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Lincoln Electric IM846-A User's Manual

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1. WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0 035 3 64 0 035 3 64 WELD MODE 98 99 101 102 14 ga 250 1 0 200 1 0 230 1 0 22511 0 28 10 400 1 0 280 1 0 425 1 0 400 1 0 2 o 3 16 550 1 0 340 1 0 670 1 0 500 1 0 E 1 4 600 1 0 400 1 0 700 1 0 550 0 9 COMMENTS Not Recommended Not Recommended Not Recommended Not Recommended below 200 WFS below 100 WFS below 200 WFS below 200 WFS LINCOLN B 7 OPERATION B 7 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 This results in improved welding performance in two primary types of applications Short Arc MIG at low procedure settings Aluminum MIG welding Power Mode is a method of high speed regulation of the output power whenever an arc is established It provides a fast response to changes in the arc The higher the Power Mode Setting the longer the arc If a welding procedure is not established the best way to determine the Power Mode Setting is by experimenta tion until the desired output result is established In the Power Mode two variables need to be set Wire Feed Speed Power Mode Trim Setting up a Power Mode procedure is similar to set ting
2. av31Y2v14 93110 3015 1v14 3NIHOVW 30 0671 3302 401 NGS0 HAVM H3AMOd F 2 POWER WAVE 405M LINCOLN E F 3 CONNECTION DIAGRAM F 3 Connection Diagram Semi automatic Simple System Electrode Positive CV Pulse Configuration shown POWER WAVE WIRE FEEDER CONTROL CABLE K1543 POWER WAVE 405M LINCOLN E DIMENSION PRINT F 4 F 4 22 wn oss ui v LAN NEP S E o 2 SIHONI 9 0 NYHL SHOW LON SM3HOS ONILNNON 1 SNOILVOOT 3 1OH ONILNNON POWER WAVE 405M LINCOLN E 5 POWER WAVE 405 LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja da Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tens
3. oaa 9 Turn power off before servicing Desconectar el cable de ali mentaci n poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X3TYTTLASU9 UAUNRUS VY FE e HEMMER SHA AHS Ab alll JA iui abil Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas O IJI RULE TIME SERE Ro ao H AREY cus 13 y e Cut Ai yl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese tm BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR f amp 5fBovRHOx z o0idBmmEtEk BA EFBRBLTF SU LTRHOR MEI TED CF EU S EE AOL REI
4. p Wave Control 10 0 l CURRENT WAVE FORM CV dann aa Aarna POWER WAVE 405M LINCOLN 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 can only be predicted when all the pulsing waveform parameters are known Using a preset voltage becomes impracti cal and instead the arc length is set by adjusting trim Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length Most pulse welding programs are synergic As the wire feed speed is adjusted the Power Wave will automatically recalculate the waveform parameters to maintain similar arc properties The Power Wave utilizes adaptive control to com pensate for changes in electrical stick out while weld ing Electrical stick out is the distance from the con tact tip to the work piece The Power Wave wave forms are optimized for a 0 75 19mm stick out The adaptive behavior supports a range of stickouts from 0 50 13mm to 1 25 32mm At very low or high wire feed speeds the adaptive range may be less due to reaching physical
5. N PULSES HIGH HEAT LOW HEAT PULSES PULSES PEAK AMPS BACKGROUND AMPS TIME The Peak Current Background Current and Frequency are identical for the high energy and low energy pulses In addition to cooling the weld down the major effect of the low energy pulses is that they form a weld ripple Since they occur at very regular time intervals the weld bead obtained is very uniform with a very consistent ripple pattern In fact the bead has its best appearance if no oscillation of the welding gun whipping is used See Figure B 5 When Arc Control is used in the Pulse on Pulse modes it does the same things it does in the other pulsed modes decreasing the Arc Control decreases the droplet transfer and weld deposition rate Increasing the Arc Control increases the droplet trans fer and weld deposition rate Since Arc Control varies weld droplet transfer rate the Arc Control can be used to vary the ripple spacing in the weld bead POWER WAVE 405M LINCOLN 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 flat position The values in the table can be helpful as a starting point to estab
6. IM846 A 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 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 E OPERATOR S MANUAL CERTIFICATE NUMBER 30273 Copyright Lincoln Global Inc LINCOLN E World s Leader in Welding and 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 i SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING
7. A 9 Control Board Dip SWIIChi A 9 nn Section B Safety Precautions 1 General DESCKDUON B 1 Recommended Processes and Equipment B 1 Recommended 1 Required Equipment ss as entente e annt d dede B 2 S B 2 Duty Cycle and Time B 2 Case Front Controls B 2 renun aman reo ex eun e REM a B 3 Fringe Proc dures B 3 Wold anse anna datent B 3 W lding AdjuStment ssh tte B 3 Constant Voltage Welding essere B 4 entem enixe eet Ec xe auos B 5 TIG GTAW SMAW and Arc GOUGING ss B 6 Power Mode and Recommended Welding Procedures B 7 LL IM Section C Optional Equipment sise C 1 Factory Installed 1 M latarzl ro DE C 1 Compatible Lincoln Equipment EEUU EEUU Section D Safety Pr cautions aiite ret deste ides ete ete ae E deua ds D 1 Capacitor Discharge Procedure ss D 1 Em D 1 Periodic naa n RENDER D 1 Calibration Specifications
8. HLIM 3140 1v14 e Er e 9 T 999004 od oo auvog TOYLNOD q 8r Voir 901 eter vs 22 E esl vub A Fia E ID JM SUL TWO u3WHOJSNVUL CLA CI Auvnixnv 9H SH LH 3NIHOVW 30 J23NNOD3H E Zoor ooze zoz 999 9990 95909 B B 1001 0101 S d i ANIHDVW 40 3015 1HOIH NS 3900 4031407 3AVM H3MOd INVHOVIG ONIHIM eJnsojoue JO euo uo 10 S 541 ALON SALON POWER WAVE 405M 2 E ed Jequunu epoo jueuudinbe e eorues 0 elqiBall s y j sjeued eunsojoue y euo uo eu episui paysed si epoo 10 eu enueui siu JO jou JO S 5141 ALON 40 3015 LN3NOdWOD LES LA Hd S OSWAS WORF IDNINDIS NIYIIWNN ALIAV2 HOLDINNOD LINDUID 14405 OL SAVTI NMOUS
