Lincoln Electric IM917-A - Manual

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 fumesoutdoors. ...

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 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 contr...

Page 6 - b) radio and television transmitters and receivers

v SAFETY v Electromagnetic Compatibility (EMC) ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility(89/336/EEC). It was manufactured in confo...

Page 7 - Methods of Reducing Emissions

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 - POWER WAVE® 405M ..............................................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 5 50 0...

Page 11 - SELECT SUITABLE LOCATION; • DO NOT MOUNT OVER COMBUSTIBLE SURFACES.; SAFETY PRECAUTIONS; • Only qualified personnel should perform this; UNDERCARRIAGE MOUNTINGS; 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 fr...

Page 12 - NEGATIVE ELECTRODE POLARITY

Output connections on some POWER WAVE®s arem a d e v i a 1 / 2 - 1 3 t h r e a d e d o u t p u t s t u d s l o c a t e dbeneath the spring loaded output cover at the bottomof the case front. Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-...

Page 13 - VOLTAGE SENSING; Process Electrode Voltage; ELECTRODE VOLTAGE SENSING

A-4 INSTALLATION POWER WAVE® 405M A-4 VOLTAGE SENSING T h e b e s t a r c p e r f o r m a n c e o c c u r s w h e n t h ePowerWaves have accurate data about the arc condi-tions. Depending upon the process, inductance withinthe electrode and work lead cables can influence thevoltage apparent at the s...

Page 14 - SYSTEM DESCRIPTION

A-5 INSTALLATION POWER WAVE® 405M A-5 P O W E R WAV E ® TO S E M I - A U TO M AT I CPOWER FEED WIRE FEEDER INTERCON-NECTIONS T h e P O W E R W A V E ® 4 0 5 M a n d s e m i - a u t o m a t i cPower Feed family communicate via a 5 conductorcontrol cable (K1543). The control cable consists oftwo power...

Page 15 - CONFIGURING THE SYSTEM; SINGLE HEAD FEEDER

A-6 INSTALLATION 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 configurethe system. If a system can not be “Auto Mapped” then the statuslight on the power source will blink green fast and thewelder output ...

Page 17 - CONTROL CABLE SPECIFICATIONS; . When these parameters are identical, the; 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. (7.6...

Page 19 - I / O RECEPTACLE SPECIFICATIONS; DIP SWITCH SETTINGS AND LOCATIONS; CONTROL BOARD DIP SWITCH:

A-10 INSTALLATION POWER WAVE® 405M 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 Volta...

Page 20 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; • T h i s P O W E R W A V E ® i s n o t r e c o m m e n d e d f o r; OPERATION; ELECTRIC SHOCK can kill.

GENERAL DESCRIPTION The POWER WAVE® 405M semi-automatic powersource is designed to be a part of a modular, multi-process welding system. Depending on configuration,it can support constant current, constant voltage, andpulse welding modes. T h e P O W E R W A V E ® 4 0 5 M p o w e r s o u r c e i sde...

Page 21 - CASE FRONT LAYOUT

P O W E R W A V E ® 4 0 5 M – S e m i - A u t o m a t i cOperation P O W E R W A V E ® 4 0 5 M c a n o n l y b e u s e d w i t hArcLink compatible Power Feed M semi-automaticwire feeders. In addition, the Power Feed M semi-automatic wire feeders may require optional equip-ment to access certain weld...

Page 22 - WELDING ADJUSTMENTS; 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 23 - CONSTANT VOLTAGE WELDING

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 refer...

Page 24 - 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 25 - TIG GTAW; The Arc Control level selects the starting mode.; SMAW; The common procedures for Arc Gouging metal are:

B-6 OPERATION B-6 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 obtain the valuesin t...

Page 26 - 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 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 is K...

Page 28 - MAINTENANCE; CAPACITOR DISCHARGE PROCEDURE; Hold resistor body with electrically insulated glove.; ROUTINE MAINTENANCE; 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 ea...

Page 29 - TROUBLESHOOTING

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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshootin...

Page 31 - 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...

Page 32 - 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/repa...

Page 35 - 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...

Page 36 - 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 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 Servic...

Page 37 - 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 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 Depar...

Page 38 - 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

Page 39 - DIMENSION PRINT; IN

F-4 DIMENSION PRINT F-4 POWER WAVE® 405M 1 4 .7 9 1 2 .4 4 3 .4 4 2 1 .6 0 2 7 .8 2 5 .5 0 1 0 .0 0 M O U N T IN G H O L E L O C A T IO N S M 1 9 5 2 7 1 3 .1 0 1 /4 -2 0 N U T ( 4 P L A C E S ) N O T E : M O U N T IN G S C R E W S C A 1 0 /0 1 N N O T P R O T R U D E M O R E T H A N 0 .5 I N C H E ...

Page 40 - NOTES