Lincoln Electric Welding System IM917 A User Manual
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IM917-A  
POWER WAVE®405M  
June, 2009  
For use with machines Code 11379, 11491  
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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 thought-  
ful 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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OPERATOR’S 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  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
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 within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
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.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
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.  
5.c. 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 prod-  
ucts.  
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.  
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.  
Jan ‘09  
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iii  
iii  
SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
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.  
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.  
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.  
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.  
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.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
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).  
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, VA 22202.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
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 cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
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.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Jan ‘09  
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iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
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.  
Sûreté Pour Soudage A L’Arc  
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 lev-  
age, 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.  
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.  
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.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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 ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
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.  
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  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
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, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
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
v
SAFETY  
Electromagnetic Compatibility (EMC)  
Conformance  
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May  
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility  
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized  
standard: EN 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 of 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 compe-  
tent 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 prob-  
lems 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  
vi  
SAFETY  
Electromagnetic Compatibility (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other  
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.  
Methods of Reducing Emissions  
Mains Supply  
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-  
tions. 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 equip-  
ment, 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 equip-  
ment 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 connec-  
tion 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 prob-  
lems of interference. Screening of the entire welding installation may be considered for special applications.  
1
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-  
uct standard for arc welding equipment.”  
L10093 3-1-96H  
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vii  
vii  
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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viii  
viii  
TABLE OF CONTENTS  
Page  
Installation .......................................................................................................Section A  
Technical Specifications - POWER WAVE® 405M ..............................................A-1  
Safety Precautions.................................................................................................A-2  
Select Suitable Location ........................................................................................A-2  
Stacking ..........................................................................................................A-2  
Tilting...............................................................................................................A-2  
Input and Grounding Connections ..................................................................A-2  
Power Cord Connection..................................................................................A-2  
Undercarriage Mountings................................................................................A-2  
Output Cables, Connections and Limitations.........................................................A-3  
Negative Electrode Polarity ...................................................................................A-3  
Voltage Sensing ................................................................................................... A-4  
POWER WAVE® to Semi-automatic Power Feed Wire Feeder Interconnections A-5  
System Description................................................................................................A-5  
System Set-Up...............................................................................................A-6, A-7  
Welding with Multiple POWER WAVE®s ..............................................................A-8  
Control Cable Specifications..................................................................................A-8  
Multiple Arc Unsynchronized sense and work leads .............................................A-9  
I / O Receptacle Specifications............................................................................A-10  
Dip Switch Settings and Locations...............................................................A-10  
Control Board Dip Switch..............................................................................A-10  
________________________________________________________________________  
Operation .........................................................................................................Section B  
Safety Precautions.................................................................................................B-1  
General Description...............................................................................................B-1  
