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Lincoln Electric POWER WAVE 405 IM746 - page 1
PO WER W A VE 405 OPERA TOR’S MANUAL For use with machines Code 10896 IM746 August, 2004 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 2
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________ ...
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Lincoln Electric POWER WAVE 405 IM746 - page 3
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin ...
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Lincoln Electric POWER WAVE 405 IM746 - page 4
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric POWER WAVE 405 IM746 - page 5
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ? ...
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Lincoln Electric POWER WAVE 405 IM746 - page 6
POWER WAVE 405 v SAFETY v L10093 3-1-96H Conf ormance standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc W elding Equipment. It All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be received b y other equipment, electr ical interference ma y result. Electr ical emissio ...
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Lincoln Electric POWER WAVE 405 IM746 - page 7
POWER WAVE 405 vi SAFETY vi L10093 3-1-96H The size of the surrounding area to be considered will depend on the structure of the building and other activities Methods of Reducing Emissions Consideration should be giv en to shielding the supply cable of per manently installed welding equipment, in metallic conduit or equivalent. Shielding should be ...
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Lincoln Electric POWER WAVE 405 IM746 - page 8
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. ...
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Lincoln Electric POWER WAVE 405 IM746 - page 9
viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 405 ....................................................A-1 Safety Precautions.......................................................................... ...
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Lincoln Electric POWER WAVE 405 IM746 - page 10
A-1 INST ALLA TION POWER WAVE 405 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 405 INPUT AC VOL T AGE & DC OUTPUT OUTPUT CABLES, CONNECTIONS AND LIMIT A TIONS 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 11
A-2 INST ALLA TION POWER WAVE 405 A-2 SELECT SUIT ABLE LOCA TION 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. • The machine must be located where there is free cir- culation of clean air such that air m ...
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Lincoln Electric POWER WAVE 405 IM746 - page 12
NEGA TIVE 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 13
5 . Replace the wrap around and screws. The PC 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 14
A-5 INST ALLA TION POWER WAVE 405 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 ...
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A-6 INST ALLA TION POWER WAVE 405 A-6 FIGURE A.2 Simple System 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 16
A-7 INST ALLA TION POWER WAVE 405 A-7 FIGURE A.3 Multiple Group System No “ FH0 ” Alllowed! FIGURE A.4 Single Group Multi-Head System No “ FH0 ” Alllowed! The Dual Head option allows the abil- ity to maintain 2 sets of procedures. If more then 2 heads are used, odd # ’ s use FH1 settings, even # ’ s use FH2 settings. 405 405 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 17
A-8 INST ALLA TION POWER WAVE 405 A-8 FIGURE A.5 Single Group Multi-Head System (Alternate Method) No “ FH0 ” Alllowed! When a standard User Iterface is used in a group with multi- ple Feed Heads, all of the Feed Heads use a single set of procedures. 405 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 18
A-9 INST ALLA TION POWER WAVE 405 A-9 WELDING WITH MUL TIPLE POWER W A VES 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 lead ...
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Lincoln Electric POWER WAVE 405 IM746 - page 19
A-10 INST ALLA TION POWER WAVE 405 A-10 I / O RECEPT ACLE SPECIFICA TIONS TABLE A.2 WIRE FEEDER RECEPTACLE PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc E 51 +40vdc TABLE A.3 VOLTAGE SENSE RECEPTACLE PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE A.4 RS232 RECEPTACLE PIN LEAD# FUNCTI ...
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Lincoln Electric POWER WAVE 405 IM746 - page 20
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 wir ...
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Lincoln Electric POWER WAVE 405 IM746 - page 21
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 require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non- Lincoln ...
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Lincoln Electric POWER WAVE 405 IM746 - page 22
The steps for operating the Power Wave will vary depending upon the options installed in the user inter- face (control box) of the welding system. The flexibility of the Power Wave system lets the user customize operation for the best performance. First, consider the desired welding process and the part to be welded. Choose an electrode material, d ...
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Lincoln Electric POWER WAVE 405 IM746 - page 23
CONST ANT VOL T AGE WELDING Synergic CV : For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The nominal preprogrammed volt- age is the average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, the Power Wave automati- ...
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Lincoln Electric POWER WAVE 405 IM746 - page 24
B-5 OPERA TION 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 25
B-6 OPERA TION B-6 POWER WAVE 405 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 w ...
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Lincoln Electric POWER WAVE 405 IM746 - page 26
B-7 OPERA TION B-7 POWER WAVE 405 POWER MODE ™ The Power Mode ™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellent control and the ability to maintain constant arc length. This results ...
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Lincoln Electric POWER WAVE 405 IM746 - page 27
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 28
D-1 MAINTENANCE D-1 POWER WAVE 405 SAFETY PRECAUTIONS CAP ACITOR 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 cap ...
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Lincoln Electric POWER WAVE 405 IM746 - page 29
E-1 TROUBLESHOOTING E-1 POWER WAVE 405 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair p ...
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Lincoln Electric POWER WAVE 405 IM746 - page 30
E-2 TROUBLESHOOTING E-2 POWER WAVE 405 USING THE ST A TUS 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 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 31
E-3 TROUBLESHOOTING E-3 POWER WAVE 405 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ERROR CO ...
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Lincoln Electric POWER WAVE 405 IM746 - page 32
E-4 TROUBLESHOOTING E-4 POWER WAVE 405 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln ...
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Lincoln Electric POWER WAVE 405 IM746 - page 33
E-5 TROUBLESHOOTING E-5 POWER WAVE 405 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln ...
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Lincoln Electric POWER WAVE 405 IM746 - page 34
E-6 TROUBLESHOOTING E-6 POWER WAVE 405 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln ...
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Lincoln Electric POWER WAVE 405 IM746 - page 35
E-7 TROUBLESHOOTING E-7 POWER WAVE 405 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS ...
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Lincoln Electric POWER WAVE 405 IM746 - page 36
F-1 DIAGRAMS F-1 POWER WAVE 405 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numb ...
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Lincoln Electric POWER WAVE 405 IM746 - page 37
F-2 CONNECTION DIAGRAM F-2 POWER WAVE 405 Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK Power Feed Family ...
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Lincoln Electric POWER WAVE 405 IM746 - page 38
F-3 DIMENSION PRINT F-3 POWER WAVE 405 1 4.7 9 1 2.4 4 3.44 21.60 27.82 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 13.1 0 1/4- 20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 10/01 N NOT PROTR UDE MORE THAN 0.5 IN CHES INSIDE THE MACHINE. 11.8 4 3.50 ...
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Lincoln Electric POWER WAVE 405 IM746 - page 39
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E ...
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Lincoln Electric POWER WAVE 405 IM746 - page 40
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes ...
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Lincoln Electric POWER WAVE 405 IM746 - page 41
• 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 • ...
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