Lincoln Electric POWER WAVE 355M, POWER WAVE 405M User Manual

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SVM181-A

January, 2008

POWER WAVE 355M/405M

For use with machine code numbers 11141, 11142

 

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!

 

 

 

 

 

 

 

!

AT

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P

RAVIS

 

 

Safety Depends on You

 

 

 

TE

ON

 

 

 

 

E O

 

 

 

 

 

 

TI

 

 

 

 

 

CA D

 

ON

 

 

 

 

 

U

E

 

 

 

 

 

 

CI

 

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 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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SERVICE MANUAL

Copyright © Lincoln Global Inc.

World's Leader in Welding and Cutting Products •

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

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95

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i

 

 

 

 

 

 

SAFETY

 

 

 

 

 

 

 

i

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 OR DEATH.

 

 

 

 

 

 

 

 

 

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

 

 

 

 

 

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-

 

 

 

chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,

 

 

 

Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the

 

 

 

Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

 

 

 

 

 

 

 

 

 

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

 

 

 

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FOR ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.h. To avoid scalding, do

not remove the

 

 

 

 

 

 

 

 

 

powered equipment.

 

 

 

 

 

 

 

 

 

 

 

 

radiator pressure cap when the engine is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

hot.

 

 

 

 

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC AND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAGNETIC FIELDS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

____________________________________________________

 

 

 

 

 

 

 

 

 

 

 

 

may be dangerous

 

 

 

 

 

 

 

 

 

 

 

1.c. Do not add the fuel near an open flame weld-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ing arc or when the engine is running. Stop

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the engine and allow it to cool before refuel-

2.a. Electric

current

flowing through

any

conductor causes

 

 

 

 

 

 

 

 

 

ing to prevent spilled fuel from vaporizing on

 

 

 

 

 

localized

Electric

and

Magnetic

Fields (EMF). Welding

 

 

 

 

 

 

 

 

 

contact with hot engine parts and igniting. Do

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

current creates EMF

fields around welding cables

and

 

 

 

 

 

 

 

 

 

not spill fuel when filling tank. If fuel is spilled,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

welding machines

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

wipe it up and do not start engine until fumes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

have been eliminated.

2.b. EMF fields may

interfere with

some

pacemakers,

and

 

 

 

____________________________________________________

 

 

 

 

 

 

 

 

 

 

welders having a pacemaker should consult their physician

 

 

 

1.d. Keep all equipment safety guards, covers and devices in posi-

 

 

 

 

 

 

 

 

 

 

 

 

 

before welding.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tion and in good repair.Keep hands, hair, clothing and tools

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

away from V-belts, gears, fans and all other moving parts

2.c. Exposure to EMF fields in welding may have other health

 

 

 

 

 

 

 

 

 

when starting, operating or repairing equipment.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

effects which are now not known.

 

 

 

 

 

 

 

____________________________________________________

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while

the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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ii

 

 

 

 

 

SAFETY

 

 

 

 

 

 

 

 

ii

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

ARC RAYS can burn.

 

 

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

 

 

the rays of the arc when welding or observing

 

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

 

 

open arc welding. Headshield and filter lens

 

 

gloves to insulate hands.

 

 

 

 

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

 

Make certain the insulation is large enough to cover your full

 

 

 

 

material to protect your skin and that of your helpers from

 

area of physical contact with work and ground.

 

 

 

 

the arc rays.

 

 

 

 

 

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

 

must be performed under electrically hazardous

 

 

 

 

screening and/or warn them not to watch the arc nor expose

 

conditions (in damp locations or while wearing wet

 

 

 

 

themselves to the arc rays or to hot spatter or metal.

 

 

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

can be dangerous.

 

 

 

the following equipment:

 

 

 

 

 

 

 

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

 

 

5.a. Welding

may

produce

fumes

and

gases

 

• DC Manual (Stick) Welder.

 

 

 

 

 

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

welding

with

ventilation and/or exhaust at the arc to ke p

 

welding gun are also electrically “hot”.

 

 

 

 

 

 

electrodes

which

require special

 

electrode

reel,

welding head,

nozzle

or

semiautomatic

 

 

 

 

fumes and gases away from the breathing zone.

When

 

 

 

 

 

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

3.d. Always be

sure

the work cable

makes

a

good electrical

 

 

 

 

instructions on container or MSDS) or on lead or

 

connection with the metal being welded. The connection

 

 

 

 

cadmium plated steel and other metals or coatings

 

should be as close as possible to the area being welded.

 

 

 

 

which produce highly toxic fumes, keep exposure as

 

 

 

 

 

 

 

 

 

 

 

low as possible and below Threshold Limit Values (TLV)

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

 

using local exhaust or mechanical ventilation. In

 

(earth) ground.

 

 

 

 

 

 

 

 

confined spaces or in some circumstances, outdoors, a

 

 

 

 

 

 

 

 

 

 

 

respirator may be required. Additional precautions are

3.f.

Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

also

required

when

welding

on

galvanized

steel.

 

welding machine in good, safe operating condition. Replace

 

5. b. The operation of welding fume control equipment is affected

 

damaged insulation.

 

 

 

 

 

 

 

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

 

 

 

 

 

 

3.g. Never dip the electrode in water for cooling.

 

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

 

welding

procedure

and

 

application

involved.

 

 

 

 

 

 

 

 

 

 

 

 

3.h. Never simultaneously touch electrically

“hot” parts of

 

 

 

 

Worker exposure level should be checked upon installation

 

 

 

 

and periodically thereafter to be certain it is within applicable

 

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

 

OSHA PEL and ACGIH TLV limits.

 

 

 

 

 

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of both welders.

 

 

 

 

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

 

 

 

 

 

3.i. When working above floor level, use a safety belt to protect

 

 

 

 

coming

from degreasing, cleaning

or spraying

operations.

 

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

 

 

 

 

 

 

3.j.

Also see Items 6.c. and 8.

 

 

 

 

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

 

 

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

 

 

 

 

 

your

welding

distributor or

from

the manufacturer.

 

 

 

 

 

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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iii

WELDING SPARKS can SAFETY

CYLINDER may explode iii

 

cause fire or explosion.

 

 

if damaged.

 

 

 

 

 

6.a. Remove fire hazards from the welding area.

 

 

 

gas

cylinders

 

If this is not possible, cover them to prevent

 

7.a. Use only

compressed

 

 

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 hoses, fittings, etc. should be suitable for

and openings to

adjacent

areas. Avoid welding near

the application and maintained in good condition.

 

hydraulic

lines. Have a fire

extinguisher readily available.

 

 

 

 

 

 

 

 

 

6.b. Where compressed gases are to be used at the job site,

7.b. Always

keep cylinders

in

an

upright position

securely

chained to an undercarriage or fixed support.