Recommended Processes and Equipment ...........................................................B-1  
Recommended Processes..............................................................................B-1  
Required Equipment .......................................................................................B-2  
Limitations.......................................................................................................B-2  
Duty Cycle and Time Period ...........................................................................B-2  
Case Front Controls........................................................................................B-2  
Nominal Procedures........................................................................................B-3  
Fringe Procedures...........................................................................................B-3  
Making a Weld ................................................................................................B-3  
Welding Adjustment ........................................................................................B-3  
Constant Voltage Welding...............................................................................B-4  
Pulse Welding .................................................................................................B-5  
TIG GTAW, SMAW, and Arc Gouging ............................................................B-6  
Power Mode and Recommended Welding Procedures ..................................B-7  
________________________________________________________________________  
Accessories.....................................................................................................Section C  
Optional Equipment...............................................................................................C-1  
Factory Installed..............................................................................................C-1  
Field Installed..................................................................................................C-1  
Compatible Lincoln Equipment  
________________________________________________________________________  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Capacitor Discharge Procedure ............................................................................D-1  
Routine Maintenance.............................................................................................D-1  
Periodic Maintenance............................................................................................D-1  
Calibration Specification........................................................................................D-1  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to use Troubleshooting Guide .......................................................................E-1  
Using the Status LED to Troubleshoot System Problems .....................................E-2  
Troubleshooting Guide.............................................................................E-3 thru E-7  
________________________________________________________________________  
Wiring Diagram ............................................................................................Section F-1  
Connection Diagram ....................................................................................Section F-2  
Dimension Print............................................................................................Section F-3  
________________________________________________________________________  
Parts Lists...............................................................................................................P-551  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - POWER WAVE® 405M  
INPUT AC VOLTAGE & DC OUTPUT  
Product Ordering Input AC  
Rated DC Output  
Output  
Range  
(continuous)  
Weight  
with Cord  
Dimensions  
HxWxD  
Name Information Voltage Amps/Volts/Duty Cycle  
50/60 Hz  
350A / 34V / 60%  
14.7”x12.5”x  
27.8”*  
Power  
200-220/  
3 Phase  
320A / 33V / 60%  
1 Phase  
Wave K 2369-2 380-400/  
AMPS  
5-425  
86.5lbs  
(37.4 kg)  
(373x318x  
706*)mm  
405M  
415  
50/60 Hz  
275A / 31V /100%  
1 Phase  
300A / 32V / 100%  
3 Phase  
* Includes  
handles  
* Overall Length Including Handle, 21.6” (549mm) without handle.  
Insulation Class 180 (H)  
POWER WAVE® 405M INPUT CURRENT  
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs  
Input 50/60 Hz Output Recommended  
300Amps@  
Voltage  
Phases  
350Amps@  
Line Cord  
Size Fuse Size  
Notes  
32Volts(100%)  
34Volts(60%)  
AWG SIZES  
200  
220  
380  
400  
415  
3
3
3
3
3
41  
37  
23  
22  
22  
48  
48  
28  
27  
26  
6
6
8
8
8
80A  
80A  
50A  
50A  
50A  
Note 2  
Note 2  
Voltage  
Phases  
275Amps@  
320Amps@  
Line Cord  
Size Fuse Size  
Notes  
31Volts(100%)  
33Volts(60%)  
200  
220  
380  
400  
415  
1
1
1
1
1
----  
64  
44  
40  
38  
----  
82  
55  
50  
48  
---  
4
6
8
8
-----  
Note 1  
Note 2  
Note 2  
125A  
80A  
80A  
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) 75°C rated:  
DUTY CYCLE  
100%  
CURRENT  
275  
350  
LENGTH UP 61m (200 FT)  
61-76m (200-250 FT)  
1/0  
1/0  
1/0  
2/0  
60%  
POWER WAVE® 405M  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
• Initial 200VAC - 230VAC operation will require an  
Input voltage panel setup.  
• Open the access panel on the rear of the machine.  
• For 200 or 230: Position the large switch to 200-  
230.  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power off at the dis-  
connect switch before attempting to  
connect or disconnect input power  
lines, output cables or control  
cables.  
• For higher voltages: Position the large switch to  
greater than 380.  
• Move the "A" lead to the appropriate terminal.  
POWER CORD CONNECTION  
• Only qualified personnel should perform this  
installation.  
• Connect the green or green/yellow lead of the  
power cord to ground per U.S.National  
Electrical Code.  
A 10ft.(3.5m) power cord is provided and wired into  
the machine. Follow the power cord connection  
instructions.  
----------------------------------------------------------------------  
CAUTION  
• Incorrect connection may result in equipment  
damage.  
SELECT SUITABLE LOCATION  
The Invertec POWER WAVE® 405M will operate in  
harsh environments. Even so, it is important that sim-  
ple preventative measures are followed in order to  
assure long life and reliable operation.  
----------------------------------------------------------------------  
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• The machine must be located where there is free cir-  
culation of clean air such that air movement in the  
back, out the sides and bottom will not be restricted.  
BROWN  
5
5
3
E
V
A
W
R
E
W
O
P
W
A
R
N
I
N
G
R
E
M
O
T
E
P
O
W
E
R
O
N
F
F
• 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.  
Single Phase Input  
Connect green/yellow lead to ground per National  
Electrical Code.  
Connect blue and brown leads to power.  
