Lincoln Electric SVM159-A User Manual
SVM159-A
December, 2003
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and 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.
SERVICE MANUAL
For use with machine code numbers 10895, 10896
POWER WAVE 355/405
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
View Safety Info View Safety Info View Safety Info View Safety Info
RETURN TO MAIN INDEX
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2003 Lincoln Global Inc.
WARNING
REMOTE
POWER
ON
OFF
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!
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
i
SAFETY
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
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.
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
purchase 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. AFree 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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The
Above For Gasoline Engines
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating products.
5.c. 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.d. 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.e. Also see item 1.b.
Mar ‘95
SAFETY
iii iii
POWER WAVE 355/405
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FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA22202.
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
SAFETY
iv iv
POWER WAVE 355/405
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PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
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
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
INSTALLATION
v v
POWER WAVE 355
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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 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 constructing 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
assess 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.
3-1-96H
L10093
INSTALLATION
vi vi
POWER WAVE 355
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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 the 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 applications.
1
1
Portions of the preceding text are contained in EN50199: "Electromagnetic Compatibility (EMC) product standard for
arc welding equipment."
3-1-96H
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
POWER WAVE 355/405
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
How to Use Troubleshooting Guide............................................................................................F-2
Troubleshooting Guide................................................................................................................F-4
Test Procedures ........................................................................................................................F-15
Replacement Procedures .........................................................................................................F-47
Electrical Diagrams..............................................................................................................Section G
Parts Manual ....................................................................................................................P-401 Series
RETURN TO MAIN INDEX
SectionA-1 Section A-1
POWER WAVE 355/405
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications 355 ......................................................................................................A-2
Technical Specifications 405 ......................................................................................................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-12
Dip Switch Settings and Locations ..........................................................................................A-12
POWER WAVE 355/405
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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)
* Overall Length Including Handle, 21.6” (549mm) without handle.
Voltage
200
208
230
380
400
415
460
575
200
208
230
380
400
415
460
575
Phases
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
300Amps @
32Volts(100%)
Not
Recommended
76
69
Not
Recommended
Not
Recommended
41
36
31
41
39
36
23
22
22
19
16
350Amps @
34Volts(60%)
Not
Recommended
94
85
Not
Recommended
Not
Recommended
64
42
37
50
50
42
28
27
26
23
18
Line Cord
AWG
2
4
--6
8
8
6
6
8
8
8
8
8
8
Fuse size
---
125A
125A
---
---
80A
70A
50A
80A
80A
70A
50A
50A
50A
50A
35A
POWER WAVE 355 INPUT CURRENT
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
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.
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
100%
60%
CURRENT
300
350
LENGTH UP 200FT.(61m)
1/0
1/0
200-250 FT. (61-76m)
1/0
2/0
Notes
Note 1
Note 2
Note 2
Note 1
Note 1
Note 2
Note 2
Note 2
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
Power
Wave
355
K2152-1
200-208
220-240
380-415
440-480
575
60/50 HZ
350A / 34V / 60%
1 & 3 Phase
300A / 32V / 100%
1 & 3 Phase
AMPS
5-425
(81.5 lbs.)
(37.0 kg.)
14.8” x 13.3” x
27.8”*
(373 x 338 x
706*)mm
*Includes
Handles
INSTALLATION
A-3 A-3
POWER WAVE 355/405
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TECHNICAL SPECIFICATIONS -
POWER WAVE 405
INPUT AC VOLTAGE & DC OUTPUT
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
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.
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 405 INPUT CURRENT
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
1. Not rated is indicated by 4-x's in the box on the rating plate
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 mm
2
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 mm
2
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
A-4 A-4
POWER WAVE 355/405
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INSTALLATION
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DIS-
CONNECT 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.
----------------------------------------------------------------------
WARNING
SAFETY PRECAUTIONS
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.
• 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 355/405 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
• Only a qualified electrician should connect the
POWER WAVE 355/405. 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.
CAUTION
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200-
230.
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.
•Incorrect connection may result in equipment
damage.
Single Phase Input (PW 355)
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 355)
Connect green lead to ground per National Electric
Code.
Connect black, red and white leads to power.
Single Phase Input (PW 405)
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 405)
Connect green/yellow lead to ground per National
Electric Code.
Connect black, blue and brown leads to power.