9. Machine won t weld can t get any Input voltage is too low or too output high Make certain that input If all recommended possible areas voltage is proper according to of misadjustments have been the Rating Plate located on the checked and the problem persists rear of the machine contact your local Lincoln If the Thermal LED is also lit Authorized Field Service Facility see Yellow Thermal LED is Lit section Primary current limit has been exceeded Possible short in out put circuit Turn machine off Remove all loads from the out put of the machine Turn back on condition persists turn power off and contact an autho rized Lincoln Electric Field Service facility This problem will normally be accompanied by an error code Error codes are displayed as a series of red and green flashes by the status light See Troubleshooting the Power Wave Power Feed System Using the Status LED section of this text 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 405M LINCOLN 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine often noodle welds out put is limited to approximately 100 amps when running a particul
10. Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 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 N FOR ENGINE 9 1 1 To avoid scalding do not remove the E em P gt radiator pressure cap when the engine is ex powered equipment 1 a the engine off before troubleshooting and maintenance 1 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 e outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment
11. individual feed heads need to be assigned to the dual head control and the POWER WAVE 405 auto mapping disabled and the Equipment Groups set on See Figure A 8 See the Feeder documentation for information on setting the feeder DIP switches POWER WAVE 405M LINCOLN 8 A 7 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 Do not combine all of the work leads into one lead The welding travel direc tions should be in the direction moving away from the work lead as shown below Connect all of the work sense leads from each power source to the work piece at the end of the weld For the best results when pulse welding set the wire size and wire feed speed the same for all the Power Waves When these parameters are identical the pulsing frequency will be the same helping to stabilize the arcs Every welding gun requires separate shielding gas regulator for proper flow rate and shielding gas cover age Do not attempt to supply shielding gas for two or more guns from only one regulator anti spatter system is in use then each gun must have its own anti spatter system See Figure 6 INSTALLATION A 7 CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln
12. 8 LIINNOD 3002 TVDIHLDDIT3 IVNOLLVN 834 MOTTSA N3389 LDINNOD LndNI 3SVHd 338HL 5 so LINDHID 2 NOLLVINSNI A009 OL 34 1 HLIM oooo 00000000 39 4 35 2 S0 Md NO 135394 AINO SI DNIGNIM OVE 14405 OL SQV31 ONY LDINNOD 3000 1v2l812313 ra LII IT YIMOd JHL NI UV SAOW NO 44d ANNOY OL AYTI N3349 193NNOD LNdNI 3SVHd 1 5 HOS Lee AZ 5 s NE u31N32 401 NO 1 353844 SI 83113 INI YIMOd SAHOD HIMO4VHD ANY 92V T8 HLIM SINIHDVW 804 2 ocr ar OVA OL OD SOPMd ASZS 05S ATddNS OL SAYIT ALIHM8 5DV I8 LDINNOD 3002 SI NMOHS NOLLD3NNOD LNdNI NOLLD3NNOO 11VIHdOHddY NO AVI 3214 TIVOILO3T3 TWNOLLWN 834 OL AVF 1 LIINNOD LNANI 3SVHd 338H1 HSWNN IAONOWWOD V ONIAVH ALINDHID HO SLNINOdWOD NOLLVINSNI A009 OL 12VX3 JHL MOHS LON SIHL GHVOS 3131402 V 40 JHL HUM LINDUID ATddNSOL SQV313LIHM 32V 18 123 02 3005 SNILO34V LNOHLIM Q8 VOS V 40 AHLINDHID HO SLNINOdWOD 32NIS WORLDS T3 TWNOLLWN tid ANNOY OL 0 31 N3349 123NNOD LAAN 3SVHd TT9NIS 404 SQHOD3MOd A
13. Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enou
14. Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 405M LINCOLN 2 USING THE STATUS LED 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 In addition errors displayed on the user inter face in most cases indicate only that a problem exists in the power source not what the problem may be Therefore prior to cycling power to the system check the power source status light for error sequences as noted below This is especially important if the user interface displays Err 006 or Err 100 Included in this section is information about the power source Status LED and some basic troubleshooting LIGHT CONDITION Status LED is solid green no blinking Status LED is blinking green Status LED is blinking red and green Status LED is solid red no blinking Status LED is blinking red TROUBLESHOOTING E 2 charts for both machine and weld performan
15. a CV MIG procedure Select a shielding gas appropriate for a short arc process For steel use 75 25 Ar COo shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 10096 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Volts Trim knob as follows For steel listen for the traditional frying egg sound of a good short arc MIG procedure to know you have the process set correctly For aluminum simply adjust the Volts Trim knob until the desired arc length is obtained Note the Volts Trim display is simply a relative number and DOES NOT correspond to voltage Some procedure recommendations appear in Table B 3 Recommended Welding Procedures for Power Mode Table B 3 MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L WIRE SIZE 0 035 0 035 0 025 0 025 0 030 0 030 0 035 0 035 0 030 0 035 GAS 100 Ar 100 Ar 100 75 25 Ar CO 100 75 25 Ar CO 100 75 25 Tri mix Tri mix c 22ga Not Recommended 100 0 8 Not Recommended 90 1 0 o E 20 ga 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5 D 18 ga 140 1 7 140 1 5 110 1 5 110 1 5 100 2 5 100 2 5 110 2 0 110 2 0 5 a 16 ga 190 2 0 1
16. an Input voltage panel setup Open the access panel on the rear of the machine For 200 or 230 Position the large switch to 200 230 For higher voltages Position the large switch to greater than 380 Move the A lead to the appropriate terminal POWER CORD CONNECTION A 10ft 3 5m power cord is provided and wired into the machine Follow the power cord connection instructions CAUTION Incorrect connection may result in equipment damage BLACK GREEN YELLOW BLUE BROWN Single Phase Input Connect green yellow lead to ground per National Electrical Code Connect blue and brown leads to power Wrap blue lead with tape to provide 600V insulation Three Phase Input Connect green yellow lead to ground per National Electric Code Connect black blue and brown leads to power UNDERCARRIAGE MOUNTINGS MOUNTING HOLE LOCATIONS NOTE MOUNTING SCREWS CAN NOT PROTRUDE MORE THAN 0 5 INCHES INSIDE THE MACHINE o 3 50 MNT o Ns NUT 4 ates 50 TT NH DH qnn o e ee cid 11 84 1001 M19527 POWER WAVE 405M LINCOLN 8 A 3 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