Wrap blue lead with tape to provide 600V insulation.  
Three Phase Input  
• Keep machine dry. Shelter from rain and snow. Do  
not place on wet ground or in puddles.  
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.  
CAUTION  
Connect green/yellow lead to ground per National  
Electric Code.  
Connect black, blue and brown leads to power.  
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.  
UNDERCARRIAGE MOUNTINGS  
----------------------------------------------------------------------  
STACKING  
POWER WAVE® 405M cannot be stacked.  
MOUNTING HOLE LOCATIONS  
NOTE: MOUNTING SCREWS CAN NOT PROTR  
UDE MORE THAN  
CHES INSIDE THE MACHINE.  
0.5 IN  
TILTING  
3.50  
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.  
1/4-20 NUT (4 PLACES)  
5.50  
INPUT AND GROUNDING CONNECTIONS  
• Only a qualified electrician should connect the  
Invertec POWER WAVE® 405M. Installation should  
be made in accordance with the appropriate  
National Electrical Code, all local codes and the  
information detailed below.  
10.00  
10/01  
11.8  
4
M19527  
• When received directly from the factory, multiple  
voltage machines are internally connected for  
400VAC. If 400VAC is the desired input, then the  
machine may be connected to the power system  
without any setup required inside the machine.  
POWER WAVE® 405M  
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A-3  
A-3  
INSTALLATION  
OUTPUT CABLES, CONNECTIONS AND  
LIMITATIONS  
Output connections on some POWER WAVE®s are  
made via 1/2-13 threaded output studs located  
beneath the spring loaded output cover at the bottom  
of the case front.  
Connect a work lead of sufficient size and length (per  
table A.1) 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.  
Most welding applications run with the electrode being  
positive (+). For those applications, connect the elec-  
trode cable between the wire feeder and the positive  
(+) output Twist-Mate 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 con-  
tact. The electrode cable should be sized according to  
the specifications given in the output cable connec-  
tions 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.  
CAUTION  
When using an inverter type power source like the  
POWER WAVE®s, use the largest welding (elec-  
trode and work) cables that are practical. At least  
2/0 copper wire - even if the average output cur-  
rent 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 weld-  
ing cables are used.  
For additional Safety information regarding the elec-  
trode and work cable set-up, See the standard "SAFE-  
TY INFORMATION" located in the front of the  
Instruction Manuals.  
----------------------------------------------------------------------  
CABLE INDUCTANCE, AND ITS EFFECTS  
ON PULSE WELDING  
CAUTION  
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), tradi-  
tional 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).  
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.  
FIGURE A.3  
POWER  
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.  
WAVE  
A
C
WORK  
B
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® 405M  
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A-4  
A-4  
INSTALLATION  
ELECTRODE VOLTAGE SENSING  
VOLTAGE SENSING  
The best arc performance occurs when the  
PowerWaves have accurate data about the arc condi-  
tions. 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 condi-  
tions and can have a dramatic effect on performance.  
Sense Lead Kits (K940-10, -25 or -50) are available  
for this purpose.  
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 config-  
ured at the feed head for all semi-automatic  
processes. Failure to do so may result in extreme-  
ly high welding outputs.  
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  
semi-automatic 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® 405M. For  
more information on the WORK sense lead (21), see  
"Work Voltage Sensing” in the following paragraph.  
----------------------------------------------------------------------  
Enable the voltage sense leads as follows:  
TABLE A.1  
Process Electrode Voltage  
Sensing 67 lead *  
GMAW 67 lead required  
GMAW-P 67 lead required  
FCAW 67 lead required  
Work Voltage  
Sensing 21 lead  
21 lead optional  
21 lead optional  
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® 405M’s default to the  
work stud (work sense lead disabled)  
For processes requiring work voltage sensing, con-  
nect 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®. (See Dip Switch Settings and  
Locations in Installation Section of this manual.)  
POWER WAVE® 405M  
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A-5  
A-5  
INSTALLATION  
POWER WAVE® TO SEMI-AUTOMATIC  
POWER FEED WIRE FEEDER INTERCON-  
NECTIONS  
The POWER WAVE® 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 communi-  
cation, 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 recepta-  
cle 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.  
