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Lincoln Electric IM746 User's Manual

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3. 11 84 10 01 M19527 POWER WAVE 405 LINCOLN 5 A 3 OUTPUT CABLES CONNECTIONS AND LIMITATIONS Connect a work lead of sufficient size and length 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 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 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 c
4. OS S LAN Oc v V o Ec o 2 ANIHOVI 3GISNI SAHONI lt 0 NVHL 3HOIN AGNYLOYd LON NVO SM3WDS ONILNNOW 3 0N SNOILVDO71 J 10H ONILNNOW 09714 7 67 7 ec8Lc 22222222 OT ET SN 6L VL POWER WAVE 405 LINCOLN 5 LELECTRIC WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is 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 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra 0 15805 9 6 9 0 7 22 5 567466 E GUB
5. 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 WAVE TO SEMI AUTOMATIC POWERFEED WIRE FEEDER INTERCON NECTIONS The POWER WAVE 405 and semi automatic PowerFeed family communicate via a 5 conductor control cable K1543 The control cable consists of two power leads one twisted pair for digital communi cation and one 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 405 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 POWER WAVE 405 LINCOLN 5 INSTALLATION A 5 SYSTEM DESCRIPTION The POWER WAVE 405 and Power Feed family of products utilize a digital communication system called Linc Net Simply put Linc Net 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 simpl
6. Auxiliary receptacle is dead no 1 Circuit breaker CB1 on case lf all recommended possible areas auxiliary voltage front may have opened Reset Of misadjustments have been Circuit breaker in recon checked and the problem persists nect area may have opened contact your local Lincoln Reset 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 405 LINCOLN E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION General degradation of the weld per 1 Check for feeding problems bad 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 CAUTI
7. A 2 7 Output Cables Connections and A 3 Negative Electrode Polarity ss A 3 ud 4 Power Wave to Semi automatic Power Feed Wire Feeder Interconnections A 4 System DeSCripliOn san cash t ceca ni mien ti da uu Re eR enun A 5 System A 6 thru A 8 Welding with Multiple Power Waves A 9 Control Cable Specifications A 9 Receptacle Specifications A 10 1 Dip Switch Settings and Locations A 10 Control Board Dip A 10 Operation pM Section B Safety ed B 1 General 0 B 1 Recommended Processes and B 1 5 5 coetu Lt dee users 1 Required Equipment lues ane B 2 ER 2 Duty Cycle and Time Period B 2 Case Front Controls 2 B 3 Nominal B 3 Fringe 000008 B 3 Makingra Waldenin eer a On erg prec ee Sr cer iae eet ipu us B 3 Welding ss net Eee anse nee ee me B 3 Constant Voltage Welding B 4
8. IM746 POWER WAVE 405 For use with machines Code 10896 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful EE OPERATOR S MANUAL ea 150 9001 lt lesigned and LINCOLN Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting 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 l 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
9. LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECUATIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SHOCK can kill e Unless using cold feed feature when feeding with gun trigger the elec 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 e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous 23 Keep your head out of fumes Use ventilation or exhaust to remove B fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away gt Do not weld on containers that have held combustibles ARC RAYS can burn 2 Wear eye ear and body protection RZ Observe additional guidelines detailed in the beginning of this manual GENERAL DESCRIPTION The Power Wave 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 constant power and pulse welding modes The Power Wave 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
10. ____ CAN communication bus off Probably due to excessive number of communication errors 12 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 eme the Service Department for instructions on reloading the Welding Software 22 the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software main transformer or output rectifier input configuration 33 fia 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 4 Capacitor A over voltage Excess voltage on the main capacitors May be caused by improp er input configuration 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 Capacitor B over voltage Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 36 37 Capacitor precharge failed Usually accompanied by codes 32 35 4l The secondary weld current limit has been exceeded When this occurs the mac
11. 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 onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 o l on pique le laitier Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations 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 POWER WAVE 405 LINCOLN 8 SAFETY ELECTROMAGNETIC COMPATIBILITY EMC Conformanc
12. 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 Ifa 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 a CV MIG procedure Select a shielding gas appropriate for a short arc process For steel use 75 25 Ar CO shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 100 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjustthe 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
13. 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