17. are out of the current paths Both Sense leads detect arc voltage accurately No voltage drop between Arc and Sense lead Best starts best arcs most reliable results POWER WAVE 405M LINCOLN 8 a INSTALLATION iin 1 RECEPTACLE SPECIFICATIONS 2 1 TABLE 2 WIRE FEEDER RECEPTACLE off auto mapping enable default PIN LEAD FUNCTION auto mapping disabled Communication Bus L Communication Bus H Electrode Voltage Sense switch 8 worksenselead Ovdc 40VDC of work sense lead not connected sense lead not connected n work sense lead connected TABLE A 3 Factory setting for Switch 8 is OFF VOLTAGE SENSE RECEPTACLE 40vdc CUREA TABLE A 4 CONTROL BOARD DIP Switch Location PIN LEAD __ FUNCTION _ 85232 Receive 85232 Transmit Pin5 Pin4 DIP SWITCH SETTINGS AND LOCATIONS DIP switches on the P C Boards allow for custom configuration of the Power Wave To access the DIP switches WARNING ELECTRIC SHOCK can kill 1 off power to the power source at the dis connect switch Insulate yourself from the work and ground Always wear dry insulating gloves 2 Remove the wrap around cover from the power source 3 The control board is on the center assembly facing the case front Locate the 8 position DIP switch and look for switch 8 of the DIP switch 4 Using pencil or other small object slide the switch to the OFF position i
18. safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while the engine is running 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap magneto wire as appropriate LINCOLN 8 localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never
19. 2Volts 100 34Volts 60 AWG SIZES 200 41 48 6 220 37 48 23 28 22 27 22 26 Notes 80A 80A 50A 50A Note 2 Note 2 6 8 8 8 Phases 275Amps 31Volts 100 320Amps 33Volts 60 Line Cord Size Fuse Size 1 Not rated is indicated by 4 x s in the box on the rating plate 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger Select the output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75 C rated OUTPUT CABLES CONNECTIONS AND LIMITATIONS DUTY CYCLE CURRENT LENGTH UP 61m 200 FT 61 76m 200 250 FT 100 275 1 0 1 0 60 350 1 0 2 0 POWER WAVE 405M LINCOLN 8 A 2 SAFETY PRECAUTIONS WARNING e 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 Connect the green or green yellow lead of the power cord to ground per U S National Electrical Code SELECT SUITABLE LOCATION The Invertec POWER WAVE 405M will operate in harsh environments Even 50 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
20. 5535 ANIHDVW MIA 1 V1 888 30 3015 1331 8022 HIDNOSNVEL 43141134 LINDY 5 OL SQV31 NMOHW 3 HDV18 AVHD LDINNOD 3300 TVIL TWNOLLVN Hd N3389 LDINNOD 3SVHd 338H1 NOILVINSNI A009 OL 3dV L QV31 32v 18 dYdM 14405 OL SQV31NMOM8 ANY AVH9 123 2 3002 WILI 38 OL QV31 MOTT3A N3389 193NNOO LNANI 3SWHd 3T5NIS HOS SQHOD 43 MOd vu ANY 92V 18 NMOUS S3NIHOVIW LINDHID ATddNS OL SQV3131IHM 2 LDINNOD 300 1V21 19313 TVNOLLVN 434 OL 1 N3349 193NNOO 3S VHd 338H1 NOLLVINSNI A009 3GIAOHd OL 3dV L HLIM QV31 d V A LINDY 144001 SQv313LIHM ANY 52V 18 LDINNOD 3002 2 12313 TVNOLLVN 3d OL QV31 N3389 193NNOO LNdNI 3SVHd 31915 SquoD3MOd ALIHM ANY 32 V718 HLIM SANIHDVW O3 SSEMd vas L EL TOULNOD ado 106 31DV1413234 930333 3UIM E 599565 5 Q SOL cd tor Qvil3llHM aJ 40 als 113 an M snivis MT MOTHA IVNY3HL at 2
21. 90 2 0 125 2 0 125 2 0 125 3 0 125 3 0 140 2 5 130 2 7 z 14 400 2 0 400 2 5 260 3 0 260 3 0 160 2 3 160 2 3 160 3 8 160 3 5 210 3 0 190 3 5 5 12 330 5 0 330 4 5 230 3 5 230 3 5 200 5 0 200 4 5 270 5 0 230 6 0 D 10 ga 500 7 0 500 7 0 300 6 0 300 6 0 240 6 5 240 7 0 325 6 5 300 7 0 3 16 570 9 0 600 7 8 400 7 5 400 7 0 1 4 700 9 1 700 8 5 Not Not comes WFS WFS POWER WAVE 405M LINCOLN 1 ACCESSORIES e 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 equipment POWER WAVE 405M LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC 5 kill not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves 27 EXPLODING PARTS can cause injury 7 Failed parts can explode or cause other parts to explode when power is applied 1 Ql Always wear a face shield and lo
22. CAE PE BA DIR 8 dE A T R D O A BI 0 SEA HYR 29 ETSAI BICI 91 asl y ud al gll ql cuales LINCOLN amp World s Leader in Welding and 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
23. D 1 Troubleshooting 2 sd desde d cide Section E How to use Troubleshooting 1 Using the Status LED to Troubleshoot System Problems amp Error Codes E 2 E 3 Troubleshooting Guide E 4 thru E 7 Wiring Diagram nn nr nennen nnne nnne nnns Section F 1 F 2 Connection Section F 3 Dimension Print eere enne nnnm nennen nennen Section F 4 1615 RERUM P 418 viii 1 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 405M INPUT AC VOLTAGE amp DC OUTPUT Rated DC Output Weight Amps Volts Duty Cycle with Cord 50 60 Hz Dimensions HxWxD Output Range continuous Product Ordering Input AC Name Information Voltage 14 7 x12 5 x 27 8 373x318x 706 mm 350A 34V 60 3 Phase 320A 33V 6096 1 Phase 200 220 380 400 415 50 60 Hz 86 37 4 Wave 2369 1 275A 31V 100 1 32V 100 3 Phase Includes handles 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 National Electrical Code And Maximum Machine Outputs Input 50 60 Hz Output Recommended Voltage Phases 300Amps 350Amps Line Cord Size Fuse Size 3
24. HIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria etai ADP53AmtRE 207 OR ames 1c OF OR S s HEEL SR ER TR S e SWA e s amp xiossH 247 8 HS 217421 MESHA 4 iua lui e bia gs 4 92 e
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26. N This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page AU ONY c Section A Technical Specifications rient tert A 1 Safety Precautions run e ence a A 2 Select Suitable LOCATION rd nre s Da sa id A 2 SLACKING ERE RUE UE E I A 2 oss iot torpet Re RE RE eee Re ER Rene A 2 Input and Grounding A 2 Power Cord Connection matin ir rd A 2 Undercarriage tandem A 2 Output Cables Connections and 6 A 3 Cable Inductance Negative Electrode A 3 Voltage SSMSIAG ERE 4 Power Feed Wire Feeder Interconnections System Decription 4 Gontiguring th Syste A 5 System Set Up Alternate amp Combination Hard Automation and Dual head A 6 Welding with Multiple Power Waves sss nennen nnne nnne A 7 Control Cable Specifications A 7 Multiple Arc Unsynchronized sense and work leads A 8 O Receptacle A 9 Dip Switch Settings and Locations
