Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
i SAFETY i 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 fume...
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; Refer to
iii SAFETY 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 ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Conformance; b) radio and television transmitters and receivers
v SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in con...
Page 7 - uct standard for arc welding equipment.”
vi SAFETY vi Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply...
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 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 ma...
Page 9 - TAbLE OF CONTENTS
viii viii TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................A-1Safety Precautions...........
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS -; INPUT AC VOLTAGE & DC OUTPUT
A-1 INSTALLATION POWER WAVE 405M A-1 TECHNICAL SPECIFICATIONS - POWER WAVE 405M 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 405M A-2 SELECT SUITAbLE LOCATION The Invertec POWER WAVE 405M will operate inharsh environments. Even so, it is important that sim-ple preventative measures are followed in order toassure long life and reliable operation. • The machine must be located where there is free...
Page 12 - NEGATIVE ELECTRODE POLARITY
Output connections on some Power Waves are madevia 1/2-13 threaded output studs located beneath thespring loaded output cover at the bottom of the casefront. Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-trode cable between the wire feed...
Page 13 - VOLTAGE SENSING; SYSTEM DESCRIPTION
A-4 INSTALLATION POWER WAVE 405M A-4 VOLTAGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc conditions.Depending upon the process, inductance within theelectrode and work lead cables can influence the volt-age apparent at the studs of the welder. Voltage...
Page 14 - CONFIGURING THE SYSTEM; SINGLE HEAD FEEDER
A-5 INSTALLATION POWER WAVE 405M A-5 CONFIGURING THE SYSTEM The power source will “Auto Map” the system eliminat-ing most of the need to set DIP switches to configurethe system. If a system can not be “Auto Mapped” then the statuslight on the power source will blink green fast and thewelder output w...
Page 16 - CONTROL CAbLE SPECIFICATIONS; TWO POWER WAVES
CONTROL CAbLE SPECIFICATIONS It is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave / Power Feed system. The use of non-standard cables, especially inlengths greater than 25ft. (7.6m), ...
Page 18 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS; CONTROL bOARD DIP SWITCH:
A-9 INSTALLATION POWER WAVE 405M A-9 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 ...
Page 19 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; • This Power Wave is not recommended for processes; OPERATION; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
GENERAL DESCRIPTION The Power Wave 405M semi-automatic power sourceis designed to be a part of a modular, multi-processwelding system. Depending on configuration, it cansupport constant current, constant voltage, and pulsewelding modes. The Power Wave 405M power source is designed tobe used with the...
Page 20 - CASE FRONT LAYOUT
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-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 the ...
Page 21 - WELDING ADJUSTMENTS; • WELDING MODE; NOMINAL PROCEDURES
WELDING ADJUSTMENTS All adjustments are made on the system componentknown 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 PowerFeed wire feeder. Typically, the Control Box is sup-plied as part of the wire ...
Page 22 - • ARC CONTROL; CONSTANT VOLTAGE WELDING; Synergic CV
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 arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS. All CV Modes: Arc Control, often ref...
Page 23 - PULSE WELDING; Current
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 24 - TIG GTAW
b-6 OPERATION b-6 bENEFITS OF PULSE ON PULSE FROMLINCOLN ELECTRIC • Excellent appearance of the weld bead• Improved cleaning action• Reduced porosityTable B.2 shows WFS and Trim settings for commonaluminum types and wire sizes when welding withPulse-on-Pulse. The welds made to obtain the valuesin th...
Page 25 - POWER MODETM
b-7 OPERATION b-7 POWER WAVE 405M 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 yLincoln 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 rAluminum...
Page 26 - ACCESSORIES; OPTIONAL EQUIPMENT; FACTORY INSTALLED; Any; ArcLink compatible; semi-automatic wire feeding
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 is K...
Page 27 - MAINTENANCE; CAPACITOR DISCHARGE PROCEDURE; Hold resistor body with electrically insulated glove.; ROUTINE MAINTENANCE; CAPACITOR; PERIODIC MAINTENANCE
D-1 MAINTENANCE D-1 POWER WAVE 405M 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 eac...
Page 28 - TROUbLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUbLESHOOTING GUIDE
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 Troubleshootin...
Page 29 - Read the
E-2 TROUbLESHOOTING E-2 POWER WAVE 405M 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 feed head) has a status light, and when aproblem occurs it is important to note the condition ofea...
Page 30 - ERROR CODES FOR THE POWERWAVE; Indication
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 troubleshoot...
Page 31 - Observe all Safety Guidelines detailed throughout this manual; TROUbLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PRObLEMS; Contact your local authorized
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/repai...
Page 34 - PRObLEMS
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 troubleshoot...
Page 35 - WIRING DIAGRAMS
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 ...
Page 36 - DIAGRAMS
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 Departm...
Page 37 - CONNECTION DIAGRAM
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 POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK
Page 38 - DIMENSION PRINT; UT
F-4 DIMENSION PRINT F-4 POWER WAVE 405M 14 .79 12 .4 4 3.4 4 21 .6 0 27 .8 2 5.5 0 10 .0 10.0 00 MO UN TI NG H OL E LO CA TI ON S M1 95 27 13 .10 1/4 - 1/4- 20 N UT (4 P LA CE S) NO TE : M OU NT IN G SC RE W S CA 10 /01 10/01 N NO T PR OT RU DE M OR E TH AN 0.5 IN 0.5 IN CH ES IN SI DE T HE M AC HI ...
Page 39 - NOTES