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Lincoln Electric POWER WAVE IM846-A - page 1
PO WER W A VE 405M &') + &)W*$%,# For use with machines Code 11142, 11490 $ December, 2010 *387FK7B7@6EA@0AG Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on ...
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Lincoln Electric POWER WAVE IM846-A - page 2
; *+0 ; &)% % BAI7D767CG;B?7@F 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 IM846-A - page 3
;; *+0 ;; ARC R A Y S can b urn. 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 ...
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Lincoln Electric POWER WAVE IM846-A - page 4
;;; *+0 ;;; FOR ELECTRIC ALL Y pow er ed 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 ...
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Lincoln Electric POWER WAVE IM846-A - page 5
;H *+0 ;H ')M,+ &%**U)+M 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: *OD7FN'AGD*AG6397#WD5 1. Protegez-vous contre la ...
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Lincoln Electric POWER WAVE IM846-A - page 6
H *+0 H 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 impl ...
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Lincoln Electric POWER WAVE IM846-A - page 7
H; *+0 H; 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 t ...
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Lincoln Electric POWER WAVE IM846-A - page 8
H;; H;; T h a n k Y o u for selecting a (,# +0 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! )736F:;E&B7D3FADE $3@G3>5A?B>7F7>K before attempting to use this equipment. Save this manual and keep ...
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Lincoln Electric POWER WAVE IM846-A - page 9
H;;; H;;; + #&&%+%+* Page @EF3>>3F;A@ ? ...
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Lincoln Electric POWER WAVE IM846-A - page 10
%*+ ## + &% '&.).-$ +% # *' + &%* '&.). -$ %',+ -&# + &,+',+ &,+',+#*&%%+ &%* %? ...
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Lincoln Electric POWER WAVE IM846-A - page 11
%*+ ## + &% '&.).-$ *#+*, + ##& + &% The Invertec POWER WAVE 405M will operate in harsh environments. Even so, it is important that sim- ple preventative measures are followed in order to assure long life and reliable operation. • The mac ...
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Lincoln Electric POWER WAVE IM846-A - page 12
Output connections on some Power Waves are made via 1/2-13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front. Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode cable between the wire feeder and the positive (+) output Twist-Mate ter ...
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Lincoln Electric POWER WAVE IM846-A - page 13
%*+ ## + &% '&.).-$ -&# + *%* % T he b es t a rc p er fo r ma nc e o c cu rs w he n t h e P ow e r Waves have accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the volt- a ...
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Lincoln Electric POWER WAVE IM846-A - page 14
%*+ ## + &% '&.).-$ &% ,) %+*0*+$ The power source will “Auto Map” the system eliminat- ing most of the need to set DIP switches to configure the system. If a system can not be “Auto Mapped” then the status light on the power source will ...
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Lincoln Electric POWER WAVE IM846-A - page 15
%*+ ## + &% '&.).-$ In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE 405M auto mapping disabled and the Equipment Groups set on (See Figure A-8). (See the Feeder documentation for information on setting the feeder DIP switch ...
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Lincoln Electric POWER WAVE IM846-A - page 16
&%+)&# #*' + &%* 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. +:7 GE7 A8 @A@EF3@63D6 534>7E 7EB75;3>>K ;@ >7@9 ...
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Lincoln Electric POWER WAVE IM846-A - page 17
%*+ ## + &% '&.).-$ $,# + '# ),%*0%)&% 1 *%*# %.&)"#'#$%+, # %* ...
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Lincoln Electric POWER WAVE IM846-A - page 18
%*+ ## + &% '&.).-$ &)'+ #*' + &%* +# . )))'+# ' % # ,%+ &% A 53 Communication Bus L B 54 Communication Bu ...
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Lincoln Electric POWER WAVE IM846-A - page 19
%)# *) '+ &% The Power Wave 405M semi-automatic power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, and pulse welding modes. The Power Wave 405M power source is designed to be used with the semi automatic fam ...
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Lincoln Electric POWER WAVE IM846-A - page 20
'&.).-$S*7?;GFA?3F;5&B7D3F;A@ Power Wave 405M can only be used with D5#;@= 5A?B3F;4>7'AI7D 776$ semi-automatic wire feed- ers. In addition, the Power Feed M semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other model ...
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Lincoln Electric POWER WAVE IM846-A - page 21
.# % !,*+$%+* All adjustments are made on the system component known as the User Interface (Control Box), which con- tains the switches, knobs, and digital displays neces- sary to control both the Power Wave and a Power Feed wire feeder. Typically, the Control Box is sup- plied as part of the wire feeder. It can be mounted dire ...