27. ON A 3 Output connections on some Power Waves 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 terminal on the power source Connect the other end of the electrode cable to the wire drive feed plate The electrode cable lug must be against the feed plate Be sure the connection to the feed plate makes tight metal to metal electrical con tact The electrode cable should be sized according to the specifications given in the output cable connec tions section Connect a work lead from the negative power source output Twist Mate terminal to the work piece The work piece connection must be firm and secure especially if pulse welding is planned For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the Instruction Manuals CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative Twist Mate terminal and work cable
28. TERCON 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 communica tion and one lead for voltage sensing The cables are designed to be connected end to end for ease of extension The output receptacle on the POWER WAVE 405M is on the case front The input receptacle on the Power Feed is typically located at the back of the feeder or on the bottom of the user interface Due to the flexibility of the platform the configuration may vary The following is a general description of the System For specific configuration information consult the semi automatic Power Feed instruction manual SYSTEM DESCRIPTION The POWER WAVE 405M and Power Feed M family of products utilize a digital communication system called ArcLink Simply put ArcLink allows large amounts of information to be passed at very high speeds between components nodes in the system The system requires only two wires for communication and because of its bus like structure the components may be connected to the network in any order thus simplifying the system set up Each system must contain only one power source The number of wire feeders is determined by the type of wire feeder Refer to the wire feeder instruction manual for details POWER WAVE 405M LINCOLN 8 A 5 INSTALLATION 5 CONFIGURING THE SYSTEM The p
29. able material away ES Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection 24 Observe additional guidelines detailed in the beginning 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 wire feeders operating as a system Each component in the system has special circuitry to talk with the other system components so each component power Source wire feeder user interface knows what the other is doing at all times These components commu nicate with Arclink The POWER WAVE 405M is a high performance dig itally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and CAC A processes It car ries an output rating of 350 Amps 34 Volts at 60 duty cycle and 300 Amps 32 volts at 100 duty cycle RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE 405M can be set up in a number of configurations some requiring optional equipment or welding programs Each machine is factory prepro grammed with multiple welding procedures typically
30. age Excess voltage on the main capacitors May be caused by improp er input configuration Capacitor B over voltage When accompanied by an under voltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Check fan operation Be sure process does not exceed duty cycle limit of the machine Capacitor precharge failed Usually accompanied by codes 32 35 The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding Secondary overcurrent error NOTE The secondary limit is 570 amps for the standard stud and 325 amps for all single phase operation Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35 The Service Navigator has additional and later Error Codes listed 71075 These codes generally indicate internal errors on the the diagnostic Utility Software Control Board If cycling the input power on the machine does not Also similar information can be found on Web site at clear the error try reloading the operating system If this fails WWW powerwavesoftware com replace the control board 36 Thermal error Indicates over temperature Usually accompanied by Thermal LED 37 41 CAUTION If for any reason yo
31. and 4 minutes of idling in a ten minute period CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 1 POWER SWITCH Controls input power to the Power Wave 2 STATUS LIGHT A two color light that indicates System errors Normal operation is a steady green light Error conditions are indicated per Troubleshooting E Section in this Manual NOTE The POWER WAVE 405M status light will flash green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up OPERATION B 2 3 HIGH TEMPERATURE LIGHT thermal overload A yellow light that comes on when an over temper ature situation occurs Output is disabled and the fan continues to run until the machine cools down When cool the light goes out and output is enabled 4 CB1 WIRE FEEDER CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply FIGURE B 1 0 204 LU CASE FRONT LAYOUT POWER WAVE 405M 5 Internal POWER CIRCUIT BREAKER Protects 115 volt AC circuit a o 6 LEAD CONNECTOR SENSE LEAD 7 DIAGNOSTIC CONNECTOR RS 232 8 WIRE FEEDER RECEPTACLE 5 PIN 9 NEGATIVE TWIST MATE TERMINAL 10 POSITIVE TWIST MATE TERMINAL POWER WAVE 405M LINCOLN B 3 NOMINAL PROCEDURES The Power Wave is designed t
32. ar procedure especially a procedure with high WFS Machine won t produce full output Auxiliary receptacle is dead no auxiliary voltage Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Secondary current limit has been exceeded and the machine has phased back to protect itself Adjust procedure or reduce load to lower current draw from the machine Input voltage may be too low limiting output capability of the power source Make certain that the input voltage is proper according to the Rating Plate located on the rear of the machine Secondary current or voltage not be properly calibrated Check values displayed on the Power Feed 10 11 verses readings on an external meter Circuit breaker CB1 on case front may have opened Reset Circuit breaker in recon nect area may have opened Reset RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 405M LINCOLN 7 TROUBLESHOOTING 7 Observe all Safety Guidelines detailed throu