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CAUTION
Machine
PW 355
PW 405
Cord Length
10 Feet
5 Meters
Lead Color Single Phase Three Phase
Connect to
ground per NEC
Power Lead
Power Lead
Power Lead
Connect to
ground per NEC
Power Lead
Power Lead
Tape, provide
600V insulation
Green
Black
White
Red
INSTALLATION
A-5 A-5
POWER WAVE 355/405
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
UNDERCARRIAGE MOUNTINGS
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.
When using an inverter type power source like the
PowerWaves, 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 T wist-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.
CAUTION
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
-----------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
When operating with 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
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.
NOTE: MOUNTING SCREWS CA
MOUNTING HOLE LOCATIONS
CHES INSIDE THE MACHINE.
0.5 IN
11.8
4
N NOT PROTR
3.50
1/4-20 NUT (4 PLACES)
10.00
UDE MORE THAN
M19527
5.50
4/01
INSTALLATION
A-6 A-6
POWER WAVE 355/405
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 355/405 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:
• 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.
WARNING
O
N
12345678
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.
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 355/405 and semi-automatic
PowerFeed 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 405
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.
INSTALLATION
A-7 A-7
POWER WAVE 355/405
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SYSTEM DESCRIPTION
The POWER WAVE 355/405 and Power Feed 10/11
family of products utilize a digital communication system called Linc-Net. Simply put, Linc-Net allows large
amounts of information to be passed at very high
speeds between components (nodes) in the system.
The system requires only two wires for communication,
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 Linc-Net. The Linc-Net
connection is generally made external through the
Linc-Net Control Cable, but can also be made internally, as with the PF-10 bench model feeder.
The most common Linc-Net 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).
FIGURE A.1
System Model
Maximum
Configuration
INSTALLATION
A-8 A-8
POWER WAVE 355/405
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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 network
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.
• Group and Feed Head ID numbers must be set on
the appropriate dip switches at each node. Consult
the PF-10/11 Instruction Manual for specific details
regarding dip switch settings.
• Feed head “0” not allowed. Exception: Simple system ignores all ID numbers, therefore “FH0” will function.
• Each node must be connected to the Linc-Net communication 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.
FIGURE A.2
Simple System
Group and Feed
Head ID numbers are
ignored in a simple
system.
INSTALLATION
A-9 A-9
POWER WAVE 355/405
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FIGURE A.3
Multiple Group System
No “FH0 Allowed!
FIGURE A.4
Single Group Multi-Head System
No “FH0 Allowed!
The Dual Head option
allows the ability to
maintain 2 sets of
procedures. If more
then 2 heads are
used, odd #’s use
FH1 settings, even
#’s use FH2 settings.
INSTALLATION
A-10 A-10
POWER WAVE 355/405
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FIGURE A.5
Single Group Multi-Head System (Alternate Method)
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 procedures.
INSTALLATION
A-11 A-11
POWER WAVE 355/405
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WELDING WITH MULTIPLE POWER
WAVES
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
CONTROL CABLE SPECIFICATIONS
It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
the Power Wave / Power Feed system.
The use of non-standard cables, especially in
lengths greater than 25 feet, can lead to communication problems (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.
CAUTION
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
Travel
Direction
TWO POWER WAVES
FIGURE A.6
POWER WAVE 355/405
POWER WAVE 355/405
INSTALLATION
A-12 A-12
POWER WAVE 355/405
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I / O RECEPTACLE SPECIFICATIONS
TABLE A.2
WIRE FEEDER RECEPTACLE
PIN LEAD# FUNCTION
A53Communication Bus L
B54Communication Bus H
C 67A Electrode Voltage Sense
D520vdc
E51+40vdc
TABLE A.3
VOLTAGE SENSE RECEPTACLE
PIN LEAD# FUNCTION
3 21A Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
PIN LEAD# FUNCTION
2 253 RS232 Receive
3 254 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:
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.
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WARNING
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
CONTROL BOARD (DIP Switch Location)
Section B-1 Section B-1
POWER WAVE 355/405
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
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-6
Pulse Welding (GMAW-P) ...........................................................................................................B-7
Pulse-on-Pulse (GMAW-PP).......................................................................................................B-8
Benefits of Pulse-on-Pulse Welding...........................................................................................B-8
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B-2
B-2
POWER WAVE 355/405
OPERATION
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 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 Linc-Net.
The POWER WAVE 355/405 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 355/405 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 355/405 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.
SAFETY PRECUATIONS
Read this entire section of operating instructions
before operating the machine.
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 sec-
onds 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.
