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P E A V E 4 0 5
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WARNING
PRECAUCION
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 Gasoline Engines The Above For Diesel Engines ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v SAFETY Electromagnetic Compatibility (EMC) 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 E
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vi vi SAFETY 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 filter
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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 L
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viii viii TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location .................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 405M INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD 50/60 Hz (continuous) 350A / 34V / 60% 14.7”x12.5”x Power 200-220/ 3 Phase 27.8”* Wave K 2369-1 380-400/ 320A / 33V / 60% AMPS 86.5lbs (373x318x 405M 415 1 Phase 5-425 (37.4 kg) 706*)mm
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A-3 A-3 INSTALLATION OUTPUT CAbLES, CONNECTIONS AND Output connections on some Power Waves are made LIMITATIONS via 1/2-13 threaded output studs located beneath the Connect a work lead of sufficient size and length (per spring loaded output cover at the bottom of the case table A.1) between the proper output terminal on the front. power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. Most welding applications run with the electrode being
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A-4 A-4 INSTALLATION ELECTRODE VOLTAGE SENSING VOLTAGE SENSING The best arc performance occurs when the Power Enabling or disabling electrode voltage sensing is Waves have accurate data about the arc conditions. automatically configured through software. The 67 Depending upon the process, inductance within the electrode sense lead is internal to the cable to the electrode and work lead cables can influence the volt- wire feeder and always connected when a wire feeder age apparent at the studs
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A-5 A-5 INSTALLATION CONFIGURING THE SYSTEM If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the The power source will “Auto Map” the system eliminat- welder output will be disabled. If a system is not ing most of the need to set DIP switches to configure “Auto-mappable”, then consult the instruction manual the system. for the accessory being used for configuration infor- mation about DIP switch settings, or consult your local If a sys
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A-6 A-6 INSTALLATION 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 PF-10R WIRE DRIVE MODULE DUAL HEAD (FH1) System that is NOT "Auto Mappable" DUAL HEAD bOOM FEEDER (using two single heads) POWER WAVE 405M DUAL HEAD FH-1 FH-2 In this case the individual feed heads need to be a
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A-7 A-7 INSTALLATION WELDING WITH MULTIPLE POWER CONTROL CAbLE SPECIFICATIONS It is recommended that genuine Lincoln control cables WAVES be used at all times. Lincoln cables are specifically designed for the communication and power needs of CAUTION the Power Wave / Power Feed system. Special care must be taken when more than one CAUTION Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or The use of non-standard cables, especially in be magnified
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A-8 A-8 INSTALLATION MULTIPLE ARC UNSYNCHRONIzED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 405M
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A-9 A-9 INSTALLATION I / O RECEPTACLE SPECIFICATIONS switch 7 auto mapping TAbLE A.2 off auto mapping enable-default WIRE FEEDER RECEPTACLE on auto mapping disabled PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense switch 8* work sense lead D 52 0vdc - off work sense lead not connected 40VDC } E 51 +40vdc + on work sense lead connected *Factory setting for Switch 8 is OFF. TAbLE A.3 VOLTAGE SENSE R
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b-1 b-1 OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION The Power Wave 405M semi-automatic power source Read this entire section of operating instructions is designed to be a part of a modular, multi-process before operating the machine. welding system. Depending on configuration, it can support constant current, constant voltage, and pulse WARNING welding modes. ELECTRIC SHOCK can kill. The Power Wave 405M power source is designed to • Unless using cold feed feature, when be used with the sem
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b-2 b-2 OPERATION POWER WAVE 405M – Semi-Automatic Operation 3. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temper- Power Wave 405M can only be used with ArcLink ature situation occurs. Output is disabled and the compatible Power Feed M semi-automatic wire feed- fan continues to run, until the machine cools down. ers. In addition, the Power Feed M semi-automatic When cool, the light goes out and output is wire feeders may require optional equipment to en