 

special precautions should be used to prevent hazardous

 

 

 

 

 

 

 

 

 

situations. Refer to “Safety in Welding and Cutting” (ANSI

7.c. Cylinders should be located:

 

 

 

 

Standard

Z49.1)

and the

operating

information for

the

 

 

 

 

• Away from areas where they may be struck or subjected to

equipment being used.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

physical damage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.c. When not welding, make certain no part of the electrode

• A safe distance from arc welding or cutting operations and

circuit is touching the work or ground. Accidental contact can

any other source of heat, sparks, or flame.

 

 

cause overheating and create a fire hazard.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.d. Do not heat, cut or weld tanks, drums or containers until the

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

 

 

proper steps have been taken to insure that such procedures

 

 

 

 

 

 

 

 

 

 

will not cause flammable or toxic vapors from substances

7.e. Keep your head and face away from the cylinder valve outlet

inside. They can cause an explosion even though they have

when opening the cylinder valve.

 

 

 

 

been “cleaned”. For information, purchase “Recommended

 

 

 

 

 

 

 

 

 

 

 

 

Safe Practices for the Preparation for Welding and Cutting of

7.f. Valve protection caps should always be in place and hand

Containers and

Piping

That

Have

Held

Hazardous

tight except when the cylinder is in use or connected for

Substances”, AWS F4.1 from the American Welding Society

use.

 

 

 

 

 

 

 

(see address above).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.e. Vent hollow castings or containers before heating, cutting or

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

welding. They may explode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“Precautions for Safe Handling of Compressed Gases in

 

 

 

 

 

 

 

 

 

 

6.f. Sparks and spatter are thrown from the welding arc. Wear oil

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

Always wear safety glasses with side shields when in a

 

FOR ELECTRICALLY

free protective garments such as leather gloves, heavy shirt,

 

 

 

 

 

 

 

 

cuffless trousers, high shoes and a cap over your hair. Wear

 

powered equipment.

ear plugs when welding out of position or in confined places.

 

 

 

 

 

 

 

 

 

welding area.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.g. Connect the work cable to the work as close to the welding

 

8.a. Turn off input power using the disconnect

area as

practical. Work cables

connected to

the building

 

 

switch at the fuse box before working on

framework or other locations away from the welding area

 

 

the equipment.

 

 

 

 

increase the possibility of the welding current passing

 

 

 

 

 

 

 

 

 

 

 

 

 

through lifting chains, crane cables or other alternate circuits.

8.b. Install equipment in accordance with the U.S. National

This can

create fire hazards or

overheat

lifting chains or

Electrical Code, all local codes and the manufacturer’s

cables until they fail.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

recommendations.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.h. Also see item 1.c.

 

 

 

 

 

 

 

 

8.c. Ground the equipment in accordance with the U.S. National

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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iv

 

 

SAFETY

iv

 

 

 

 

 

 

 

 

 

 

 

PRÉCAUTIONS DE SÛRETÉ

 

6.

prévenir tout risque d’incendie dû aux étincelles.

 

 

 

 

 

 

Eloigner les matériaux inflammables ou les recouvrir afin de

 

 

Pour votre propre protection lire et observer toutes les instructions

7.

Quand on ne soude pas, poser la pince à une endroit isolé de

 

 

et les précautions de sûreté specifiques qui parraissent dans ce

 

 

 

 

la masse. Un court-circuit accidental

peut provoquer un

 

 

manuel aussi bien que les précautions de sûreté générales suiv-

 

 

 

 

 

 

échauffement et un risque d’incendie.

 

 

 

antes:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sûreté Pour Soudage A LʼArc

 

 

8.

S’assurer que la masse est connectée le plus prés possible de

 

 

 

 

 

 

 

 

 

1. Protegez-vous contre la secousse électrique:

 

 

 

 

la zone de travail qu’il est pratique de le faire. Si on place la

 

 

 

 

 

 

 

masse sur la charpente de la construction ou d’autres endroits

 

 

 

 

 

 

 

 

 

 

 

a. Les circuits à l’électrode et à la piéce sont sous tension

 

 

éloignés de la zone de travail, on augmente le risque de voir

 

 

 

 

 

passer le courant de soudage par les

chaines de levage,

 

 

 

quand la machine à souder est en marche. Eviter toujours

 

 

 

 

 

 

 

câbles de grue, ou autres circuits. Cela peut provoquer des

 

 

 

tout contact entre les parties sous tension et la peau nue

 

 

 

 

 

 

 

risques d’incendie ou d’echauffement

des chaines et des

 

 

 

ou les vétements mouillés. Porter des gants secs et sans

 

 

 

 

 

 

 

câbles jusqu’à ce qu’ils se rompent.

 

 

 

 

trous pour isoler les mains.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

b. Faire trés attention de bien s’isoler de la masse quand on

9.

Assurer une ventilation suffisante dans la zone de soudage.

 

 

 

soude dans des endroits humides, ou sur un plancher met-

 

 

 

 

 

Ceci est particuliérement important pour le soudage de tôles

 

 

 

allique ou des grilles metalliques, principalement dans

 

 

 

 

 

 

 

galvanisées plombées, ou cadmiées ou tout autre métal qui

 

 

 

les positions assis ou couché pour lesquelles une grande

 

 

 

 

 

 

 

produit des fumeés toxiques.

 

 

 

 

partie du corps peut être en contact avec la masse.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c. Maintenir le porte-électrode, la pince de masse, le câble de

 

10. Ne pas souder en présence de vapeurs de chlore provenant

 

 

 

soudage et la machine à souder en bon et sûr état defonc-

 

 

 

 

 

 

d’opérations de dégraissage, nettoyage ou pistolage. La

 

 

 

tionnement.

 

 

 

 

 

 

 

 

 

 

 

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

 

 

 

d.Ne jamais plonger le porte-électrode dans

l’eau pour le

 

 

 

 

 

 

 

du solvant pour produire du phosgéne (gas fortement toxique)

 

 

 

refroidir.

 

 

 

 

 

 

 

 

 

 

 

ou autres produits irritants.

 

 

 

 

e. Ne jamais toucher simultanément les parties sous tension

 

 

 

 

 

 

 

 

 

 

 

 

 

des porte-électrodes connectés à deux machines à souder

 

11. Pour obtenir de plus amples renseignements sur la sûreté, voir

 

 

 

parce que la tension entre les deux pinces peut être le total

 

 

 

 

 

 

le code “Code for safety in welding and cutting” CSA Standard

 

 

 

de la tension à vide des deux machines.

 

 

 

 

 

 

 

 

 

 

 

W 117.2-1974.

 

 

 

 

f. Si on utilise la machine à souder comme une source de

 

 

 

 

 

 

 

 

 

 

 

 

 

courant pour soudage semi-automatique, ces precautions

 

PRÉCAUTIONS DE SÛRETÉ POUR

 

 

 

2. Dans le cas de travail au dessus du niveau du sol, se protéger

 

 

 

 

pour le porte-électrode s’applicuent aussi au pistolet de

 

 

 

 

 

 

 

soudage.

 

 

 

 

 

 

 

 

 

corps.

