Gebruiksaanwijzing /service van het product POWER WAVE 405 IM746 van de fabrikant Lincoln Electric
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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 .
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.
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.
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.
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.
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.
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.
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.
viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 405 .................................................
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 W.
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.
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.
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.
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Als u nog geen Lincoln Electric POWER WAVE 405 IM746 heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Lincoln Electric POWER WAVE 405 IM746 vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Lincoln Electric POWER WAVE 405 IM746 leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Lincoln Electric POWER WAVE 405 IM746 krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
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