14. Pulse Welding AM Lose rre et retten ee rt tcn Fette tees B 5 Pulse on Pulse Benefits on Pulse on Pulse Tig GTAW B 6 Power Mode Recommended Welding Procedures for Power Mode B 7 II ADEM Section C C 1 Optional EQUIPMO Factory Installed De pe ee eee terret Pe at C 1 PIO A MSTA me C 1 Compatible Lincoln Equipment Section D Safety Precautions iii D 1 Capacitor Discharge Procedure ii nade ngu D 1 Routine D 1 Periodic D 1 Calibration Specifications D 1 Aroubleshooting Section How to use Troubleshooting Guide E 1 Using the Status LED to Troubleshoot System E 2 Troubleshooting Guide ss E 3 thru E 7 Wiring Diagram 22 0 Section F 1 Connection Diagram 2 s1 nccnscccetnceceeeeccteesenseceeesneveseeceestncenvaceseneueeeeseareneccees Section F 2 Dimension Print ss reine nnnm nario e aa pnt nn sqm ias Section F 3 Parts P 418 viii 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS POWER WAVE 405 INPUT AC VOLTAGE amp DC OUTPUT Product Ordering Rated DC Output Output Weight Dim
15. S Oa EERTE ecu 5893 Xe 8 HZA Weal AMI 1 slt DA daua Y Jio 6 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 inflamaveis bem guarda dos 945 3 464 LU CIE e 0 MR 8 135 o Jo ALD al gl 5 5 Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y 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 corpo HAUSHERMRELTTF EU RRR 55 ez 119 59 5 356 41 53 de Lily vues al gl ne 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL 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 L
16. 405 Group Of roup 0 bw 2 Single Group Multi Head System FIGURE A 4 No FHO Alllowed The Dual Head option allows the abil ity to maintain 2 sets of procedures lf more then 2 heads are used odd s use FH1 settings even 5 use FH2 settings Power Wave 405 POWER WAVE 405 LINCOLN INSTALLATION A 8 Single Group Multi Head System Alternate Method FIGURE A 5 No FHO Alllowed When a standard User is used in a group with multi ple Feed Heads all of the Feed Heads use a single set of procedures Power Wave405 POWER WAVE 405 LINCOLN 5 A 9 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 See Figure A 6 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 a s
17. E 2 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave Power Feed are best diagnosed as a system Each component power source user inter face and feedhead 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 performance 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 405 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 norm
18. 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 below 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 ting 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 NOS Wave Control 410 0 077 Way Control 0 00 OPERATION aat Se lt ge Wave Control 10 0 B 4 CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed a corresponding voltage is preprogrammed into the machine through special soft ware atthe factory The nominal preprogrammed volt age is the 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 Non Synergic CV This type of CV mode behaves more like a conven tional CV power source Voltage and WFS are inde pendent adjustm
19. 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 are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 405 LINCOLN 5 E 6 TROUBLESHOOTING E 6 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 Machine often noodle welds out 1 Secondary current limit has been put is limited to approximately 100 exceeded and the machine has amps when running a particular phased back to protect itself procedure especially a procedure 2 Adjust procedure or reduce load with high WFS to lower current draw from the machine Machine won t produce full output 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
20. 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 100 002 75 25 100 CO 75 25 Ar CO 100 75 25 Ar CO Tri mix Tri mix 22 ga NotRecommended 100 0 8 NotRecommended 90 1 0 9 20 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5 y 8 18 3 140 1 7 140 1 5 110 1 5 110 1 5 100 2 5 100 2 5 110 2 0 110 2 0 5 9 16 190 2 0 190 2 0 125 2 0 125 2 0 125 3 0 125 3 0 140 2 5 130 2 7 2 6 14 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 5 12 ga 330 5 0 330 4 5 230 3 5 230 3 5 200 5 0 200 4 5 270 5 0 230 6 0 lt 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 57019 0 600 7 8 400 7 5 400 7 0 1 4 700 9 1 700 8 5 Not Not comes rman WFS WFS POWER WAVE 405 LINCOLN P C 1 ACCESSORIES E OPTIONAL E
21. initiation A setting of 10 reduces hot start Procedure to start the weld and from there to ramp to the welding procedure over a specified amount of time Typically starting procedure ona higher setting is known as a Hot Start Setting a start ing procedure on a lower setting is known as a Cold 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 with 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
22. normal situation as the machine goes through a self test at power up TABLE B 1 condition 000 8000 Condition Steady Green System OK Power source communicating normal ly with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 405 is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration 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 405 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 sepa rated by a green light To clear the error turn power source off and back on to reset See Troubleshooting Section Non recoverable hardware fault Generally indicates nothing is connected to the POWER WAVE 405 wire feeder receptacle See Trouble Shooting Section Blinking Red Not applicable Steady Red 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