SYSTEM DESCRIPTION  
The POWER WAVE® 405M and Power Feed M 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 number of wire feeders is determined by the type  
of wire feeder. Refer to the wire feeder instruction  
manual for details  
POWER WAVE® 405M  
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A-6  
A-6  
INSTALLATION  
CONFIGURING THE SYSTEM  
If a system can not be “Auto Mapped” then the status  
light on the power source will blink green fast and the  
welder output will be disabled. If a system is not  
“Auto-mappable”, then consult the instruction manual  
for the accessory being used for configuration infor-  
mation about DIP switch settings, or consult your local  
Lincoln sales representative.  
The power source will “Auto Map” the system eliminat-  
ing most of the need to set DIP switches to configure  
the system.  
If a system can not be “Auto Mapped” then the status  
light on the power source will blink green fast and the  
welder output will be disabled.  
SINGLE HEAD FEEDER  
DUAL HEAD FEEDER  
UP TO 4 WIRE FEEDERS  
ALLOWED  
POWER WAVE®  
POWER WAVE®  
405M  
405M  
CONTROL BOX  
FEED HEAD  
SINGLE HEAD BOOM FEEDER  
UP TO 4 FEED HEADS  
ALLOWED  
POWER WAVE®  
405M  
FEED HEAD 1  
SINGLE HEAD BOOM FEEDER  
POWER WAVE® 405M  
ROBOT  
PLC CONTROLLER  
ANALOG INTERFACE  
PF-10R  
WIRE  
DRIVE  
MODULE  
etc.  
POWER WAVE® 405M  
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A-7  
A-7  
INSTALLATION  
ALTERNATE HARD AUTOMATIC APPLICATION  
(using a User Interface, Wire Drive Module, and POWER FEED-10R)  
POWER WAVE® 405M  
PF-10R  
WIRE  
DRIVE  
MODULE  
(FH1)  
COMBINATION HARD AUTOMATION APPLICATION  
(w/ Semi-Auto Feeder, Wire Drive Module, and POWER FEED-10R)  
POWER WAVE® 405M  
PF-10R  
WIRE  
DRIVE  
MODULE  
DUAL HEAD  
(FH1)  
System that is NOT "Auto Mappable"  
DUAL HEAD BOOM FEEDER  
(using two single heads)  
POWER WAVE®  
405M  
DUAL HEAD  
FH-1  
FH-2  
In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE®  
405M auto mapping disabled and the Equipment Groups set on (See Figure A-8). (See the Feeder documenta-  
tion for information on setting the feeder DIP switches)  
POWER WAVE® 405M  
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A-8  
A-8  
INSTALLATION  
WELDING WITH MULTIPLE POWER  
WAVES®  
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.  
CAUTION  
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.  
CAUTION  
The use of non-standard cables, especially in  
lengths greater than 25ft. (7.6m), can lead to com-  
munication 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.  
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 direc-  
tions 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 cover-  
age.  
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)  
FIGURE A.6  
POWER WAVE 405M  
®
POWER WAVE 405M  
®
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® 405M  
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A-9  
A-9  
INSTALLATION  
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES  
POWER WAVE® 405M  
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A-10  
A-10  
INSTALLATION  
I / O RECEPTACLE SPECIFICATIONS  
switch 7  
auto mapping  
auto mapping enable-default  
TABLE A.2  
off  
WIRE FEEDER RECEPTACLE  
on  
auto mapping disabled  
PIN  
A
B
C
D
LEAD#  
53  
54  
67A  
52  
51  
FUNCTION  
Communication Bus L  
Communication Bus H  
Electrode Voltage Sense  
switch 8*  
work sense lead  
work sense lead not connected  
work sense lead connected  
0vdc  
-
off  
on  
40VDC  
}
E
+40vdc +  
*Factory setting for Switch 8 is OFF.  
