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Lincoln Electric 405M User Manual

Browse online or download User Manual for Welding System Lincoln Electric 405M. Lincoln Electric 405M User's Manual

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POWER WAVE
®
405M
OPERATOR’S MANUAL
For use with machines Code 11379, 11491
IM917-A
June, 2009
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.
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• 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
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
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1 2 3 4 5 6 ... 43 44

Summary of Contents

Page 1 - POWER WAVE

POWER WAVE®405MOPERATOR’S MANUALFor use with machines Code 11379, 11491IM917-AJune, 2009Safety Depends on YouLincoln arc welding and cuttingequipment

Page 2 - MAGNETIC FIELDS

A-1INSTALLATIONPOWER WAVE® 405MA-1TECHNICAL SPECIFICATIONS -POWER WAVE® 405MINPUT AC VOLTAGE & DC OUTPUTOUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Page 3 - FUMES AND GASES

A-2INSTALLATION POWER WAVE® 405MA-2SELECT SUITABLE LOCATIONThe Invertec POWER WAVE® 405M will operate inharsh environments. Even so, it is importan

Page 4

Output connections on some POWER WAVE®s aremade via 1/2-13 threaded output studs locatedbeneath the spring loaded output cover at the bottomof th

Page 5 - REDRESSEUR

A-4INSTALLATION POWER WAVE® 405MA-4VOLTAGE SENSINGThe best arc performance occurs when thePowerWaves have accurate data about the arc condi-ti

Page 6 - L10093 3-1-96H

A-5INSTALLATION POWER WAVE® 405MA-5POWER WAVE® TO SEMI-AUTOMATICPOWER FEED WIRE FEEDER INTERCON-NECTIONS The POWER WAVE® 405M and semi-automaticPo

Page 7

A-6INSTALLATION POWER WAVE® 405MA-6CONFIGURING THE SYSTEMThe power source will “Auto Map” the system eliminat-ing most of the need to set DIP switch

Page 8 - Thank You

A-7INSTALLATION POWER WAVE® 405MA-7In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE®405M auto

Page 9 - TABLE OF CONTENTS

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for

Page 10 - INSTALLATION

A-9INSTALLATION POWER WAVE® 405MA-9 MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

Page 11

A-10INSTALLATION POWER WAVE® 405MA-10I / O RECEPTACLE SPECIFICATIONSTABLE A.2WIRE FEEDER RECEPTACLE PIN LEAD# FUNCTIONA 53 Communication Bus LB 54

Page 12

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

Page 13

GENERAL DESCRIPTIONThe POWER WAVE® 405M semi-automatic powersource is designed to be a part of a modular, multi-process welding system. Depending

Page 14

POWER WAVE® 405M – Semi-AutomaticOperationPOWER WAVE® 405M can only be used withArcLink compatible Power Feed M semi-automaticwire feeders.

Page 15

WELDING ADJUSTMENTSAll adjustments are made on the system componentknown as the User Interface (Control Box), which con-tains the switches, knobs, an

Page 16 - POWER WAVE® 405M

Non Synergic CV:This type of CV mode behaves more like a conven-tional CV power source. Voltage and WFS are inde-pendent adjustments. Therefore to

Page 17

B-5OPERATIONB-5PULSE WELDINGPulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc

Page 18

B-6OPERATIONB-6BENEFITS OF PULSE ON PULSE FROMLINCOLN ELECTRIC• Excellent appearance of the weld bead• Improved cleaning action• Reduced porosityTable

Page 19

B-7OPERATIONB-7POWER WAVE® 405MPOWER MODE™The Power Mode™ process was developed byLincoln to maintain a stable and smooth arc at lowprocedure set

Page 20 - OPERATION

C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDNone Available.FIELD INSTALLED K940-Work Voltage Sense Lead KitK1764-1-Undercarriage*K1838-1-Valet

Page 21

D-1MAINTENANCED-1POWER WAVE® 405MSAFETY PRECAUTIONSCAPACITOR DISCHARGE PROCEDURE1. Obtain a power resistor (25 ohms, 25 watts).2. Hold resistor body w

Page 22

E-1TROUBLESHOOTINGE-1POWER WAVE® 405MIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, co

Page 23

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

Page 24

E-2TROUBLESHOOTINGE-2POWER WAVE® 405MUSING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe POWER WAVE® / Power Feed are best diag-nosed as a system

Page 25

E-3TROUBLESHOOTINGE-3POWER WAVE® 405MObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

Page 26

E-4TROUBLESHOOTINGE-4POWER WAVE® 405MObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

Page 27 - ACCESSORIES

E-5TROUBLESHOOTINGE-5POWER WAVE® 405MObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

Page 28 - MAINTENANCE

E-6TROUBLESHOOTINGE-6POWER WAVE® 405MObserve all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

Page 29 - TROUBLESHOOTING

E-7TROUBLESHOOTINGE-7POWER WAVE® 405MObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

Page 30

F-1WIRING DIAGRAMSF-1POWER WAVE® 405MNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

Page 31

F-2DIAGRAMSF-2POWER WAVE® 405MNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif

Page 32

F-3CONNECTION DIAGRAMF-3POWER WAVE® 405MConnection Diagram Semi-automatic "Simple System"(Electrode Positive, CV/Pulse Configuration shown)

Page 33

F-4DIMENSION PRINTF-4POWER WAVE® 405M14.7912.443.4421.6027.825.5010.00MOUNTING HOLE LOCATIONSM1952713.101/4-20 NUT (4 PLACES)NOTE: MOUNTING SCREWS CA

Page 34

iiiSAFETYiiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.

Page 35

NOTES POWER WAVE® 405M

Page 36 - WIRING DIAGRAMS

NOTES POWER WAVE® 405M

Page 37 - DIAGRAMS

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

Page 38 - CONNECTION DIAGRAM

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

Page 39 - DIMENSION PRINT

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

Page 40 - NOTES

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques q

Page 41

vSAFETYvElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3

Page 42

viSAFETYviElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building and othera

Page 43

viiviiThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

Page 44

viiiviiiTABLE OF CONTENTSPageInstallation ..........................Secti

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