33. ations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place SAFETY Electromagnetic Compatibility Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telep
34. cable POWER WAVE 405M LINCOLN E 3 TROUBLESHOOTING E 3 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 or Err 100 on the user interface display ErorCode 7 onae Probably due to excessive number of communication errors User Interface time out error UI is no longer responding to the Power Source The most likely cause is a fault bad connection in the communication leads or con trol cable 21 Unprogrammed Weld Mode Contact the Service Department for instructions on reloading the Welding Software 22 ea OOO Weld Table Contact the Service Department for instructions on reloading the ee hee Software Contact the Service Department for instructions on reloading the Welding Software BUND al main transformer or output rectifier Capacitor A under voltage Low voltage on the main capacitors May be caused by improper input configuration 33 Capacitor B under voltage When accompanied by an overvoltage error on the same side it indicates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine Capacitor A over volt
35. ce The STATUS LIGHT is a two color light that indicates system errors Normal operation is a steady green light Error conditions are indicated in the following chart NOTE The POWER WAVE 405M status light will flash green and sometimes red and green for up to one minute when the machine is first turned on This is a normal situation as the machine goes through a self test at power up MEANING 1 System OK Power source communicating normally with wire feeder and its components if other fea tures and components show they are powered up Occurs during a reset and indicates the POWER WAVE 405M is mapping identifying each compo nent in the system Normal for first 1 10 seconds after power is turned on or if the system configura tion is changed during operation Non recoverable system fault If the PS Status light is flashing any combination of red and green errors are present in the POWER WAVE 405M Read the error code before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light To clear the error turn power source off and back on to reset Non recoverable hardware fault Generally indicates nothing is connected to the POWER WAVE 405M wire feeder receptacle See Trouble Shooting Section Not appli
36. ce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritan
37. check input volt age selection below Input voltage selection made improperly Power down check input voltage reconnect according to diagram on reconnect cover RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustments have been checked and the problem persists contact your local Lincoln Authorized Field Service Facility 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 Lincoln Electric Field Service Facility for technical assistance POWER WAVE 405M LINCOLN 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Thermal LED is lit Fan thermostat has opened Check for proper fan operation Fan should run whenever out put power is on Check for material blocking intake or exhaust louvers or for excessive dirt clogging cooling channels in machine Blow air in rear louvers to remove dirt around the fan Secondary rectifier or Choke thermostat has opened After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers DC Bus PC board thermostat has opened check for excessive load on 40VDC supply
38. coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electricall
39. 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 CAUTION The use of non standard cables especially in lengths greater than 25ft 7 6m can lead to munication problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems The K1543 series of control cables can be connected end to end for ease of extension Do not exceed more than 100 feet 30 5 m total control cable FIGURE A 6 POWER WAVE 405M TWO POWER WAVES Travel Direction POWER WAVE 405M Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 405M LINCOLN 8 8 INSTALLATION 8 MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES P ow BAD Current flow from Arc Z1 affects sense lead 2 Current flow from Arc 2 affects sense lead 1 Neither sense lead picks up the correct work voltage causing starting and welding arc instability Power BETTER Power Source Source Sense 1 is only affected by weld current from Arc 1 Sense 2 is only affected by weld current from Arc 2 Due to voltage drops across work piece Work 1 Arc voltage may be low causing need Sense 1 for deviation from standard procedures BEST Both Sense leads
40. correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in acco
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42. f the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 5 Replace the wrap around and screws PC board will read the FIGURE A 8 Switch at power up and configure the work voltage sense lead appropriately CONTROL BOARD DIP SWITCH switch 1 reserved for future use switch 2 reserved for future use Switch 3 equipment group 1 selcted default off Switch 4 equipment group 2 selcted default off switch 5 reserved for future use switch 6 reserved for future use switch 7 2 auto mapping switch 8 work sense lead See Figure A 8 Dual Head Boom Feeder POWER WAVE 405M LINCOLN 8 B 1 OPERATION B 1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill Unless using cold feed feature when ER feeding with gun trigger trode and drive mechanism are always electrically energized and could remain energized several sec onds after the welding ceases Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous ay Keep your head out of fumes Use ventilation or exhaust to remove a fumes from breathing zone WELDING SPARKS can cause fire or explosion Nr Keep flamm
43. g should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the work
44. gh ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 54 LINCOLN 8 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an exp