TABLE A.3  
VOLTAGE SENSE RECEPTACLE  
PIN  
LEAD#  
FUNCTION  
3
21A  
Work Voltage Sense  
FIGURE A.7  
CONTROL BOARD (DIP Switch Location)  
TABLE A.4  
RS232 RECEPTACLE  
PIN  
2
3
LEAD#  
253  
254  
#
FUNCTION  
RS232 Receive  
RS232 Transmit  
Pin5  
4
5
#
Pin4  
6
20  
7
# #  
# #  
251  
Pin20  
Pin6  
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:  
WARNING  
ELECTRIC SHOCK can kill.  
1. Turn off power to the power source at the dis-  
connect switch.  
• Insulate yourself from the work and ground.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------------------------  
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.  
FIGURE A.8  
CONTROL BOARD DIP SWITCH:  
switch 1 = reserved for future use  
switch 2 = reserved for future use  
switch 3 = equipment group 1 selcted (default=off)  
switch 4 = equipment group 2 selcted (default=off)  
switch 5 = reserved for future use  
switch 6 = reserved for future use  
switch 7 = auto mapping  
switch 8 = work sense lead  
(See Figure A.8 for Dual Head Boom Feeder)  
POWER WAVE® 405M  
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B-1  
B-1  
OPERATION  
SAFETY PRECAUTIONS  
GENERAL DESCRIPTION  
The POWER WAVE® 405M semi-automatic power  
source is designed to be a part of a modular, multi-  
process welding system. Depending on configuration,  
it can support constant current, constant voltage, and  
pulse welding modes.  
Read this entire section of operating instructions  
before operating the machine.  
WARNING  
ELECTRIC SHOCK can kill.  
The POWER WAVE® 405M 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 com-  
ponents communicate with Linc-Net.  
• Unless using cold feed feature, when  
feeding with gun trigger, the elec-  
trode 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.  
The POWER WAVE® 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.  
• 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.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
-----------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
RECOMMENDED PROCESSES  
The POWER WAVE® 405M can be set up in a num-  
ber of configurations, some requiring optional equip-  
ment or welding programs. Each machine is factory  
preprogrammed with multiple welding procedures, typ-  
ically including GMAW, GMAW-P, FCAW, GTAW, and  
CAC-A for a variety of materials, including mild steel,  
stainless steel, cored wires, and aluminum.  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
-----------------------------------------------------------  
ARC RAYS can burn.  
The POWER WAVE® 405M is recommended for  
semi-automatic welding, and may also be suitable for  
basic hard automation applications.  
• Wear eye, ear, and body protection.  
• This POWER WAVE® is not recommended for  
processes other than those listed.  
Observe additional guidelines detailed in the  
beginning of this manual.  
POWER WAVE® 405M  
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B-2  
B-2  
OPERATION  
POWER WAVE® 405M  
Operation  
–
Semi-Automatic  
3. HIGH TEMPERATURE LIGHT (thermal overload):  
A yellow light that comes on when an over temper-  
ature 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.  
POWER WAVE® 405M can only be used with  
ArcLink compatible Power Feed M semi-automatic  
wire feeders. In addition, the Power Feed M semi-  
automatic wire feeders may require optional equip-  
ment 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.  
4. CB1 WIRE FEEDER CIRCUIT BREAKER:  
Protects 40 volt DC wire feeder power supply.  
FIGURE B.1  
All welding programs and procedures are selected  
through the Power Feed M semi-automatic user inter-  
face  
2
3
REQUIRED EQUIPMENT  
7
Any ArcLink compatible semi-automatic wire feeding  
equipment. Specifically, the semi-automatic Power  
Feed M family.  
4
1
6
LIMITATIONS  
• Only ArcLink compatible Power Feed M semi-  
automatic wire feeders and users interfaces may be  
used. Other Lincoln wire feeders or non-Lincoln wire  
feeders cannot be used.  
8
9
• POWER WAVE® 405M Output Limitations  
The POWER WAVE® 405M will support maximum  
average output current of 350 Amps @ 60% duty  
cycle.  
10  
5
CASE FRONT LAYOUT  
POWER WAVE® 405M  
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.  