23. 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 405 is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfactory weld performance To ensure optimal performance the cal ibration 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 procedure 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 405 LINCOLN 5 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Perso
24. system components so each component power source wire feeder user interface knows what the other is doing atall times These components commu nicate with Linc Net The POWER WAVE 405 is a high performance digi tally controlled inverter welding power source capable of complex high speed waveform control Properly equipped it can support the Constant Power GMAW GMAW P Pulse on Pulse FCAW SMAW GTAW and CAC A processes It carries 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 405 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 including Constant Power GMAW GMAW P Pulse on Pulse FCAW GTAW and CAC A for a variety of materials including mild steel stainless steel cored wires and aluminum The POWER WAVE 405 is recommended for semi automatic welding and may also be suitable for basic hard automation applications This Power Wave 15 not recommended for processes other than those listed POWER WAVE 405 LINCOLN P B 2 OPERATION B 2 POWER WAVE 405 Semi Automatic Operation Semi Automatic Power Waves can only be used with Linc Net compatible Power Feed semi automatic wire feeders In addition the Power Feed semi automatic wire feeders may re
25. with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically 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 the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 Protect other nearby personnel with suitable non flammable screening and or warn them n
26. 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 6 h Also see item 1 c CYLINDER may explode 22238 sr if damaged 7 a Use only compressed gas cylinders containing the 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 weldin
27. AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING 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 Z49 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 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 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 elimi
28. 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 Ne STEEL BUTTED TOGTHER Mode 9 in the Power Wave 405 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 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 0 225 1 0 10 ga 400 1 0 280 1 0 4251 1 0 400 1 0 3 16 550 1 0 340 1 0 670 1 0 500 1 0 MATERIAL THICKNESS WFS TRIM 114 600 1 0 400 1 0 700 1 0 550 0 9 COMMENTS Not Recommended below 200 WFS Not Recommended below 100 WFS Not Recommended below 200 WFS Not Recommended below 200 WFS POWER WAVE 405 LINCOLN P B 7 OPERATION B 7 POWER The Power Mode
29. CIRCUIT BREAKER Protects 40 volt DC wire feeder power supply POWER WAVE 405 LINCOLN B 3 CASE FRONT LAYOUT POWER WAVE 405 Internal POWER CIRCUIT BREAKER Protects 115 volt AC circuit LEAD CONNECTOR SENSE LEAD DIAGNOSTIC CONNECTOR RS 232 WIRE FEEDER RECEPTACLE 5 PIN NEGATIVE TWIST MATE TERMINAL 0 POSITIVE TWIST MATE TERMINAL NOMINAL PROCEDURES The Power Wave is designed to operate with 3 4 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 A 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 OPERATION B 3 The steps for operating the Power Wave will vary depending upon the options installed in the user inter face contro
30. ESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS 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 0 aspiraci n para gases Gardez la t te a 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 fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 98 80 7780 es 24758 else 55445598 MAS sis PARAH 552 5 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE 23 6 e HMDS RK AGS XA Do
31. ON 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 405 LINCOLN YS Jequunu epoo eu 104 3ueuniedeg 29m9 9 si eui j sjeued einsoj oue eu Jo euo uo eui LL peised s epoo 104 siy Aq je 104 eq jou 10 51 SIUL 310 Q4vO8 40 NOHATAMEIN RSA Had SOUS ONINSANNN ALIYO HOLOSNNOO LINOHI A1dd 01 SOYI NMOHE 9 3TTI8LO3NNOO 3009 WOIHLO3TE VNOLLVN LOINNOO LNANI 3SVHd per HLLILOUd NOLLVINSNI A009 3DIAOd OL HYL HLIM 0031 o o o 39 8 1NONJ3SVO OnOHHSNVd NO LN3S3HdATNO SI ONIGNIM 022 3 MOV dv 1 7915 01 SAYTI NMOS 3178 LONNOI 1009 WOHLITIA ra P LOI IHL SAOW 3 VNOLLVN YH OL GV MOTTIAINSIHO 123 02 6 1 3SYHd3TINIS 803 nmm prep cT MIL ar i 1 1 507
32. Pin4 Pin20 Pin6 RS232 Commom 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 A WARNING ELECTRIC SHOCK can kill 1 Turn off power to the power source at the disconnect switch 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 a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 0 A 5 6 7 8 5 the wrap around and screws The PC board will read the switch at power up and config ure the work voltage sense lead appropriately 12 3 4 INSTALLATION A 10 CONTROL BOARD DIP SWITCH switch 1 reserved for future use switch 2 reserved for future use switch 3 reserved for future use switch 4 reserved for future use switch 5 reserved for future use switch 6 reserved for future use switch 7 reserved for future use switch 8 work sense lead switch 8 work sense lead work sense lead not connected work sense lead connected F actory setting for Switch 8 is OFF FIGURE A 7 CONTROL BOARD DIP Switch Location POWER WAVE 405
33. QUIPMENT 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 Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family POWER WAVE 405 LINCOLN 5 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves 7 EXPLODING PARTS can cause PO injury Failed parts can explode or cause other parts to explode when power is applied VI e Tl Always wear a face shield and long 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 RESISTOR 3 Use a DC voltmeter to check that voltage is