45. ghout this manual General degradation of the weld per 1 Check for feeding problems bad formance connections excessive loops in cabling etc Verify weld mode is correct for processes The power source may require calibration Check the actual current dis played on the Power Feed 10 vs actual current measured via exter nal meter Check the actual voltage dis played on the Power Feed 10 vs actual voltage measured via exter nal meter Check the actual WFS displayed on the Power Feed 10 vs actual WFS measured via external meter Excessively long and erratic arc Check for proper configuration and implementation of voltage sensing circuits If Wire Feed Speed is in Question Check system with K283 speed Inch Per Minute meter tester Manual Check by Turning off all run in features of the feeder Cut wire flush to weld gun electrode tip Feed wire for 6 seconds Measure feed wire length from the end of the electrode tip to the end of the feed wire Multiple 10 to the measured length Example You measure 24 then your results will be 240 IPM 10 x 24 240 IPM CAUTION 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 POWER WAVE 405M LINCOLN WIRING DIAGRAMS F 1 Jequunu
46. hone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables con
47. including GMAW GMAW P FCAW GTAW and CAC A for a variety of materials including mild steel stainless steel cored wires and aluminum The POWER WAVE 405M is recommended for semi automatic welding and may also be suitable for basic hard automation applications This Power Wave is not recommended for processes other than those listed POWER WAVE 405M LINCOLN B 2 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 welding programs and procedures are selected through the Power Feed M semi automatic user inter face REQUIRED EQUIPMENT Any ArcLink compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed M family LIMITATIONS Only ArcLink compatible Power Feed M semi automatic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used POWER WAVE 405M Output Limitations The POWER WAVE 405M will support maximum average output current of 350 Amps 60 duty cycle DUTY CYCLE AND TIME PERIOD The duty cycle is based upon a ten minute period A 60 duty cycle represents 6 minutes of welding
48. ing of 00 0 may be displayed as OFF on some Power Feed wire feeder control panels See the Welding Mode descriptions below for detailed explanations of how the Arc Control affects each mode CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The nominal preprogrammed volt age is the best average voltage for a given wire feed speed but may be adjusted to preference When the wire feed speed changes the Power Wave automati cally adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range OPERATION 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 CV Modes Arc Control often referred to as wave control adjusts the inductance of the wave shape The wave control adjustment is similar to the pinch function in that it is inversely proportional to inductance Therefore increasing wave control greater than 0 0 results in a harsher colder arc while decreasing the wave control to less than 0 0 provides a softer hotter arc See Figure B 2 FIGURE B 2 Wave Control 410 0 P eat Wav Control 0 00 D Current __
49. ion solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electro dos com a pele ou roupa molhada sole se da e terra e EPOT S ISLE 72 e T4 PT AD A tksigs e BLBXSCR MID D ERE RAE ATAH 2452 84 mc uu 9 AXE HER OAR jas Quali Y wp badly A outils dan DE dus ule Y jo Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e Hav v6008 EA e 18 9 RH EL 248 YZ AIX nig ALI 3 pu e Wear eye ear and body protection Prot jase los ojos los oidos el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUSBICRBRELTE SU e ARR HRAEBSHRRAR ez 119 0 AIS dil s die Lily jules cil sai T 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR T
50. ith cellulosic types of electrodes E6010 E7010 E6011 a higher energy arc is required to maintain arc stability This is usually indi cated when the electrode sticks to the work piece or when the arc pops out during manipulative technique For low hydrogen types of electrodes E7018 E8018 E9018 etc a softer arc is usually desirable and the lower end of the Arc Control suits these types of elec trodes In either case the arc control is available to increase or decrease the energy level delivered to the arc ARC GOUGING Gouging is basically removing metal to form a bevel or groove in a piece of steel with controlled forced air and a carbon rod The common procedures for Arc Gouging metal are Removing poor welds from a weldment so that new welds can be made Creating a welding groove or grooves in two pieces of steel butted together See Example below WELD GROOVES CREATED BY ARC GOUGING STEEL BUTTED TOGTHER Mode 9 in the POWER WAVE 405M is specifically for gouging Gouging can also be done in the stick soft and crisp modes Setting the output of the Stick Soft mode to 425 amps will enable the arc gouging mode The actual output current will depend on the size of carbon used The recommended maximum size car bon is 5 16 WELDING PROCEDURES FOR PULSE ON PULSE TABLE B 2 MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 100 Ar 100 Ar 100 Ar 100 Ar
51. limitations of the welding process Arc Control often referred to as wave control in pulse programs usually adjusts the focus or shape of the arc Wave control values greater than 0 0 increase the pulse frequency while decreasing the background cur rent resulting in a tight stiff arc best for high speed sheet metal welding Wave control values less than 0 0 decrease the pulse frequency while increasing the background current for a soft arc good for out of posi tion welding See Figure B 3 FIGURE B 3 CURRENT WAVE FORM PULSE Current Wave Control 10 0 Wave Control 0 0 1 1 Wave Control 10 0 Time OPERATION B 5 PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically designed for use in welding relatively thin less than 1 4 6 4mm O thick aluminum See Table B 3 It gives weld beads with very consistent uniform ripple In Pulse on Pulse modes two distinct pulse types are used instead of the single pulse type normally used in GMAW P A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc Such pulses are shown in Figure B 4 After a number N of such pulses depending on the wire feed speed used an identical number N of low ener gy pulses are performed These low energy pulses shown in Figure B 4 do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low N PULSES