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  
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  
Troubleshooting E Section in this Manual.  
NOTE: The POWER WAVE® 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.  
POWER WAVE® 405M  
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B-3  
B-3  
OPERATION  
WELDING ADJUSTMENTS  
NOMINAL PROCEDURES  
The POWER WAVE® is designed to operate with  
3/4"(19.1mm) electrode stick-out for CV and Pulse  
processes.  
All adjustments are made on the system component  
known as the User Interface (Control Box), which con-  
tains the switches, knobs, and digital displays neces-  
sary to control both the POWER WAVE® and a Power  
Feed wire feeder. Typically, the Control Box is sup-  
plied as part of the wire feeder. It can be mounted  
directly on the wire feeder itself, the front of the power  
source, or mounted separately, as might be done in a  
welding boom installation.  
FRINGE PROCEDURES  
Excessively short or long electrode stick-outs may  
function only on a limited basis, if at all.  
MAKING A WELD  
WARNING  
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 manu-  
al.  
The serviceability of a product or structure utiliz-  
ing 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 selec-  
tion.  
• WFS / AMPS:  
In synergic welding modes (synergic CV, pulse  
GMAW) WFS (wire feed speed) is the dominant con-  
trol 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 cur-  
rent) according to pre-programmed settings contained  
in the POWER WAVE®.  
------------------------------------------------------------------------  
The steps for operating the POWER WAVE® will vary  
depending upon the options installed in the user inter-  
face (control box) of the welding system. The flexibility  
of the POWER WAVE® system lets the user cus-  
tomize operation for the best performance.  
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 oper-  
ator must adjust the voltage to compensate for any  
changes made to the WFS.  
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.)  
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.  
Second, find the program in the welding software that  
best matches the desired welding process. The stan-  
dard software shipped with the POWER WAVE®s  
encompasses a wide range of common processes  
and will meet most needs. If a special welding pro-  
gram is desired, contact the local Lincoln Electric  
sales representative.  
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 set-  
ting of 1.000 is a good starting point for most condi-  
tions.  
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 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 com-  
plete description of the welding modes available in the  
POWER WAVE®, see the explanation following.  
POWER WAVE® 405M  
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B-4  
B-4  
OPERATION  
• ARC CONTROL  
Non Synergic CV:  
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 set-  
ting 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.  
This type of CV mode behaves more like a conven-  
tional CV power source. Voltage and WFS are inde-  
pendent adjustments. Therefore to maintain the arc  
characteristics, the operator must adjust the voltage to  
compensate for any changes made to the WFS.  
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)  
CONSTANT VOLTAGE WELDING  
Synergic CV:  
For each wire feed speed, a corresponding voltage is  
preprogrammed into the machine through special soft-  
ware at the factory. The nominal preprogrammed volt-  
age is the best average voltage for a given wire feed  
speed, but may be adjusted to preference. When the  
wire feed speed changes, the POWER WAVE® auto-  
matically adjusts the voltage level correspondingly to  
maintain similar arc characteristics throughout the  
WFS range.  
FIGURE B.2  
CURRENT WAVE FORM (CV)  
Current  
Time  
POWER WAVE® 405M  
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B-5  
B-5  
OPERATION  
(See Figure B.3)  
PULSE WELDING  
PULSE-ON-PULSE™ (GMAW-PP)  
Pulse welding procedures are set by controlling an  
overall "arc length" variable. When pulse welding, the  
arc voltage is highly dependent upon the waveform.  
The peak current, back ground current, rise time, fall  
time and pulse frequency all affect the voltage. The  
exact voltage for a given wire feed speed can only be  
predicted when all the pulsing waveform parameters  
are known. Using a preset voltage becomes impracti-  
cal, and instead the arc length is set by adjusting  
"trim".  