34. 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 405 For more information on the WORK sense lead 21 see Work Voltage Sensing in the following paragraph POWER WAVE 405 LINCOLN A 4 INSTALLATION A 4 Enable the voltage sense leads as follows TABLE A 1 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 s default to the work stud work sense lead disabled For processes requiring work voltage sensing con nect the 21 work voltage sen
35. able 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 INSTALLATION A 3 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 to the positive Twist Mate terminal When operating with negative electrode polarity 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 VOLTAGE SENSING The best arc performance occurs when the PowerWaves have accurate data about the arc condi tions Depending upon the process inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder Voltage sense leads improve the accuracy of the arc condi tions and can have
36. ally with wire feeder and its components Occurs during a reset and indicates the POWER WAVE 405 is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration 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 405 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 405 wire feeder receptacle See Trouble Shooting Section Not applicable POWER WAVE 405 LINCOLN 5 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 405 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 Error Code ____________
37. and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 POWER WAVE 405 LINCOLN 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
38. ary the ripple spacing in the weld bead POWER WAVE 405 LINCOLN P 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 establish 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 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 set ting of 0 results in the most positive arc
39. ay 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 pulse on pulse GMAW WFS wire feed speed is the domi nant control 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 output characteristics output voltage output cur rent according to pre programmed settings contained in the Power Wave POWER WAVE 405 LINCOLN 5 Current B 4 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 welding modes pulse and Pulse on 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 setting of 1 000 is a good starting point for most conditions WELDING MODE May be selected by name CV MIG CC
40. cular 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 the 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 workpiece 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 connection 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 an
41. d equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN50199 Electromagnetic Compatibility EMC product standard for arc welding equipment 3 1 96H L10093 POWER WAVE 405 LINCOLN vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you 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 purchaser 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 o
42. e Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 50 199 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 telephone 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 ca
43. e 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 6 do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low FIGURE B 4 N PULSES N PULSES HIGH HEAT PULSES LOW HEAT 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 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 v
44. e 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 400 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 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 5 meter power cord is provided and wired into the machine Follow the power cord connection instruc tions 4 CAUTION Incorrect connection may result in equipment damage Single Phase Input Connect green yellow lead to ground per National Electrical Code Connect blue and brown leads to power Wrap black 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 1 3 50 DT 4 4 20 NUT 4 TERI HHH 5 10 O1
45. ensions Information Voltage Amps Volts Duty Cycle Range with Cord HxWxD 50 60 Hz continuous 350A 60 12 5 14 7 200 220 3 Phase 27 8 380 400 320A 33V 60 86 5lbs 373 318 415 1 Phase 37 4 kg 706 mm 275A 31V 100 1 Phase 300A 32V 100 Includes 3 Phase handles Overall Length Including Handle 21 6 649mm without handle 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 Notes 32Volts 100 34Volts 60 AWG SIZES 200 6 80A Note 2 230 80A Note 2 380 50A 400 50A 415 6 8 8 8 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 OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select the output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated DUTY CYCLE 100 60 POWER WAVE 405 LINCOLN 5 A 2 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill TURN THE INPUT POWER OFF THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS CONNECT INPUT POWER LINES OUTPUT CABLES OR CONTROL CABLES Only qualified personnel should perform t
46. ents Therefore to maintain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS All CV Modes Arc Control often referred to as wave control adjusts the inductance of the waveshape 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 wt FIGURE B 2 CURRENT WAVE FORM CV POWER WAVE 405 LINCOLN P 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 All pulse welding programs are synergic As the wire feed speed is adjusted the Power Wave will automati cally recalculate the wa