 

 

 

LES MACHINES À SOUDER À

 

 

 

 

 

 

TRANSFORMATEUR ET À

 

 

 

contre les chutes dans le cas ou on recoit un choc. Ne jamais

 

REDRESSEUR

 

 

 

 

enrouler le câble-électrode autour de n’importe quelle partie du

 

 

 

 

 

 

 

 

 

 

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

1.

Relier à la terre le chassis du poste conformement au code de

qu’un verre blanc afin de se protéger les yeux du rayon-

 

l’électricité et aux recommendations du fabricant. Le dispositif

nement de l’arc et des projections quand on soude ou

 

de montage ou la piece à souder doit être branché à une

quand on regarde l’arc.

 

bonne mise à la terre.

b. Porter des vêtements convenables afin de protéger la peau

 

 

de soudeur et des aides contre le rayonnement de l‘arc.

2.

Autant que possible, I’installation et l’entretien du poste seront

c. Protéger l’autre personnel travaillant à proximité au

 

effectués par un électricien qualifié.

soudage à l’aide d’écrans appropriés et non-inflammables.

 

 

 

 

 

 

3.

Avant de faires des travaux à l’interieur de poste, la debranch-

4. Des gouttes de laitier en fusion sont émises de l’arc de

 

er à l’interrupteur à la boite de fusibles.

soudage. Se protéger avec des vêtements de protection libres

 

 

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

4.

Garder tous les couvercles et dispositifs de sûreté à leur place.

talons sans revers, et chaussures montantes.

 

 

5. Toujours porter des lunettes de sécurité dans la zone de

 

 

soudage. Utiliser des lunettes avec écrans lateraux dans les

 

 

zones où l’on pique le laitier.

 

 

 

 

 

Mar ‘93

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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v

SAFETY

v

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 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a)other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment;

b)radio and television transmitters and receivers;

c)computer and other control equipment;

d)safety critical equipment, e.g., guarding of industrial equipment;

e)the health of the people around, e.g., the use of pacemakers and hearing aids;

f)equipment used for calibration or measurement

g)the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

h)the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

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vi

SAFETY

vi

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 precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica-

tions. 1

_________________________

1Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

L10093 3-1-96H

I

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

I

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Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-418 Series

POWER WAVE 355M/405M

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A-1

TABLE OF CONTENTS - INSTALLATION SECTION

A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications 355M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .A-2

Technical Specifications 405M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .A-3

Safety Precautions .....................................................................................................................................

A-4

Stacking......................................................................................................................................................

A-4

Tilting..........................................................................................................................................................

A-4

Input Grounding Connections....................................................................................................................

A-4

Power Cord Connection.............................................................................................................................

A-4

Output Cables, Connections and Limitations............................................................................................

A-5

Negative Electrode Polarity........................................................................................................................

A-5

Voltage Sensing..........................................................................................................................................

A-5

Power Wave to Semi-Automatic Wire Feeder ...........................................................................................

A-6

System Description ....................................................................................................................................

A-7

System Set-up ...........................................................................................................................................

A-8

Multiple Group System...............................................................................................................................

A-9

Single Group Multi-Head System ............................................................................................................

A-10

Welding with Multiple Power Waves ........................................................................................................

A-11

Control Cable Specifications....................................................................................................................

A-11

I/0 Receptacle Specifications ..................................................................................................................

A-13

Dip Switch Settings and Locations..........................................................................................................

A-13

POWER WAVE 355M/405M

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A-2

 

 

INSTALLATION

 

A-2

 

TECHNICAL SPECIFICATIONS - POWER WAVE 355

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

(continuous)

 

 

 

 

 

 

 

 

 

 

 

Power

 

200-208

 

 

 

 

 

Wave

K2152-1

220-240

350A / 34V / 60%

 

 

14.8” x 13.3” x

 

355

 

380-415

1 & 3 Phase

AMPS

 

 

 

(81.5 lbs.)

27.8”*

 

 

 

440-480

 

 

 

 

 

 

(37.0 kg.)

(373 x 338 x

 

 

 

575

 

5-425

 

 

 

 

 

706*)mm

 

 

 

 

 

 

 

 

 

60/50 HZ

300A / 32V / 100%

 

 

*Includes

 

 

 

 

 

Handles

 

 

 

 

1 & 3 Phase

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* Overall Length Including Handle, 21.6” (549mm) without handle.

POWER WAVE 355 INPUT CURRENT

Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs

Input 50/60 Hz

Output

Recommended

 

 

 

 

 

 

 

 

 

 

 

 

Voltage

Phases

300Amps @

350Amps @

Line Cord

Fuse size

Notes

 

 

32Volts(100%)

34Volts(60%)

AWG

 

 

 

 

200

1

Not

Not

 

---

Note 1

 

 

 

 

Recommended

Recommended

 

 

 

 

 

208

1

76

94

2

125A

Note 2

230

1

69

85

4

125A

Note 2

380

1

Not

Not

 

---

Note 1

 

 

Recommended

Recommended

 

 

 

 

 

400

1

Not

Not

---

---

Note 1

 

 

 

Recommended

Recommended

 

 

 

 

 

415

1

41

64

6

80A

Note 2

460

1

36

42

8

70A

 

 

 

575

1

31

37

8

50A

 

 

 

 

 

 

 

 

 

 

200

3

41

50

6

80A

Note 2

208

3

39

50

6

80A

Note 2

230

3

36

42

8

70A

 

 

 

380

3

23

28

8

50A

 

 

 

400

3

22

27

8

50A

 

 

 

415

3

22

26

8

50A

 

 

 

460

3

19

23

8

50A

 

 

 

575

3

16

18

8

35A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.

Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Select The output cable size based upon the following chart.*

 

Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:

 

 

 

 

 

 

DUTY CYCLE

CURRENT

LENGTH UP 200FT.(61m)

 

200-250 FT. (61-76m)

100%

300

1/0

 

1/0

60%

350

1/0

 

2/0

 

 

 

 

 

*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.

POWER WAVE 355M/405M

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A-3

 

 

INSTALLATION

 

A-3

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

 

 

 

 

 

(continuous)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

350A / 34V / 60%

 

 

14.7”x12.5”x

 

Power

 

200-208 /

3 Phase

 

 

27.8”*

 

Wave

K 2152-2

220-240/

320A / 33V / 60%

AMPS

86.5lbs

(373x318x

405

 

380-415/

1 Phase

5-425

(37.4 kg)

706*)mm

 

 

 

3/50/60

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60/50 Hz

275A / 31V /100%

 

 

 

 

 

 

 

1 Phase

 

 

 

 

 

 

 

300A / 32V / 100%

 

 

* Includes

 

 

 

 

3 Phase

 

 

handles

 

 

 

 

 

 

 

 

* Overall Length Including Handle, 21.6” (549mm) without handle.