Pulse on Pulse™ is a Lincoln process specifically  
designed for use in welding relatively thin (less than  
1/4"(6.4mm)0 thick) aluminum (See Table B.3). 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. A number of high energy pulses are used  
to obtain spray transfer and transfer metal across the  
arc. Such pulses are shown in Figure B.4. After a  
number "N" of such pulses, depending on the wire  
feed speed used, an identical number "N" of low ener-  
gy pulses are performed. These low energy pulses,  
shown in Figure B.4, do not transfer any filler metal  
across the arc and help to cool the arc and keep the  
Trim adjusts the arc length and ranges from 0.50 to  
1.50, with a nominal value of 1.00. Trim values greater  
than 1.00 increase the arc length, while values less  
than 1.00 decrease the arc length.  
Most pulse welding programs are synergic. As the  
wire feed speed is adjusted, the POWER WAVE® will  
automatically recalculate the waveform parameters to  
maintain similar arc properties.  
"N" PULSES  
"N" PULSES  
HIGH HEAT  
PULSES  
LOW HEAT  
PULSES  
PEAK  
AMPS  
BACKGROUND  
AMPS  
The POWER WAVE® utilizes "adaptive control" to  
compensate for changes in electrical stick-out while  
welding. (Electrical stick-out is the distance from the  
contact tip to the work piece.) The POWER WAVE®  
wave forms are optimized for a 0.75" (19mm) stick-  
out. The adaptive behavior supports a range of stick-  
outs from 0.50" (13mm) to 1.25" (32mm). At very low  
or high wire feed speeds, the adaptive range may be  
less due to reaching physical limitations of the welding  
process.  
TIME  
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  
Arc Control, often referred to as wave control, in pulse  
programs usually adjusts the focus or shape of the  
arc. Wave control values greater than 0.0 increase the  
pulse frequency while decreasing the background cur-  
rent, resulting in a tight, stiff arc best for high speed  
sheet metal welding. Wave control values less than  
0.0 decrease the pulse frequency while increasing the  
background current, for a soft arc good for out-of-posi-  
tion welding.  
gun ("whipping") is used.(See Figure B.5)  
FIGURE B.3  
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 trans-  
fer 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.  
CURRENT WAVE FORM (PULSE)  
Current  
Time  
POWER WAVE® 405M  
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B-6  
B-6  
OPERATION  
BENEFITS OF PULSE ON PULSE FROM  
LINCOLN ELECTRIC  
SMAW  
In SMAW (STICK mode), arc control adjusts the arc  
force. It can be set to the lower range for a soft and  
less penetrating arc characteristic (negative numeric  
values) or to the higher range (positive numeric val-  
ues) 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 indi-  
cated 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 elec-  
trodes. In either case the arc control is available to  
increase or decrease the energy level delivered to the  
arc.  
• 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, adjust-  
ments need to be made to set the proper procedure  
for each specific application (out-of-position, other  
types of joints, etc.).  
The comments on Table B.3 show values of WFS  
below which it is not recommended to weld. The rea-  
son 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.  
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.  
TIG GTAW  
The common procedures for Arc Gouging metal are:  
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.  
• Removing poor welds from a weldment so that new  
welds can be made.  
The Arc Control level selects the starting mode.  
• Creating a welding groove or grooves in two pieces  
of steel butted together. (See Example below)  
WELD GROOVES CREATED BY ARC GOUGING  
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 set-  
ting of 0, results in the most positive arc initiation. A  
setting of -10 reduces hot start.  
STEEL BUTTED TOGTHER  
Mode 9 in the POWER WAVE® 405M 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".  
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.  
WELDING PROCEDURES FOR PULSE-ON-PULSE (TABLE B.2)  
MATERIAL  
GAS  
Aluminum 4043  
100% Ar.  
E4043  
Aluminum 4043  
100% Ar.  
E4043  
Aluminum 5356  
100% Ar.  
E5356  
Aluminum 5356  
100% Ar.  
E5356  
WIRE  
WIRE SIZE  
WELD MODE  
0.035  
3/64  
0.035  
3/64  
98  
99  
101  
102  
14 ga.  
250 / 1.0  
200 / 1.0  
230 / 1.0  
225 / 1.0  
10 ga.  