47. eperate 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 If an anti spatter system is in use then each gun must have its own anti spatter system INSTALLATION A 9 CONTROL CABLE SPECIFICATIONS It is recommended that genuine Lincoln control cables be used at all times Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed system CAUTION The use of non standard cables especially in lengths greater than 25 feet can lead to communi cation problems system shutdowns poor motor acceleration poor arc starting and low wire dri ving 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 length FIGURE A 6 POWER WAVE 405 TWO POWER WAVES Travel Direction POWER WAVE 405 Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint POWER WAVE 405 LINCOLN A 10 RECEPTACLE SPECIFICATIONS TABLE A 2 Communication Bus L Communication Bus H Electrode Voltage Sense Ovdc 0 TABLE VOLTAGE SENSE RECEPTACLE LEAD FUNCTION PIN Work Voltage Sense TABLE A 4 RS232 RECEPTACLE RS232 Transmit Pin5
48. g 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 CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders 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 accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 POWER WAVE 405 LINCOLN 5 SAFETY PRECAUTIONS DE SURETE 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 Sdret Pou
49. heet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 POWER WAVE 405 LINCOLN 5 SAFETY 7 WELDING SPARKS can gt 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 explosion 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
50. hine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding Thermal error Secondary overcurrent error NOTE The secondary limit is 570 amps for the standard stud and 325 amps for all single phase operation The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35 43 Capacitor delta error Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the Control Board If cycling the input power on the machine does not Clear the error try reloading the operating system If this fails replace the control board 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 405 LINCOLN 5 E 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 loca
51. his installation Connect the green yellow lead of the power cord to ground per U S National Electrical Code 8 SELECT SUITABLE LOCATION The Invertec POWER WAVE 405 will operate in harsh environments Even so it is important that simple pre ventative measures are followed in order to assure long life and reliable operation machine must be located where there is free cir culation 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 A 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 EE than 5 90 150mm beyond the equipment on all sides STACKING POWER WAVE 405 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 e Only a qualified electrician should connect the Invertec POWER WAVE 405 Installation should be made in accordanc
52. i fying the system set up Each system must contain only one power source The power source may be connected to a maximum of four feeder groups Each group containing one user interface and up to seven Feed Heads FH SEE FIGURE A 1 The UI controls all of the FH s of that group The Ul s and FH s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards For example all of the FH s to be controlled by a given UI must have their Group ID switches set to the same group number as the UI In addition each FH must be assigned a separate FH number within that group See the system set up sec tion for further details System Model From a network perspective each component in the system is considered a separate node regardless of its physical location For example even though a UI and FH may be physically mounted together they are still viewed as separate pieces nodes by the net work and can only communicate via Linc Net The Linc Net connection is generally made external through the Linc Net Control Cable but can also be made internally as with the PF 10 bench model feed er The most common Linc Net configuration called a simple system consists of one power source one user interface and one feeder Under these circum stances the group and feed head ID DIP switches are ignored and the system will function regardless of their position The same is true for the minimu
53. l 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 CB3 in recon nect area may have opened Reset Also 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 405 LINCOLN 5 E 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Obser
54. l 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 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 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 m
55. m sys tem consisting of a power source and one UI Example a stick welding system FIGURE A 1 POWER WAVE 405 LINCOLN Simple System Power Wave 405 INSTALLATION SYSTEM SET UP Basic Rules Each group is required to have one user interface No group may have more than one user interface Each group can have up to seven Feed Heads Exception Group 3 is limited to a maximum of six Feed Heads Each system has only one power source For net work purposes the PS belongs to Group 3 which is why group 3 is only allowed 6 feed heads in addition it s user interface No two feed heads can have identical Group and Feed Head numbers Group and Feed Head ID numbers must be set on the appropriate dipswitches at each node Consult the appropiate Power Feed Wire Feeder Instruction Manual for specific details regarding dipswitch set tings Feed head 0 not allowed Exception Simple sys tem ignores all ID numbers therefore FHO will function Each node must be connected to the Linc Net com munication network The order of connection is not important as each node is identified by it s unique Group and Feed Head ID number as defined on it s dipswitches See Figures A 2 thru A 5 FIGURE A 2 POWER WAVE 405 LINCOLN Group and Feed Head ID numbers are ignored in a simple system A 7 INSTALLATION A 7 Multiple Group System FIGURE A 3 No FHO Alllowed Power Wave