52. lish a welding procedure From there adjust ments need to be made to set the proper procedure for each specific application out of position other types of joints etc The comments on Table B 3 show values of WFS below which it is not recommended to weld The rea son is that below these values the weld transfer will change from spray arc to a short arc which is not advisable when welding aluminum TIG GTAW The TIG mode features continuous control from 5 to 425 amps The TIG mode can be run in either the Touch Start TIG or Scratch start mode The Arc Control level selects the starting mode Between 10 and 0 the Touch Start TIG mode is selected The OCV is controlled below 10V and the short circuit TIG touch current is maintained at approximately 25 amps independent of the preset current When the tungsten is lifted an arc is initiated and the output is regulated at the preset value A set ting of O results in the most positive arc initiation A setting of 10 reduces hot start Between 0 and 10 the Scratch starting TIG mode is selected In this range the OCV of the machine is controlled between 50 and 70 volts OPERATION B 6 SMAW In SMAW STICK mode arc control adjusts the arc force It can be set to the lower range for a soft and less penetrating arc characteristic negative numeric values or to the higher range positive numeric val ues for a crisp and more penetrating arc Normally when welding w
53. losion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 3 7 a Use only compressed gas cylinders containing the
54. ng sleeves when servicing See additional warning information throughout this Operator s Manual 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 position shown Hold in each position for 1 second Repeat for all four capacitors 3 Use a DC voltmeter to check that voltage is not present across the terminals on all four capacitors ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a low pressure airstream to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine PERIODIC MAINTENANCE Calibration of the POWER WAVE 405M is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improp erly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the fac tory 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 pr
55. o operate with 3 4 19 1mm electrode stick out for CV and Pulse processes FRINGE PROCEDURES Excessively short or long electrode stick outs may function only on a limited basis if at all MAKING A WELD WARNING The serviceability of a product or structure utiliz ing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selec tion The steps for operating the Power Wave will vary depending upon the options installed in the user inter face control box of the welding system The flexibility of the Power Wave system lets the user customize operation for the best performance First consider the desired welding process and the part to be welded Choose an electrode material diameter shielding gas and process GMAW GMAW P etc Second find the program in the welding software that best matches the desired welding process The stan dard software shipped with the Power Waves encom passes a wide range of common processes and will meet most needs If a special
56. ocedure itself requires the use of a grid and certified actual meters for voltage and cur rent The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use Detailed instructions are available with the utility POWER WAVE 405M LINCOLN TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service
57. of clean air such that air movement in the back out the sides and bottom will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles DO NOT MOUNT OVER COMBUSTIBLE SURFACES CAUTION Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STACKING POWER WAVE 405M cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUNDING CONNECTIONS Only a qualified electrician should connect the Invertec POWER WAVE 405M Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information detailed below When received directly from the factory multiple voltage machines are internally connected for 400VAC If 400VAC is the desired input then the machine may be connected to the power system without any setup required inside the machine INSTALLATION A 2 Initial 200VAC 230VAC operation will require
58. ower 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 SINGLE HEAD FEEDER ALLOWED POWER WAVE 405M UP TO 4 WIRE FEEDERS 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 Lincoln sales representative DUAL HEAD FEEDER POWER WAVE 405M FEED HEAD SINGLE HEAD BOOM FEEDER POWER WAVE 405M ROBOT PLC CONTROLLER ANALOG INTERFACE etc UP TO 4 FEED HEADS ALLOWED POWER WAVE 405M WIRE DRIVE MODULE POWER WAVE 405M LINCOLN 8 A 6 INSTALLATION A 6 ALTERNATE HARD AUTOMATIC APPLICATION using a User Interface Wire Drive Module and POWER FEED 10R POWER WAVE 405M PF 10R WIRE DRIVE MODULE FH1 COMBINATION HARD AUTOMATION APPLICATION w Semi Auto Feeder Wire Drive Module and POWER FEED 10R POWER WAVE 405M one eg F P System that is NOT Auto Mappable DUAL HEAD BOOM FEEDER using two single heads POWER WAVE 405 In this case
59. piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connec tion of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob lems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment LINCOLN 8 vii vii for selecting a QUALITY product by Lincoln Electric We want you i to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about thei
60. problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid excessive lengths and do not coil excess cable CAUTION When using an inverter type power source like the Power Waves use the largest welding electrode and work cables that are practical At least 2 0 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used CABLE INDUCTANCE AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes cable inductance will cause the welding performance to degrade For the total welding loop length less than 50 ft 15 24m tradi tional welding cables may be used without any effects on welding performance For the total welding loop length greater than 50 ft 15 24m the K1796 Coaxial Welding Cables are recommended The welding loop length is defined as the total of electrode cable length A work cable length B work length C See Figure f FIGURE A 3 For long work piece lengths a sliding ground should be considered to keep the total welding loop length less than 50 ft 15 24m See Figure A 4 FIGURE 4 T SLIDING WORK K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE INSTALLATI