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Lincoln Electric POWER WAVE IM846-A - page 22
%A@*K@7D9;5- This type of CV mode behaves more like a conven- tional CV power source. Voltage and WFS are inde- pendent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. >>-$A67E Arc Control, often referred to as wave contr ...
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Lincoln Electric POWER WAVE IM846-A - page 23
&') + &% ',#*.# % 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 a nd pul se fre quency a ll aff ect th e volt ...
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Lincoln Electric POWER WAVE IM846-A - page 24
&') + &% % +* & ',#* &% ',#* )&$ # %&#%#+) • 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 ...
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Lincoln Electric POWER WAVE IM846-A - page 25
&') + &% '&.).-$ '&.)$&Q The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellen ...
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Lincoln Electric POWER WAVE IM846-A - page 26
**&) * &'+ &%# (, '$%+ + &) 0 %*+ ## None Available. # %*+ ## 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 ...
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Lincoln Electric POWER WAVE IM846-A - page 27
$ %+%% '&.).-$ *+0 '),+ &%* ' +&) *)')&,) 1. Obtain a power resistor (25 ohms, 25 watts). 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect ...
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Lincoln Electric POWER WAVE IM846-A - page 28
+)&,#*&&+ % '&.).-$ If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your #A53>#;@5A>@GF:AD;L76;7>6*7DH;5735;>;FK for technical troubleshooting assistance before yo ...
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Lincoln Electric POWER WAVE IM846-A - page 29
+)&,#*&&+ % '&.).-$ ,* %+*+ +,*#+& +)&,#*&&+*0*+$')&#$* The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status l ...
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Lincoln Electric POWER WAVE IM846-A - page 30
+)&,#*&&+ % '&.).-$ 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 #A53>#;@5A>@GF:AD;L76;7>6*7DH;57? ...
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Lincoln Electric POWER WAVE IM846-A - page 31
+)&,#*&&+ % '&.).-$ Observe all Safety Guidelines detailed throughout this manual +)&,#*&&+ %, Observe Safety Guidelines detailed in the beginning of this manual. ,+ &% If for any reason you do not understand the test procedur ...
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Lincoln Electric POWER WAVE IM846-A - page 32
+)&,#*&&+ % '&.).-$ Observe all Safety Guidelines detailed throughout this manual +)&,#*&&+ %, Observe Safety Guidelines detailed in the beginning of this manual. ,+ &% If for any reason you do not understand the test procedur ...
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Lincoln Electric POWER WAVE IM846-A - page 33
+)&,#*&&+ % '&.).-$ Observe all Safety Guidelines detailed throughout this manual +)&,#*&&+ %, Observe Safety Guidelines detailed in the beginning of this manual. ,+ &% If for any reason you do not understand the test procedur ...
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Lincoln Electric POWER WAVE IM846-A - page 34
+)&,#*&&+ % '&.).-$ 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 #A53>#;@5A>@GF:AD;L76;7>6*7DH;57? ...
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Lincoln Electric POWER WAVE IM846-A - page 35
. ) % )$* '&.).-$ %&+ 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 S ...
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Lincoln Electric POWER WAVE IM846-A - page 36
)$* '&.).-$ %&+ 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 Depa ...
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Lincoln Electric POWER WAVE IM846-A - page 37
&%%+ &% )$ '&.).-$ A@@75F;A@;39D3?*7?;3GFA?3F;5*;?B>7*KEF7? (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK ...
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Lincoln Electric POWER WAVE IM846-A - page 38
$%* &%') %+ '&.).-$ 1 4.7 9 1 2.44 3.44 21.60 27.82 5.50 10.0 10.0 0 0 MOUNTING HOLE LOCATIONS M19527 13.1 0 1/4- 1/4- 20 NUT (4 PLACES) NOTE: MOUNTING SCREWS CA 10/01 10/01 N NOT PROTR UDE MORE THAN 0.5 IN 0.5 IN CHES INSIDE THE MACHINE. CHES INSIDE THE MACHINE. 11.8 4 3.50 1 ...
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Lincoln Electric POWER WAVE IM846-A - page 39
%&+* '&.).-$ ...
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Lincoln Electric POWER WAVE IM846-A - page 40
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERS T AND THE MANUF ACTURER’S INS TRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PR ACTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC ...
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Lincoln Electric POWER WAVE IM846-A - page 41
W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTRUÇÕES DO F ABRIC ANTE P ARA ESTE EQ UIP AMENT O E AS P ARTES DE USO , E SIGA A S PRÁ TICA S DE SEGUR ANÇ A DO EMPREGADOR. • Kee p your head out of fume s. • Use venti lation or ex haust ...
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Lincoln Electric POWER WAVE IM846-A - page 42
• 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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