WARNING
OPERATION
B-3 B-3
POWER WAVE 355/405
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POWER WAVE 355/405 – Semi-Automatic
Operation
Semi Automatic Power Waves can only be used with
Linc-Net compatible Power Feed semi-automatic wire
feeders. In addition, the Power Feed semi-automatic
wire feeders may require optional equipment to access
certain weld modes in the Power Wave. Other models
of Lincoln feeders, or any models of non-Lincoln wire
feeders, cannot be used.
All welding programs and procedures are selected
through the Power Feed semi-automatic user interface
REQUIRED EQUIPMENT
Any Linc-Net compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
Feed family (PF-10, PF-10X2, PF-11).
LIMITATIONS
• Only Linc-Net 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 355/405 Output Limitations
The POWER WAVE 355/405 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: Atwo color light that indicates sys-
tem errors. Normal operation is a steady green
light. Error conditions are indicated, per table B.1.
NOTE: The POWER WAVE 355/405 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
Condition
Steady Green
Blinking
Green
Alternating
Green and
Red
Steady Red
Blinking Red
Meaning
System OK. Power source communicating normally with wire feeder and its components.
Occurs during a reset, and indicates the
POWER WAVE 355/405 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
Non-recoverable system fault. If the PW
Status light is flashing any combination of
red and green, errors are present in the
POWER WAVE 355/405. 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 separated by a green light.
To clear the error, turn power source off, and
back on to reset.
Non recoverable hardware fault. Generally
indicates nothing is connected to the
POWER WAVE 355/405 wire feeder receptacle. See Trouble Shooting Section.
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.
OPERATION
B-4 B-4
POWER WAVE 355/405
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FIGURE B.1
10
4
6
1
3
2
5
7
8
9
CASE FRONT LAYOUT
POWER WAVE 355/405
5.
Internal POWER CIRCUIT BREAKER:
Protects 115
volt AC circuit.
6. LEAD CONNECTOR (SENSE LEAD)
7. DIAGNOSTIC CONNECTOR (RS-232)
8. WIRE FEEDER RECEPTACLE (5-PIN)
9. NEGATIVE TWIST- MATE TERMINAL
10. POSITIVE TWIST- MATE TERMINAL
NOMINAL PROCEDURES
The Power Wave is designed to operate with 3/4" electrode stick-out for CV and Pulse processes.
FRINGE PROCEDURES
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.
MAKING A WELD
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.
------------------------------------------------------------------------
WARNING
The steps for operating the Power Wave will vary
depending upon the options installed in the user interface (control box) of the welding system. The flexibility
of the Power Wave system lets the user customize
operation for the best performance.
First, consider the desired welding process and the
part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAW-P,
etc.)
Second, find the program in the welding software that
best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will
meet most needs. If a special welding program is
desired, contact the local Lincoln Electric sales representative.
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicated
digitally via the control cable.
WELDING ADJUSTMENTS
All adjustments are made on the system component
known as the User Interface (Control Box), which contains the switches, knobs, and digital displays necessary to control both the Power Wave and a Power
Feed wire feeder. Typically, the Control Box is supplied
as part of the wire feeder. It can be mounted directly on
the wire feeder itself, the front of the power source, or
mounted separately, as might be done in a welding
boom installation.
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.
OPERATION
B-5 B-5
POWER WAVE 355/405
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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. ATrim 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. For a more complete
description of the welding modes available in the
Power Wave, see the explanation below.
• 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, below, for 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
Time
CURRENT WAVE FORM (CV)
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OPERATION
B-6 B-6
POWER WAVE 355/405
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. Asetting of
0, results in the most positive arc initiation. Asetting of
-10 reduces hot start.
Between 0 and 10, the Scratch starting TIG mode is
selected. In this range, the OCV of the machine is controlled between 50 and 70 volts.
SPECIAL WELDING PROCESSES
AVAILABLE ON THIS MACHINE
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 procedure recommendations appear in the table
below.
Recommended Welding Procedures for Power Mode
MATERIAL
WIRE
WIRE SIZE
GAS
MATERIAL THICKNESS
WFS / POWER MODE SETTING
Aluminum 4043 Aluminum 5356 Mild Steel
E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L
0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035
100% Ar. 100% Ar. 100% CO
125 / 2.25 125 / 1.75 100 / 0.8 90 / 1.0
22 ga.
150 / 2.5 150 / 2.3 120 / 1.0
20 ga.
18 ga.
200 / 3.75 200 / 3.0
16 ga.
300 / 7.75 300 / 6.85
14 ga.
