWER WAVE® 405M A-2 SELECT SUIT ABLE LOCA TION The Invertec POWER WAVE® 405M will operate in harsh environments. Even so, it is important that sim- ple preventative measures are followed in order to assure long life and reliable operation. • The machine must be located where there is free cir- culation of clean air such that[...]

Output connections on some POWER WAVE®s are made via 1/2-13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front. Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode cable between the wire feeder and the positive (+) output Twist-Mate t[...]

A-4 INST ALLA TION POWER WAVE® 405M A-4 VOL T AGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc condi- tions. 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[...]

A-5 INST ALLA TION POWER WAVE® 405M A-5 P O W E R WAV E ® T O S E M I - A U T O M A T I C 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 lea[...]

A-6 INST ALLA TION POWER WAVE® 405M A-6 CONFIGURING THE SYSTEM The power source will “Auto Map” the system eliminat- ing most of the need to set DIP switches to configure 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 can n[...]

A-7 INST ALLA TION POWER WAVE® 405M A-7 In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE® 405M auto mapping disabled and the Equipment Groups set on (See Figure A-8). (See the Feeder documenta- tion for information on setting the feeder DIP switches) System that is NOT "Auto Mappable"[...]

CONTROL CABLE SPECIFICA TIONS It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the POWER WAVE ® / Power Feed ™ system. The use of non-standard cables, especially in lengths greater than 25ft. (7.6m), can lead to com- munication problems ([...]

A-9 INST ALLA TION POWER WAVE® 405M A-9  MUL TIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES[...]

A-10 INST ALLA TION POWER WAVE® 405M A-10 I / O RECEPT ACLE SPECIFICA TIONS TABLE A.2 WIRE FEEDER RECEPTACLE PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc - E 51 +40vdc + TABLE A.3 VOLTAGE SENSE RECEPTACLE PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE A.4 RS232 RECEPTACLE PIN LEAD#[...]

GENERAL DESCRIPTION The POWER WAVE® 405M semi-automatic power source is designed to be a part of a modular, multi- process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes. The POWER WAVE® 405M power source is designed to be used with the semi automatic family of Power Feed wir[...]

POWER WAVE® 405M – Semi-Automatic Operation POWER WAVE® 405M can only be used with ArcLink compatible Power Feed M semi-automatic wire feeders. In addition, the Power Feed M semi- automatic wire feeders may require optional equip- ment to access certain weld modes in the POWER WAVE®. Other model s of Lincoln feeders, or a ny models of non-Linc[...]

WELDING ADJUSTMENTS All adjustments are made on the system component known as the User Interface (Control Box), which con- tains the switches, knobs, and digital displays neces- sary to control both the POWER WAVE® and a Power Feed wire feeder. Typically, the Control Box is sup- pl ied a s p art of t he wi re f ee der . I t c an be mo un ted direc[...]

Non Synergic CV: This type of CV mode behaves more like a conven- tional CV power source. Voltage and WFS are inde- pendent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. All CV Modes: Arc Control, often referred to as wave control, adjusts the inductan[...]

B-5 OPERA TION B-5 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 [...]

B-6 OPERA TION B-6 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 fla[...]

B-7 OPERA TION B-7 POWER WAVE® 405M POWER MODE™ The Power Mode™ process w as 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. This result[...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACT OR Y INST ALLED None Available. FIELD INST ALLED 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: K852-7[...]

D-1 MAINTENANCE D-1 POWER WAVE® 405M SAFETY PRECAUTIONS CAP ACITOR DISCHARGE PROCEDURE 1. Obtain a power resistor (25 ohms, 25 watts). 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resis- tor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all four [...]

E-1 TROUBLESHOOTING E-1 POWER WAVE® 405M 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. CAUTION This Troubleshooting Guide is provided to help you locate and repai[...]

E-2 TROUBLESHOOTING E-2 POWER WAVE® 405M USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The POWER WAVE® / Power Feed are best diag- nosed as a system. Each component (power source, user interface, and feed head) has a status light, and when a problem occurs it is important to note the con- dition of each. In addition, errors displayed on [...]

E-3 TROUBLESHOOTING E-3 POWER WAVE® 405M Observe all Safety Guidelines detailed throughout this manual 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. CAUTION ERROR[...]

E-4 TROUBLESHOOTING E-4 POWER WAVE® 405M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 Linco[...]

E-5 TROUBLESHOOTING E-5 POWER WAVE® 405M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 Linco[...]

E-6 TROUBLESHOOTING E-6 POWER WAVE® 405M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 Linco[...]

E-7 TROUBLESHOOTING E-7 POWER WAVE® 405M Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBL[...]

F-1 WIRING DIAGRAMS F-1 POWER WAVE® 405M NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment[...]

F-2 DIAGRAMS F-2 POWER WAVE® 405M NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code n[...]

F-3 CONNECTION DIAGRAM F-3 POWER WAVE® 405M Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown)  POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK[...]

F-4 DIMENSION PRINT F-4 POWER WAVE® 405M 1 4 .7 9 1 2 .4 4 3. 44 21.60 27.82 5. 50 10 .0 0 M OU NT IN G HO LE L OC AT I ON S M 19 52 7 13 .1 0 1/ 4-20 NU T ( 4 P LAC ES ) N OT E : M OU N TI N G S C RE WS C A 10 /0 1 N NO T P R OT R UD E M OR E T HA N 0. 5 IN C HE S IN SI D E T H E M AC H IN E. 11 .8 4 3. 50[...]

NOTES POWER WAVE® 405M[...]

NOTES POWER WAVE® 405M[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head o ut of f umes. ● Use ventil ation or exha ust to remo ve fum[...]

• 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 • World's Leader in Welding and Cutting Products •[...]