POWER WAVE 405 INPUT CURRENT

Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs

 

Input 50/60 Hz

Output

Recommended

 

 

Voltage

 

Phases

300Amps@

 

350Amps@

Line Cord

Size Fuse Size

Notes

 

 

 

 

 

 

32Volts(100%)

34Volts(60%)

Size mm2

 

200

 

3

41

 

48

 

16

 

80A

Note 2

220

 

3

37

 

48

 

16

 

80A

Note 2

380

 

3

23

 

28

 

10

 

50A

 

400

 

3

22

 

27

 

10

 

50A

 

415

 

3

22

 

26

 

10

 

50A

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage

 

Phases

275Amps@

320Amps@

 

Line Cord

 

Fuse Size

Notes

 

 

31Volts(100%)

33Volts(60%)

 

 

Size mm2

 

 

 

 

200

1

Not Recommended

Not Recommended

 

---

 

-----

Note 1

 

220

1

64

 

82

 

20

 

125A

Note 2

 

380

1

44

 

55

 

16

 

80A

Note 2

 

400

1

40

 

50

 

10

 

80A

 

 

415

1

38

 

48

 

10

 

80A

 

 

 

 

 

 

 

 

 

 

 

 

 

1.Not rated is indicated by 4-x's in the box on the rating plate

2.When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Select the output cable size based upon the following chart.

Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:

 

DUTY CYCLE

CURRENT

LENGTH UP 61m (200 FT)

61-76m (200-250 FT)

 

 

100%

275

1/0

1/0

 

 

60%

350

1/0

2/0

 

 

 

 

 

 

 

POWER WAVE 355M/405M

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A-4

INSTALLATION

A-4

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• TURN THE INPUT POWER OFF AT

THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DISCONNECT INPUT POWER LINES, OUTPUT

CABLES, OR CONTROL CABLES.

Only qualified personnel should perform this installation.

Connect the green/yellow lead of the power cord to ground per U.S.National Electrical Code.

----------------------------------------------------------------------

SELECT SUITABLE LOCATION

In order to assure long life and reliable operation, the owner of this machine should follow these simple preventative measures:

The machine must be located where there is free circulation of clean air such that air movement in the back, out the sides and bottom will not be restricted.

Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.

Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.

CAUTION

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.

STACKING

POWER WAVE 355M/405M cannot be stacked.

TILTING

Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.

INPUT AND GROUNDING CONNECTIONS

Open the access panel on the rear of the machine.

For 200 or 230: Position the large switch to 200230.

For higher voltages: Position the large switch to 380-575.

Move the "A" lead to the appropriate terminal.

POWER CORD CONNECTION

A power cord is provided and wired into the machine. Follow the power cord connection instructions.

Machine

Cord

Length

PW 355

10

Feet

PW 405

5 Meters

CAUTION

Incorrect connection may result in equipment damage.

A

V

Single Phase Input (PW 355M)

Connect green lead to ground per National Electrical Code.

Connect black and white leads to power.

Wrap red lead with tape to provide 600V insulation.

Three Phase Input (PW 355M)

Connect green lead to ground per National Electric Code.

Connect black, red and white leads to power.

Lead Color

Single Phase

Three Phase

Green

Connect to

Connect to

 

ground per NEC

ground per NEC

 

 

 

Black

Power Lead

Power Lead

 

 

 

White

Power Lead

Power Lead

Red

Tape, provide

Power Lead

 

600V insulation

 

 

 

 

Only a qualified electrician should connect the POWER WAVE 355M/405M. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information detailed below.

When received directly from the factory, multiple voltage machines are internally connected for the highest voltage. Always double-check connections before powering up the machine.

Initial 200VAC - 415VAC and 575VAC operation will require an Input voltage panel setup.

Single Phase Input (PW 405M)

Connect green/yellow lead to ground per National Electrical Code.

Connect blue and brown leads to power.

Wrap black lead with tape to provide 600V insulation.

Three Phase Input (PW 405M)

Connect green/yellow lead to ground per National Electric Code.

Connect black, blue and brown leads to power.

POWER WAVE 355M/405M

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A-5

INSTALLATION

A-5

UNDERCARRIAGE MOUNTINGS

CAUTION

MOUNTING HOLE LOCATIONS

Excessive voltage drops

caused

by poor work

NOTE: MOUNTING SCREWS CAN NOT PROTRUDE MORE THAN

0.5 INCHES INSIDE THE MACHINE.

piece connections often result in unsatisfactory

 

3.50

welding performance.

 

 

 

 

 

 

 

 

 

 

 

 

 

-----------------------------------------------------------------------

 

 

1/4-20 NUT (4 PLACES)

 

 

NEGATIVE ELECTRODE POLARITY

 

5.50

When negative electrode polarity is required, such as

 

 

 

 

 

 

 

 

in some Innershield applications, reverse the output

 

10.00

 

 

 

connections at the power source (electrode cable to

 

 

 

 

 

 

 

 

the negative (-) Twist-Mate terminal, and work cable

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to the positive (+) Twist-Mate terminal.

11.84

 

4/01

 

M19527

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Connect a work lead of sufficient size and length between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. Avoid excessive lengths and do not coil excess cable.

CAUTION

When using inverter type power sources like the Power Waves, use the largest welding (electrode and work) cables that are practical. At least 2/0 copper wire - even if the average output current would not normally require it. When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.

------------------------------------------------------------------------

Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire feeder and the positive

(+) output Twist-Mate terminal on the power source. Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the output cable connections section. Connect a work lead from the negative (-) power source output Twist-Mate terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the Instruction Manuals.

When operating with electrode polarity negative the "Electrode Sense Polarity" DIP switch must be set to the "Negative" position on the Wire Drive Feed Head PC Board. The default setting of the switch is positive electrode polarity. Consult the Power Feed instruction manual for further details.

VOLTAGE SENSING

The best arc performance occurs when the PowerWaves have accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance. Sense Lead Kits (K940-10, -25 or -50) are available for this purpose.

CAUTION

If the voltage sensing is enabled but the sense leads are missing, improperly connected, or if the electrode polarity switch is improperly configured, extremely high welding outputs may occur.

------------------------------------------------------------------------

The ELECTRODE sense lead (67) is built into the control cable, and is automatically enabled for all semiautomatic processes. The WORK sense lead (21) connects to the Power Wave at the four pin connector. By default the WORK voltage is monitored at the output stud in the POWER WAVE 355/405. For more information on the WORK sense lead (21), see"Work Voltage Sensing” in the following paragraph.

POWER WAVE 355M/405M

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A-6

INSTALLATION

A-6

Enable the voltage sense leads as follows:

TABLE A.1

Process

Electrode Voltage

Work Voltage

 

Sensing 67 lead *

Sensing 21 lead

GMAW

67 lead required

21 lead optional

GMAW-P

67 lead required

21 lead optional

FCAW

67 lead required

21 lead optional

GTAW

Voltage sense at studs

Voltage sense at studs

GMAW

Voltage sense at studs

Voltage sense at studs

SAW

67 lead required

21 lead optional

CAC-C

Voltage sense at studs

Voltage sense at studs

 

 

 

*The electrode voltage 67 sense lead is integral to the control cable to the wire feeder.