400 / 9.0 400 / 7.5
12 ga.
450 / 9.5 450 / 8.0
10 ga.
500 / 10.0 500 / 8.5
3/16
600 / 11.25 600 / 9.5
1/4
700 / 11
Not Recommended Not Recommended
140 / 1.7
190 / 2.0
260 / 3.0
330 / 5.0
Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel
2
75/25% Ar/CO
2
120 / 1.0
140 / 1.5
190 / 2.0
260 / 3.0
330 / 4.5
100% CO
100 / 0.7
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.5
2
75/25% Ar/CO
100 / 1.0
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.0
100% CO
2
2
75/25% Ar/CO
2
Tri-mix Tri-mix
80 / 1.5 50 / 0.5
100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0
125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7
160 / 3.8 160 / 3.5 190 / 3.5210 / 3.0
200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0
240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0
INSTALLATION
B-7 B-7
POWER WAVE 355
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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).
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, lower wire
feed speeds and 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.
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
PEAK AMPS
FREQUENCY
SPRAY TRANSITION
CURRENT
INSTALLATION
B-8 B-8
POWER WAVE 355
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PULSE-ON-PULSE™ (GMAW-PP)
Pulse on Pulse™ is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum (See the table below). It gives
weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are
used, instead of the single pulse type normally used in
GMAW-P. Anumber of high energy pulses are used to
obtain spray transfer and transfer metal across the arc.
Such pulses are shown in the figure below. After a
number "N" of such pulses, depending on the wire feed
speed used, an identical number "N" of low energy
pulses are performed. These low energy pulses,
shown in the figure below, do not transfer any filler
metal across the arc and help to cool the arc and keep
the heat input low.
The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down,
the major effect of the low energy pulses is that they
form a weld ripple. Since they occur at very regular
time intervals, the weld bead obtained is very uniform
with a very consistent ripple pattern. In fact, the bead
has its best appearance if no oscillation of the welding
gun ("whipping") is used.(See the figure below)
When Arc Control is used in the Pulse on Pulse modes,
it does the same things it does in the other pulsed
modes: decreasing the Arc Control decreases the
droplet transfer and weld deposition rate. Increasing
the Arc Control increases the droplet transfer and weld
deposition rate. Since Arc Control varies weld droplet
transfer rate, the Arc Control can be used to vary the
ripple spacing in the weld bead.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
Table B.2 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position. The values in the table can be helpful as a starting point to
establish a welding procedure. From there, adjustments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).
The comments on the table below show values of WFS
below which it is not recommended to weld. The reason is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.
WELDING PROCEDURES FOR PULSE-ON-PULSE
"N" PULSES "N" PULSES
HIGH HEAT
PEAK
AMPS
BACKGROUND
AMPS
PULSES
TIME
LOW HEAT
PULSES
MATERIAL
GAS
WIRE
WIRE SIZE
MATERIAL
THICKNESS
WFS /
ARC CONTROL
COMMENTS
14 ga. 250 / 0 200 / 0 230 / 0 225 / 0
10 ga. 400 / 0 280 / 0 425 / 0 400 / 0
Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356
100% Ar. 100% Ar. 100% Ar. 100% Ar.
E4043 E4043 E5356 E5356
0.035 3/64 0.035 3/64
3/16 550 / 0 340 / 0 670 / 0 500 / 0
1/4 600 / 0 400 / 0 700 / 0 550 / 0
Not Recommended
below 200 WFS
Not Recommended
below 100 WFS
Not Recommended
below 200 WFS
Not Recommended
below 200 WFS
C-1 C-1
POWER WAVE 355/405
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TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories...........................................................................................................................Section C
Optional Equipment....................................................................................................................C-2
Field Installed .......................................................................................................................C-2
Compatible Lincoln Equipment............................................................................................C-2
ACCESSORIES
C-2 C-2
POWER WAVE 355/405
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OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.
FIELD INSTALLED
K940-Work Voltage Sense Lead Kit
K1764-1-Undercarriage*
K1838-1-Valet Style Undercarriage
K1796-Coaxial Welding Cable-
(Requires Adapter K2176-1)
K2176-1 Twist-mate to Lug Adapters
* Dual Cylinder Kit for K1764-1 is K1702-1
Welding Cable Connectors:
K852-70 1/0-2/0 CABLE
K852-95 2/0-3/0 CABLE
COMPATIBLE LINCOLN EQUIPMENT
Any Linc-Net compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power Feed
family (PF-10, PF-10X2, PF-11).
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