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! WARNING ! ATTENTION
AVISO DE
! 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 Diesel Engines The Above For Gasoline 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 SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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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 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use
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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 recommendations. If interference occurs, it may be necessary to take additional precau
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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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipm
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viii viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 405 ....................................................A-1 Safety Precautions.................................................................................................A-2 Select Suitable Location ........................................................................................A-2 Stackin
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE 405 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 2152-2 380-400/ 320A / 33V / 60% AMPS 86.5lbs (373x318x 405 415 1 Phase 5-425 (37.4 kg) 706*)mm 60/50 Hz 275A /
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l li ! WARNING ! ATTENTION ! WARNING ! AVISO DE e e L Ltto ,,llor e iiee e d d rm m d d ia a p pm m iiis s u u n n m m o o d d n nu u o olo m m om m l s r rsy y tit n n a a ib ib m m h h ie ee e tt u uc c o on is n s m m i s s o e ec od dc te t e t tn n ttu uiie e c c id d u u a a ir rn n d dtt p p u ut tiiis siin c cng g i e e L L t, e to ,ore ll iieeP d d rm m d d ia a p ipm m iis s u um n RE n m o on d d nu u ool m m o or s m m l rsy y t n it n a a ib b m m h h iie e eCA e tt u uc c o
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A-3 A-3 INSTALLATION OUTPUT CABLES, CONNECTIONS AND NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required, such as LIMITATIONS in some Innershield applications, reverse the output Connect a work lead of sufficient size and length connections at the power source (electrode cable to between the proper output terminal on the power the negative (-) Twist-Mate terminal, and work cable source and the work. Be sure the connection to the to the positive (+) Twist-Mate terminal. wo
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A-4 A-4 INSTALLATION Enable the voltage sense leads as follows: 5. Replace the wrap around and screws. The PC TABLE A.1 board will “read” the switch at power up, and config- Process Electrode Voltage Work Voltage ure the work voltage sense lead appropriately. Sensing 67 lead * Sensing 21 lead GMAW 67 lead required 21 lead optional ELECTRODE VOLTAGE SENSING GMAW-P 67 lead required 21 lead optional Enabling or disabling electrode voltage sensing is FCAW 67 lead required 21 lead optional automa
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A-5 A-5 INSTALLATION From a network perspective, each component in the SYSTEM DESCRIPTION system is considered a separate node, regardless of its physical location. For example, even though a UI The POWER WAVE 405 and Power Feed family of and FH may be physically mounted together, they are products utilize a digital communication system called still viewed as separate pieces (nodes) by the net- Linc-Net. Simply put, Linc-Net allows large amounts of work, and can only communicate via Linc-Net.
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A-6 A-6 INSTALLATION 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 net- work purposes, the PS belongs to Group 3, which is why group 3 is only allowed 6 feed heads in addition it’s user interface. � No two feed heads can have identical Group and Feed Head numbers
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A-7 A-7 INSTALLATION Multiple Group System FIGURE A.3 No “FH0” Alllowed! 405 Single Group Multi-Head System FIGURE A.4 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 POWER WAVE 405
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A-8 A-8 INSTALLATION Single Group Multi-Head System (Alternate Method) No “FH0” Alllowed! FIGURE A.5 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 POWER WAVE 405
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A-9 A-9 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 Power Wave is welding simultaneously on a single CAUTION part. Arc blow and arc interference may occur or The use of non-standard cables, especially in be magnified
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A-10 A-10 INSTALLATION CONTROL BOARD DIP SWITCH: I / O RECEPTACLE SPECIFICATIONS switch 1 = reserved for future use TABLE A.2 switch 2 = reserved for future use WIRE FEEDER RECEPTACLE switch 3 = reserved for future use PIN LEAD# FUNCTION switch 4 = reserved for future use A 53 Communication Bus L switch 5 = reserved for future use B 54 Communication Bus H switch 6 = reserved for future use C 67A Electrode Voltage Sense switch 7 = reserved for future use D 52 0vdc switch 8* = work sense lead
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B-1 B-1 OPERATION SAFETY PRECUATIONS GENERAL DESCRIPTION The Power Wave semi-automatic power source is Read this entire section of operating instructions 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, constant WARNING power and pulse welding modes. ELECTRIC SHOCK can kill. The Power Wave power source is designed to be • Unless using cold feed feature, when used with th