Work Voltage Sensing

The standard POWER WAVE 355M/405M default to the work stud (work sense lead disabled)

For processes requiring work voltage sensing, connect the (21) work voltage sense lead (K940) from the Power Wave work sense lead receptacle to the work piece. Attach the sense lead to the work piece as close to the weld as practical, but not in the return current path. Enable the work voltage sensing in the Power Wave as follows:

WARNING

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

1.Turn off power to the power source at the disconnect switch.

2.Remove the wrap around cover from the power source.

3.The control board is on the center assembly facing the case front. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.

4.Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.

5.Replace the wrap around and screws. The PC board will “read” the switch at power up, and configure 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 always connected when a wire feeder is present.

PF10M feeder has user preference features to select voltage senses temporarily for testing sense leads.

CAUTION

Important: The electrode polarity must be configured at the feed head for all semi-automatic processes. Failure to do so may result in extremely high welding outputs.

------------------------------------------------------------------------

POWER WAVE TO SEMI-AUTOMATIC POWERFEED WIRE FEEDER INTERCONNECTIONS

The POWER WAVE 355M/405M and semi-automatic Power Feed family communicate via a 5 conductor control cable (K1543). The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The cables are designed to be connected end to end for ease of extension. The output receptacle on the POWER WAVE 405M is on the case front. The input receptacle on the Power Feed is typically located at the back of the feeder, or on the bottom of the user interface.

Due to the flexibility of the platform the configuration may vary. The following is a general description of the system. For specific configuration information, consult the semi-automatic Power Feed instruction manual.

O

N

1 2 3 4 5 6 7 8

POWER WAVE 355M/405M

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A-7

INSTALLATION

A-7

SYSTEM DESCRIPTION

The POWER WAVE 355M/405M and Power Feed 10/11 family of products utilize a digital communication system called Arclink. Simply put, Arclink 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, and because of its bus-like structure, the components may be connected to the network in any order, thus simplifying the system set-up.

Each "system" must contain only one power source. The power source may be connected to a maximum of four feeder groups. Each group containing one user interface (UI), and up to seven Feed Heads (FH). SEE FIGURE A.1. The UI controls all of the FH’s of that group. The UI’s and FH’s are assigned to groups by setting a code on the DIP switches mounted on their individual control boards. For example all of the FH’s to be controlled by a given UI must have their "Group ID" switches set to the same group number as the UI. In addition, each FH must be assigned a separate FH number within that group. See the system set-up section for further details.

From a network perspective, each component in the system is considered a separate node, regardless of its physical location. For example, even though a UI and FH may be physically mounted together, they are still viewed as separate pieces (nodes) by the network, and can only communicate via Arclink. The connection is generally made externally through the Linc-Net Control Cable, but can also be made internally, as with the PF10 bench model feeder.

The most common Arclink configuration (called a simple system) consists of one power source, one user interface and one feeder. Under these circumstances the group and feed head ID DIP switches are ignored and the system will function regardless of their position. The same is true for the minimum system consisting of a power source and one UI (Example: a stick welding system).

System Model

FIGURE A.1

Maximum

Configuration

POWER WAVE 355M/405M

 

 

 

A-8

INSTALLATION

A-8

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SYSTEM SET-UP

 

Basic Rules

 

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Masterto

 

• Each group is required to have one user interface. No

 

 

 

 

 

 

 

 

 

 

 

 

group may have more than one user interface.

 

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• Each group can have up to seven Feed Heads.

 

Feed Heads.

 

 

 

 

 

 

Exception: Group 3 is limited to a maximum of six

 

 

 

 

 

 

• Each system has only one power source. For network

 

 

 

 

 

 

purposes, the PS belongs to Group 3, which is why

 

 

 

 

 

 

group 3 is only allowed 6 feed heads in addition to it’s

 

 

 

 

 

 

user interface.

 

 

 

 

 

 

• No two feed heads can have identical Group and

 

TOC

TOC

Feed Head numbers.

 

• Group and Feed Head ID numbers must be set on the

 

Section

Master

appropriate dip switches at each node. Consult the

 

 

 

 

 

 

 

 

 

 

 

 

PF-10/11 Instruction Manual for specific details

 

to

to

regarding dip switch settings.

 

 

 

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• Feed head “0” not allowed. Exception: Simple sys-

 

 

 

 

 

 

 

 

 

 

 

 

tem ignores all ID numbers, therefore “FH0” will func-

 

 

 

 

 

 

tion.

 

 

 

 

 

 

• Each node must be connected to the Linc-Net com-

 

 

 

 

 

 

munication network. The order of connection is not

 

 

 

 

 

 

important, as each node is identified by it’s unique

 

 

 

 

 

 

Group and Feed Head ID number as defined on it’s

 

 

 

 

 

 

dip switches. See Figures A.2 thru A.5.

 

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Simple System

FIGURE A.2

 

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Group and Feed Head ID numbers are ignored in a simple system.

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POWER WAVE 355M/405M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A-9

INSTALLATION

A-9

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Multiple Group System

 

 

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FIGURE A.3

No “FH0 Allowed!

 

 

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Single Group Multi-Head System

 

 

 

 

 

 

 

 

 

FIGURE A.4

 

 

 

No “FH0 Allowed!

 

TOC

TOC

The Dual Head option

allows

the

ability

to

Section

Master

maintain

2

sets

of

 

 

 

 

 

 

 

 

procedures. If

more

to

to

then

2

heads

 

are

used,

odd

#’s

use

Return

Return

FH1 settings, even #’s

 

 

 

 

 

 

 

 

use FH2 settings.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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POWER WAVE 355M/405M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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A-10

INSTALLATION

A-10

Single Group Multi-Head System (Alternate Method)

 

 

FIGURE A.5

No “FH0 Allowed!

When a standard User Interface is used in a group with multiple Feed Heads, all of the Feed Heads use a single set of proce- dures.

POWER WAVE 355M/405M

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A-11

INSTALLATION

A-11

WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS

 

WAVES

 

It is recommended that genuine Lincoln control cables

 

 

be used at all times. Lincoln cables are specifically

CAUTION

 

designed for the communication and power needs of

 

 

the Power Wave / Power Feed system.

 

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 leads into one lead. The welding travel directions should be in the direction moving away from the work lead as shown below. Connect all of the work sense leads from each power source to the work piece at the end of the weld.

For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.

Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas coverage.

Do not attempt to supply shielding gas for two or more guns from only one regulator.

If an anti-spatter system is in use then each gun must have its own anti-spatter system. (See Figure A.6)

CAUTION

The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems such as: system shutdowns, poor motor acceleration, poor arc starting) and low wire driving force (wire feeding problems).

