Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv 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 seco...
Page 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ma...
Page 9 - TABLE OF CONTENTS
viii viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 405 ....................................................A-1Safety Precautions.............................
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS -; INPUT AC VOLTAGE & DC OUTPUT
A-1 INSTALLATION POWER WAVE 405 A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 405 INPUT AC VOLTAGE & DC OUTPUT OUTPUT CABLES, CONNECTIONS AND LIMITATIONS Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD 50/60 Hz (...
Page 11 - SELECT SUITABLE LOCATION; CAUTION
A-2 INSTALLATION POWER WAVE 405 A-2 SELECT SUITABLE LOCATION The Invertec POWER WAVE 405 will operate in harshenvironments. Even so, it is important that simple pre-ventative measures are followed in order to assurelong life and reliable operation. • The machine must be located where there is free c...
Page 13 - Process Electrode Voltage
5. R e p l a c e t h e w r a p a r o u n d a n d s c r e w s . T h e P C board will “ read ” the switch at power up, and config- ure the work voltage sense lead appropriately. ELECTRODE VOLTAGE SENSINGEnabling or disabling electrode voltage sensing isautomatically configured through software. The 67...
Page 14 - SYSTEM DESCRIPTION; System Model
A-5 INSTALLATION POWER WAVE 405 A-5 SYSTEM DESCRIPTION The POWER WAVE 405 and Power Feed family ofproducts utilize a digital communication system calledLinc-Net. Simply put, Linc-Net allows large amounts ofinformation to be passed at very high speeds betweenc o m p o n e n t s ( n o d e s ) i n t h ...
Page 15 - Simple System
A-6 INSTALLATION POWER WAVE 405 A-6 FIGURE A.2 Simple System 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 sixFeed Heads. • Eac...
Page 16 - Multiple Group System
A-7 INSTALLATION POWER WAVE 405 A-7 FIGURE A.3 Multiple Group System No “ FH0 ” Alllowed! FIGURE A.4 Single Group Multi-Head System No “ FH0 ” Alllowed! T h e D u a l H e a doption allows the abil-ity to maintain 2 setso f p r o c e d u r e s . I fm o r e t h e n 2 h e a d sare used, odd # ’ s use F...
Page 18 - TWO POWER WAVES
A-9 INSTALLATION POWER WAVE 405 A-9 WELDING WITH MULTIPLE POWERWAVES Special care must be taken when more than onePower Wave is welding simultaneously on a singlepart. Arc blow and arc interference may occur orbe magnified. Each power source requires a work lead from thework stud to the welding fixt...
Page 19 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS
A-10 INSTALLATION POWER WAVE 405 A-10 I / O RECEPTACLE SPECIFICATIONS 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 Sen...
Page 20 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; OPERATION; SAFETY PRECUATIONS; ELECTRIC SHOCK can kill.
GENERAL DESCRIPTION The Power Wave semi-automatic power source isdesigned to be a part of a modular, multi-processwelding system. Depending on configuration, it cansupport constant current, constant voltage, constantpower and pulse welding modes. The Power Wave power source is designed to beused wit...
Page 21 - Semi-Automatic Operation; REQUIRED EQUIPMENT
POWER WAVE 405 – Semi-Automatic Operation Semi Automatic Power Waves can only be used withLinc-Net compatible Power Feed semi-automatic wirefeeders. In addition, the Power Feed semi-automaticw i r e f e e d e r s m a y r e q u i r e o p t i o n a l e q u i p m e n t t oaccess certain weld modes in t...
Page 22 - WELDING ADJUSTMENTS; NOMINAL PROCEDURES
The steps for operating the Power Wave will varydepending upon the options installed in the user inter-face (control box) of the welding system. The flexibilityof the Power Wave system lets the user customizeoperation for the best performance. First, consider the desired welding process and thepart ...
Page 23 - CONSTANT VOLTAGE WELDING; Synergic CV; Current; WELDING MODE
CONSTANT VOLTAGE WELDING Synergic CV : For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The nominal preprogrammed volt-age is the average voltage for a given wire feedspeed, but may be adjusted to preference. When thewire fe...
Page 24 - PULSE WELDING
B-5 OPERATION B-5 PULSE WELDING Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. The...
Page 25 - TIG GTAW
B-6 OPERATION B-6 POWER WAVE 405 BENEFITS OF PULSE ON PULSE FROMLINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.2 shows WFS and Trim settings for commonaluminum types and wire sizes when welding withPulse-on-Pulse. The welds made to obta...
Page 26 - POWER MODE; Recommended Welding Procedures for Power Mode - Table B.3
B-7 OPERATION B-7 POWER WAVE 405 POWER MODE ™ T h e P o w e r M o d e ™ p r o c e s s w a s d e v e l o p e d b y Lincoln to maintain a stable and smooth arc at lowprocedure settings which are needed to weld thinm e t a l w i t h o u t p o p - o u t s o r b u r n i n g - t h r o u g h . F o rAluminu...
Page 27 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-[ ]Work Voltage Sense Lead KitK1764-1-Undercarriage*K1838-1-Valet Style UndercarriageK1796-Coaxial Welding Cable-(Requires Adapter K2176-1)K2176-1 Twist-mate to Lug Adapters* Dual Cylinder Kit for K1764-1 i...
Page 28 - MAINTENANCE; SAFETY PRECAUTIONS; CAPACITOR DISCHARGE PROCEDURE; ROUTINE MAINTENANCE; PERIODIC MAINTENANCE; s Manual
D-1 MAINTENANCE D-1 POWER WAVE 405 SAFETY PRECAUTIONS CAPACITOR 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 positionshown. Hold in each...
Page 29 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER WAVE 405 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...
Page 30 - Read the
E-2 TROUBLESHOOTING E-2 POWER WAVE 405 USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed asa system. Each component (power source, user inter-face, and feedhead) has a status light, and when aproblem occurs it is important to note the condition ofeach...
Page 31 - ERROR CODES FOR THE POWERWAVE; Indication
E-3 TROUBLESHOOTING E-3 POWER WAVE 405 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 troubleshooti...
Page 32 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
E-4 TROUBLESHOOTING E-4 POWER WAVE 405 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/repair...
Page 35 - PROBLEMS
E-7 TROUBLESHOOTING E-7 POWER WAVE 405 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 troubleshooti...
Page 36 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER WAVE 405 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departm...
Page 37 - CONNECTION DIAGRAM; POWER WAVE
F-2 CONNECTION DIAGRAM F-2 POWER WAVE 405 Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK Power Feed Family
Page 38 - DIMENSION PRINT
F-3 DIMENSION PRINT F-3 POWER WAVE 405 14.7 9 1 2.4 4 3.44 21.60 27.82 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 13.1 0 1/4- 20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 10/01 N NOT PROTR UDE MORE THAN 0.5 IN CHES INSIDE THE MACHINE. 11.8 4 3.50
Page 39 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...