56. nated 2 a Electric current flowing through any conductor causes 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 1 d Keep all equipment 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 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 1 e In some cases it may be necessary to remove safety nes 5 minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode
57. nnel 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 SY MP 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 F acility If you do not understand are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service F acility A 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 405 LINCOLN 5
58. not operate with panel open 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 com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE 805 gt 607 e 8 09 17 8 BUS gt SHAE Ro 9 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai dul jua Sarin os Qui BALL cal sd ue Aie pha J jui gail e Ads cuts il gall l Jai y e Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CL TRHORERMEI HS TFE Uo 85 ET BE SUCR Rr de OE D EL ES AMENER 0 FAIS ele EFSA BEHE ET gl illai Gud al ply Gail guet A LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL
59. ot to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health 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 below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data s
60. quire additional protection measures the time of day that welding or other activities are to be carried out L10093 POWER WAVE 405 LINCOLN 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 recommendations 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 equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding 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 equipment 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 parti
61. quire 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 All welding programs and procedures are selected through the Power Feed semi automatic user inter face REQUIRED EQUIPMENT Any Linc Net compatible semi automatic wire feeding equipment Specifically the semi automatic Power Feed family PF 10 PF 10M Single and Dual Wire Feeder PF 11 and PF 15 LIMITATIONS Only Linc Net compatible Power Feed semi auto matic wire feeders and users interfaces may be used Other Lincoln wire feeders or non Lincoln wire feeders cannot be used POWER WAVE 405 Output Limitations The POWER WAVE 405 will support maximum aver age 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 and 4 minutes of idling in a ten minute period CASE FRONT CONTROLS 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 table B 1 NOTE The POWER WAVE 405 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
62. r 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 parce 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 assu
63. rer 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 irritants 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 POUR 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 TRANSFORMATEUR Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR
64. se 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 of the electrode to the ground clamp Enable the work voltage sensing in the Power Wave as fol lows A WARNING Do not touch electrically live parts electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves 1 Turn off power to the power source at the discon nect switch 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 a pencil or other small object slide the switch to the OFF position if the work sense lead is NOT connected Conversely slide the switch to the ON position if the work sense lead is present 123 45 67 8 A 5 Replace the wrap around and screws The board will read the switch at power up and config ure the work voltage sense lead appropriately 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
65. ses this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructing 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 competent to assess 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 problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transmitters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may re
66. ve 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 l 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 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 If condition persists turn power off and contact an autho rized Lincoln Electric Field Service facility This problem will normally be
67. veform 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 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 0 0 Wave Control 10 0 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 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 typ
68. ver 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page eee E Section A 31 0 513 Technical Specifications POWER WAVE 405 A 1 A 2 Safety Precautions Select Suitable Location ue e A 2 SLACKING sees sain A 2 UE A 2 Input and Grounding A 2 Power Cord ed ea nu aun A 2

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