------------------------------------------------------------------------

The K1543 series of control cables can be connected end to end for ease of extension. Do not exceed more than 100 feet (30.5 m) total control cable length.

FIGURE A.6

POWEERR WAVEE3535/4/4055

POWEERR WAVE 35/45/4055

TWO POWER WAVES

Travel

Direction

Connect All Work

Sense Leads at the End

of the Joint

Connect All Welding

Work Leads at the

Beginning of the Joint

POWER WAVE 355M/405M

Lincoln Electric POWER WAVE 355M, POWER WAVE 405M User Manual

 

 

A-12

INSTALLATION

A-12

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MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES

 

 

 

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POWER WAVE 355M/405M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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A-13

INSTALLATION

A-13

I / O RECEPTACLE SPECIFICATIONS

TABLE A.2

WIRE FEEDER RECEPTACLE

PIN LEAD#

FUNCTION

A53 Communication Bus L

B54 Communication Bus H

C67A Electrode Voltage Sense

D

52

+40vdc

E

51

0vdc

TABLE A.3

VOLTAGE SENSE RECEPTACLE

 

PIN

LEAD#

FUNCTION

 

3

21A

Work Voltage Sense

 

 

TABLE A.4

 

 

RS232 RECEPTACLE

 

PIN

LEAD#

FUNCTION

2253 RS232 Receive

3254 RS232 Transmit

4

#

Pin5

5

#

Pin4

6

# #

Pin20

20

# #

Pin6

7

251

RS232 Common

DIP SWITCH SETTINGS AND LOCATIONS

DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches:

CONTROL BOARD DIP SWITCH: switch 1 = reserved for future use switch 2 = reserved for future use switch 3 = reserved for future use switch 4 = reserved for future use switch 5 = reserved for future use switch 6 = reserved for future use switch 7 = reserved for future use switch 8* = work sense lead

switch 8*

work sense lead

 

off

work sense lead not connected

 

on

work sense lead connected

 

 

 

 

*Factory setting for Switch 8 is OFF.

FIGURE A.7

CONT RO LB OAR D( DIP Switch Loc ation )

WARNING

1. Turn off power to the power source at the dis-

NOTE:

For PF10M Dual Boom Feeder set/up and op-

connect switch.

 

eration. The Power Wave 355M/405M control

------------------------------------------------------------------------

 

 

board dip switches must be set with 3, 4, 7 to

2. Remove the wrap around cover from the power

 

 

the “ON” position (Power Wave 355M/405M

source.

 

 

input on/off switch must be cycled to enable

 

 

 

 

any change of dip switches).

3.The control board is on the center assembly facing the case front. Locate the 8-position DIP switch and look for switch 8 of the DIP switch.

4.Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.

5.Replace the wrap around and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.

O

N

1 2 3 4 5 6 7 8

POWER WAVE 355M/405M

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A-14

INSTALLATION

A-14

CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING

For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than 50 ft.(15.24m), traditional welding cables may be used without any effects on welding performance. For the total welding loop length greater than 50 ft.(15.24m)), the K1796 Coaxial Welding Cables are recommended. The welding loop length is defined as the total of electrode cable length

(A) + work cable length (B) + work length (C) (See Figure A.3).

POWER

 

 

WAVE

 

A

 

 

 

 

C

 

 

WORK

 

B

 

Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire feeder and the positive

(+) output Twist-Mate terminal on the power source. Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the output cable connections section. Connect a work lead from the negative (-) power source output Twist-Mate terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the Instruction Manuals.

For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less than 50 ft.(15.24m). (See Figure A.4.)

 

FIGURE A.4

 

 

 

POWER

 

A

 

A

WAVE

 

 

 

 

 

 

 

 

C

WORK

C

 

 

B

 

B

 

 

SLIDING

WORK

 

K1796 COAXIAL CABLE

 

 

 

 

MEASURE FROM END

 

 

 

OF OUTER JACKET OF

 

 

 

CABLE

 

 

 

 

POWER WAVE 355M/405M

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B-1

TABLE OF CONTENTS - OPERATION SECTION

B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions.......................................................................................................................................

B-2

General Description .....................................................................................................................................

B-2

Recommended Processes and Equipment .................................................................................................

B-2

Required Equipment ....................................................................................................................................

B-3

Limitations....................................................................................................................................................

B-3

Duty Cycle and Time Period........................................................................................................................

B-3

Case Front Controls.....................................................................................................................................

B-3

Making a Weld .............................................................................................................................................

B-4

Welding Adjustments ...................................................................................................................................

B-4

Constant Voltage Welding............................................................................................................................

B-5

Tig (GTAW) ...................................................................................................................................................

B-6

Special Welding Processes Available ..........................................................................................................

B-6

Power Mode.................................................................................................................................................

B-7

Pulse Welding (GMAW-P) ............................................................................................................................

B-8

Pulse-on-Pulse (GMAW-PP) ......................................................................................................................

B-10

Benefits of Pulse-on-Pulse Welding ..........................................................................................................

B-10

POWER WAVE 355M/405M

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B-2

OPERATION

B-2

SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.

Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

-----------------------------------------------------------

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

-----------------------------------------------------------

WELDING SPARKS can cause fire or explosion.

Keep flammable material away.

Do not weld on containers that have held combustibles.

-----------------------------------------------------------

ARC RAYS can burn.

• Wear eye, ear, and body protection.

-----------------------------------------------------------

Observe additional guidelines detailed in the beginning of this manual.

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, and pulse welding modes.

The Power Wave power source is designed to be used with the semi automatic family of Power Feed M wire feeders, operating as a system. Each component in the system has special circuitry to "talk with" the other system components, so each component (power source, wire feeder, user interface) knows what the other is doing at all times. These components communicate with Arclink.

The POWER WAVE 355M/405M is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW, GMAW-P, FCAW, SMAW, GTAW, and CAC-A processes. It carries an output rating of 350 Amps, 34 Volts at 60% duty cycle and 300 Amps, 32 volts at 100% duty cycle.

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The POWER WAVE 355M/405M can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, GTAW, and CAC-A for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.

The POWER WAVE 355M/405M is recommended for semi-automatic welding, and may also be suitable for basic hard automation applications.

This Power Wave is not recommended for processes other than those listed.

POWER WAVE 355M/405M

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B-3

OPERATION

B-3

POWER WAVE 355M/405M – Semi-Automatic

Operation

Semi Automatic Power Waves can only be used with Arclink 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 wire feeders, cannot be used.

All welding programs and procedures are selected through the Power Feed semi-automatic user interface

REQUIRED EQUIPMENT

Any Arclink compatible semi-automatic wire feeding equipment. Specifically, the semi-automatic Power Feed family (PF10M Series, Power Feed 15M and Power Feed 25M).

LIMITATIONS

Only Arclink compatible Power Feed semi-automatic wire feeders and users interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.

POWER WAVE 355M/405M Output Limitations

The POWER WAVE 355M/405M will support maximum average output current of 350 Amps @ 60% duty cycle.