61. r against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTIO
62. r 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 We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchase
63. rdance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder par
64. to the positive Twist Mate terminal When operating with electrode polarity negative the Electrode Sense Polarity DIP switch must be set to the Negative position on the Wire Drive Feed Head PC Board The default setting of the switch is positive electrode polarity Consult the Power Feed instruction manual for further details POWER WAVE 405M LINCOLN 8 4 VOLTAGE SENSING The best arc performance occurs when the Power Waves have accurate data about the arc conditions 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 Sense Lead Kits K940 10 25 or 50 are available for this purpose CAUTION If the voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity switch is improperly configured extremely high welding outputs may occur The ELECTRODE sense lead 67 is built into the control cable and is automatically enabled for all semi automatic processes The WORK sense lead 21 connects to the Power Wave at the four pin con nector By default the WORK voltage is monitored at the output stud in the POWER WAVE 405M For more information on the WORK sense lead 21 see Work Voltage Sensing in the following paragraph Enable the voltage sense leads as follo
65. trol cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities to be carried out LINCOLN 8 vi SAFETY vi Electromagnetic 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 mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shieldin
66. ts Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER gu corpa TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommend
67. u do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 405M LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal covers are removed Input fuses keep blowing or input breaker keeps tripping Machine will not power up no lights no fan etc POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service facility for technical assis tance Make certain that fuses or breakers are properly sized See Installation section of this manual for recommended fuse and breaker sizes Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle or both There is internal damage to the power source Contact an authorized Lincoln Electric Service facility Make certain that the Power Switch SW1 is in the ON position Circuit Breaker CB1 on Case Front may have opened Reset an over load on the 40V Wire Feeder supply may cause this to trip Circuit breaker in recon nect area may have opened Reset Also
68. ut characteristics output voltage output current accord ing to pre programmed settings contained in the Power Wave In non synergic modes the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc characteristics the oper ator must adjust the voltage to compensate for any changes made to the WFS In constant current modes stick TIG this control adjusts the output current in amps VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse synergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 500 to 1 500 A Trim set ting of 1 000 is a good starting point for most condi tions WELDING MODE May be selected by name CV MIG CC Stick Crisp Gouge etc or by a mode number 10 24 71 etc depending on the Control Box options Selecting a welding mode determines the output characteristics of the Power Wave power source For a more complete description of the welding modes available in the Power Wave see the explanation following POWER WAVE 405M LINCOLN 8 B 4 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 t
69. 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 The Power Feed PF family of feeders communicate settings to the Power Wave through control cable connection Arc length wire feed speed arc control etc are all communicat ed digitally via the control cable OPERATION 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 plied as part of the wire feeder It can be mounted directly on the wire feeder itself the front of the power Source or mounted separately as might be done in a welding boom installation Because the Control Box can be configured with many different options your system may not have all of the following adjustments Regardless of availability all controls are described below For further information consult the Power Feed wire feeder instruction manu al WFS AMPS In synergic welding modes synergic CV pulse GMAW WFS wire feed speed is the dominant con trol parameter controlling all other variables The user adjusts WFS according to factors such as weld size penetration requirements heat input etc The Power Wave then uses the WFS setting to adjust its outp
70. ws TABLE A 1 INSTALLATION Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs Work Voltage Sensing 21 lead 21 lead optional 21 lead optional 21 lead optional Voltage sense at studs Voltage sense at studs 21 lead optional Voltage sense at studs The electrode voltage 67 sense lead is integral to the control cable to the wire feeder Work Voltage Sensing The standard POWER WAVE 405 default to the work stud work sense lead disabled For processes requiring work voltage sensing con nect the 21 work voltage sense lead K940 from the Power Wave work sense lead receptacle to the work piece Attach the sense lead to the work piece as close to the weld as practical but not in the return cur rent path Enable the work voltage sensing in the Power Wave See Dip Switch Settings and Locations in Installation Section of this manual ELECTRODE VOLTAGE SENSING Enabling or disabling electrode voltage sensing is automatically configured through software The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present CAUTION Important The electrode polarity must be config ured at the feed head for all semi automatic processes Failure to do so may result in extreme ly high welding outputs POWER FEED WIRE FEEDER IN
71. y hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 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 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health

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