DUTY CYCLE AND TIME PERIOD

The duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.

CASE FRONT CONTROLS

All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1)

1.POWER SWITCH: Controls input power to the Power Wave.

2.STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated, per table B.1.

NOTE: The POWER WAVE 355M/405M status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

 

TABLE B.1

 

 

Light

Meaning

Condition

 

Steady Green

System OK. Power source communicating

 

normally with wire feeder and its components

 

if other feeder & components show they are

 

powered up.

 

 

Blinking

Occurs during a reset, and indicates the

Green

POWER WAVE 355M/405M is mapping

 

(identifying) each component in the system.

 

Normal for first 1-10 seconds after power is

 

turned on, or if the system configuration is

 

changed during operation

 

 

Alternating

Non-recoverable system fault. If the PW

Green and

Status light is flashing any combination of red

Red

and green, errors are present in the POWER

 

WAVE 355M/405M. Read the error code

 

before the machine is turned off.

 

Error Code interpretation through the Status

 

light is detailed in the LED Status Chart.

 

Individual code digits are flashed in red with

 

a long pause between digits. If more than

 

one code is present, the codes will be sepa-

 

rated by a green light.

 

To clear the error, turn power source off, and

 

back on to reset.

 

 

Steady Red

Non recoverable hardware fault. Generally

 

indicates nothing is connected to the

 

POWER WAVE 355M/405M wire feeder

 

receptacle. See Trouble Shooting Section.

 

 

Blinking Red

Not applicable.

 

 

3.HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled and the fan continues to run, until the machine cools down. When cool, the light goes out and output is enabled.

4.CB1 WIRE FEEDER CIRCUIT BREAKER: Protects 40 volt DC wire feeder power supply.

POWER WAVE 355M/405M

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B-4

 

OPERATION

B-4

FIGURE B.1

 

 

The steps for operating the Power Wave will vary

 

 

 

 

depending upon the options installed in the user inter-

2

3

 

 

face (control box) of the welding system. The flexibility

 

 

of the Power Wave system lets the user customize

7

 

 

 

operation for the best performance.

 

 

 

 

 

 

 

 

 

 

First, consider the desired welding process and the

 

 

 

 

part to be welded. Choose an electrode material, diam-

6

 

4

 

eter, shielding gas and process (GMAW, GMAW-P,

 

 

 

 

etc.)

 

8

 

1

 

Second, find the program in the welding software that

 

 

best matches the desired welding process. The stan-

 

 

 

 

dard software shipped with the Power Waves encom-

 

 

 

 

passes a wide range of common processes and will

9

 

 

 

meet most needs. If a special welding

program is

 

 

 

desired, contact the local Lincoln Electric sales repre-

 

 

 

 

10

5

 

 

sentative.

 

 

 

 

 

CASE FRONT LAYOUT

 

 

To make a weld, the Power Wave needs to know the

 

 

desired welding parameters. The Power Feed (PF)

POWER WAVE 355M/405M

 

 

family of feeders communicate settings to the Power

5. Internal POWER CIRCUIT BREAKER: Protects 115

Wave through control cable connection. Arc length,

wire feed speed, arc control, etc. are all communicated

volt AC circuit.

 

 

 

 

 

 

digitally via the control cable.

 

6. LEAD CONNECTOR (SENSE LEAD)

 

 

 

 

 

 

 

7. DIAGNOSTIC CONNECTOR (RS-232)

 

 

 

 

8. WIRE FEEDER RECEPTACLE (5-PIN)

 

 

 

 

9. NEGATIVE TWISTMATE TERMINAL

 

 

WELDING ADJUSTMENTS

 

10. POSITIVE TWISTMATE TERMINAL

 

 

 

 

NOMINAL PROCEDURES

 

 

All adjustments are made on the system component

 

 

known as the User Interface (Control Box), which con-

The Power Wave is designed to operate with 3/4" elec-

tains the switches, knobs, and digital displays neces-

trode stick-out for CV and Pulse processes.

 

 

 

 

sary to control both the Power Wave and a Power Feed

 

 

 

 

FRINGE PROCEDURES

 

 

wire feeder. Typically, the Control Box is supplied as

 

 

part of the wire feeder. It can be mounted directly on

Excessively short or long

electrode stick-outs

may

the wire feeder itself, the front of the power source, or

 

 

 

 

function only on a limited basis, if at all.

mounted separately, as might be done in a welding

 

MAKING A WELD

boom installation.

 

WARNING

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

------------------------------------------------------------------------

Because the Control Box can be configured with many different options, your system may not have all of the following adjustments. Regardless of availability, all controls are described below. For further information, consult the Power Feed wire feeder instruction manual.

WFS / AMPS:

In synergic welding modes (synergic CV, pulse GMAW) WFS (wire feed speed) is the dominant control parameter, controlling all other variables. The user adjusts WFS according to factors such as weld size, penetration requirements, heat input, etc. The Power Wave then uses the WFS setting to adjust its output characteristics (output voltage, output current) according to pre-programmed settings contained in the Power Wave.

POWER WAVE 355M/405M

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B-5

OPERATION

B-5

In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.

In constant current modes (stick, TIG) this control adjusts the output current, in amps.

VOLTS / TRIM:

In constant voltage modes (synergic CV, standard CV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting to adjust the arc length. It is adjustable from 0.500 to 1.500. A Trim setting of 1.000 is a good starting point for most conditions.

• WELDING MODE

May be selected by name (CV/MIG, CC/Stick Crisp, Gouge, etc.) or by a mode number (10, 24, 71, etc.) depending on the Control Box options. Selecting a welding mode determines the output characteristics of the Power Wave power source. A more complete description of all modes can be found in this section.

• ARC CONTROL

Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from "soft" to "harsh" in all weld modes. It is adjustable from -10.0 to +10.0, with a nominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels). See the Welding Mode descriptions for a more detailed explanations of how the Arc Control affects each mode.

CONSTANT VOLTAGE WELDING

Synergic CV:

For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, the Power Wave automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range.

Non Synergic CV:

This type of CV mode behaves more like a conventional CV power source. Voltage and WFS are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.

All CV Modes:

Arc Control, often referred to as wave control, adjusts the inductance of the wave shape. The wave control adjustment is similar to the "pinch" function in that it is inversely proportional to inductance. Therefore, increasing wave control greater than 0.0 results in a harsher, colder arc while decreasing the wave control to less than 0.0 provides a softer, hotter arc.

(See Figure B.2)

FIGURE B.2

CURRENT WAVE FORM (CV)

Current

POWER WAVE 355M/405M

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B-6

OPERATION

B-6

TIG GTAW

The TIG mode features continuous control from 5 to 425 amps. The TIG mode can be run in either the Touch Start TIG or Scratch start mode.

The Arc Control level selects the starting mode.

Between –10 and 0, the Touch Start TIG mode is selected. The OCV is controlled below 10V and the short circuit "TIG touch" current is maintained at approximately 25 amps, independent of the preset current. When the tungsten is lifted, an arc is initiated and the output is regulated at the preset value. A setting of 0, results in the most positive arc initiation. A setting of -10 reduces the start procedure to start the weld, and from there, to ramp to the welding procedure over a specified amount of time.

A setting above 0 selects a Scratch Start. Full OCV is available when the arc initiates the output is regulated to the preset value

Typically starting procedure on a higher “+” setting is known as a “Hot Start”. Setting a starting procedure on a lower setting is known as a “Cold Start”.

NOTE: Later versions of weld software eliminated the Arc Control Function in TIG mode and only allow for “Touch Start” operation.

SMAW

In SMAW (STICK mode), the arc control adjusts the arc force. It can be set to the lower range (0 to -10) for a soft and less penetrating arc characteristic or to the higher range (0 to +10) for a crisp and more penetrating arc. Normally, when welding with cellulosic types of electrodes (E6010, E7010, E6011), a higher energy arc is required to maintain arc stability. This is usually indicated when the electrode sticks to the work-piece or when the arc pops-out during manipulative technique. For low hydrogen types of electrodes (E7018, E8018, E9018, etc.) a softer arc is usually desirable and the lower end of the Arc Control suits these types of electrodes. In either case the arc control is available to increase or decrease the energy level delivered to the arc.

Recommended Welding Procedures for Power Mode

TABLE B.2

 

MATERIAL

Aluminum 4043

Aluminum 5356

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Stainless Steel

Stainless Steel

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRE

E4043

E5356

L56

L56

L56

L56

L56

L56

E308L

E308L

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRE SIZE

0.035

0.035

0.025

0.025

0.030

0.030

0.035

0.035

0.030

0.035

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS

100% Agr.

100% Agr.

100% CD2

75/25 Ar/CO2

100% CD2

75/25 Ar/CO2

100% CD2

75/25 Ar/CO2

Tri-mix

Tri-mix

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22 ga.

 

 

Not

100 / 0.8

Not

90 / 1.0

 

 

 

 

 

 

 

 

recommended

recommended

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20 ga.

 

 

120 / 1.0

120 / 1.0

100 / 0.7

100 / 1.0

 

 

80 / 1.5

50 / 0.5

THICKNESS

SETTINGMODE

 

 

 

 

 

 

 

 

 

 

 

18 ga.

 

 

140 / 1.7

140 / 1.5

110 / 1.5

110 / 1.5

100 / 2.5

100 / 2.5

110 / 2.0

110 / 2.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16 ga.

 

 

190 / 2.0

190 / 2.0

125 / 2.0

125 / 2.0

125 / 3.0

125 / 3.0

140 / 2.5

130 / 2.7

 

 

 

 

 

 

 

 

 

 

 

 

 

MATERIAL

POWER/WFS

14 ga.

400 / 2.0

400 / 2.5

260 / 3.0

260 / 3.0

160 / 2.3

160 / 2.3

160 / 3.8

160 / 3.5

210 / 3.0

190 / 3.5

 

 

 

 

 

 

 

 

 

 

 

12 ga.

 

 

330 / 5.0

330 / 4.5

230 / 3.5

230 / 3.5

200 / 5.0

200 / 4.5

270 / 5.0

230 / 6.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10 ga.

500 / 7.0

500 / 7.0

 

 

300 / 6.0

300 / 6.0

240 / 6.5

240 / 7.0

325 / 6.5

300 / 7.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/16

570 / 90

600 / 7.8

 

 

400 / 7.5

400 / 7.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4

700 / 9.1

700 / 8.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Not

Not

 

 

 

 

 

 

 

 

 

COMMENTS

Recommended

Recommended

 

 

 

 

 

 

 

 

 

below 400

below 400

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WFS

WFS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER WAVE 355M/405M

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B-7

OPERATION

B-7

ARC GOUGING

 

 

Gouging is basically removing metal to form a bevel or groove in a piece of steel with controlled forced air and a carbon rod.

The common procedures for Arc Gouging metal are:

Removing poor welds from a weldment so that new welds can be made.

Creating a welding groove or grooves in two pieces of steel butted together. (See Example below)

WELD GROOVES CREATED BY ARC GOUGING

STEEL BUTTED TOGTHER

Mode 9 in the POWER WAVE 355M is specifically for gouging. Gouging can also be done in the stick soft and crisp modes. Setting the output of the Stick Soft mode to 425 amps will enable the arc-gouging mode. The actual output current will depend on the size of carbon used. The recommended maximum size carbon is 5/16".

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 in improved welding performance in two primary types of applications.

Short Arc MIG at low procedure settings.

Aluminum MIG welding.

Power Mode™ is a method of high speed regulation of the output power whenever an arc is established. It provides a fast response to changes in the arc. The higher the Power Mode Setting, the longer the arc. If a welding procedure is not established, the best way to determine the Power Mode Setting is by experimentation until the desired output result is established.

In the Power Mode variables need to be set:

Wire Feed Speed

Output

Arc Control

Setting up a Power Mode procedure is similar to setting a CV MIG procedure. Select a shielding gas appropriate for a short arc process.

For steel, use 75/25 Ar/CO2 shield gas.

For Stainless, select a Helium blend Tri-Mix.

For Aluminum, use 100% Ar.

Start by setting the wire feed speed based upon material thickness and appropriate travel speed. Then adjust the Output knob as follows:

For steel, listen for the traditional “frying egg” sound of a good short-arc MIG procedure to know you have the process set correctly.

For aluminum, simply adjust the Output knob until the desired arc length is obtained.

Note the Volts display is simply a relative number and DOES NOT correspond to voltage.

Some Power Mode procedure recommendations appear in Table B.2.

POWER WAVE 355M/405M

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B-8

OPERATION

B-8

SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE

PULSE WELDING (GMAW-P)

The pulsed-arc process is, by definition, a spray transfer process wherein spray transfer occurs in pulses at regularly spaced intervals. In the time between pulses, the welding current is reduced and no metal transfer occurs.

Pulsed-arc transfer is obtained by operating a power source between low and high current levels. The high current level or “pulse” forces an electrode drop to the workpiece. The low current level or “background” maintains the arc between pulses. (See Figure B.3).

Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while minimizing or eliminating their disadvantages. Unlike short circuit, pulsed MIG does not create spatter or run the risk of cold lapping. The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient. Unlike the spray arc process, pulsing offers controlled heat input that allows better welding on thin materials. Pulsing allows for lower wire feed speeds which leads to less distortion and improved overall quality and appearance. This is especially important with stainless, nickel and other alloys that are sensitive to heat input.

In GMAW-P mode, arc control adjusts the background current and frequency of the wave. When arc control goes up, the frequency increases thus increasing the droplet transfer.

FIGURE B.3

EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL

PEAK AMPS

FREQUENCY

SPRAY TRANSITION

CURRENT

POWER WAVE 355M/405M

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