3/16  
1/4  
400 /1.0  
550 / 1.0  
600 / 1.0  
280 / 1.0  
340 / 1.0  
400 / 1.0  
425 / 1.0  
670 / 1.0  
700 / 1.0  
400 / 1.0  
500 / 1.0  
550 / 0.9  
Not Recommended  
below 200 WFS  
Not Recommended  
below 100 WFS  
Not Recommended  
below 200 WFS  
Not Recommended  
below 200 WFS  
COMMENTS  
POWER WAVE® 405M  
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B-7  
B-7  
OPERATION  
POWER MODE™  
Start by setting the wire feed speed based upon mate-  
rial thickness and appropriate travel speed. Then  
adjust the Volts/Trim knob as follows:  
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.  
• 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 Volts/Trim knob  
until the desired arc length is obtained.  
• Short Arc MIG at low procedure settings.  
• Aluminum MIG welding.  
Note the Volts/Trim display is simply a relative number  
and DOES NOT correspond to voltage.  
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 experimenta-  
tion until the desired output result is established.  
Some procedure recommendations appear in Table  
B.3.  
In the Power Mode two variables need to be set:  
• Wire Feed Speed  
• Power Mode Trim  
Setting up a Power Mode procedure is similar to set-  
ting a CV MIG procedure. Select a shielding gas  
appropriate for a short arc process.  
• For steel, use 75/25 Ar/CO shield gas.  
2
• For Stainless, select a Helium blend Tri-Mix.  
• For Aluminum, use 100% Ar.  
Recommended Welding Procedures for Power Mode - Table B.3  
MATERIAL  
WIRE  
Aluminum 4043 Aluminum 5356  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Mild Steel  
L56  
Stainless Steel Stainless Steel  
E4043  
0.035  
E5356  
0.035  
E308L  
0.030  
E308L  
0.035  
WIRE SIZE  
GAS  
0.025  
0.025  
0.030  
0.030  
0.035  
0.035  
100% Ar.  
100% Ar.  
100% CO2  
75/25 Ar/CO2  
100 / 0.8  
120 / 1.0  
140 / 1.5  
190 / 2.0  
260 / 3.0  
330 / 4.5  
100% CO2  
75/25 Ar/CO2  
90 / 1.0  
100% CO2  
75/25 Ar/CO2  
Tri-mix  
Tri-mix  
22 ga.  
Not Recommended  
120 / 1.0  
140 / 1.7  
190 / 2.0  
260 / 3.0  
330 / 5.0  
Not Recommended  
100 / 0.7  
110 / 1.5  
125 / 2.0  
160 / 2.3  
230 / 3.5  
300 / 6.0  
400 / 7.5  
20 ga.  
18 ga.  
16 ga.  
14 ga.  
12 ga.  
10 ga.  
3/16  
100 /1.0  
110 / 1.5  
125 / 2.0  
160 / 2.3  
230 / 3.5  
300 / 6.0  
400 / 7.0  
80 / 1.5  
110 / 2.0  
140 / 2.5  
210 / 3.0  
270 / 5.0  
325 / 6.5  
50 / 0.5  
110 / 2.0  
130 / 2.7  
190 / 3.5  
230 / 6.0  
300 / 7.0  
100 / 2.5  
125 / 3.0  
160 / 3.8  
200 / 5.0  
240 / 6.5  
100 / 2.5  
125 / 3.0  
160 / 3.5  
200 / 4.5  
240 / 7.0  
400 / 2.0  
400 / 2.5  
500 / 7.0  
570 / 9.0  
500 / 7.0  
600 / 7.8  
1/4  
700 / 9.1  
Not  
700 / 8.5  
Not  
Recommended Recommended  
COMMENTS  
below 400  
WFS  
below 400  
WFS  
POWER WAVE® 405M  
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C-1  
C-1  
ACCESSORIES  
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 ArcLink compatible semi-automatic wire feeding  
equipment.  
POWER WAVE® 405M  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
PERIODIC MAINTENANCE  
Calibration of the POWER WAVE® 405M is critical to  
its operation. Generally speaking the calibration will  
not need adjustment. However, neglected or improp-  
erly calibrated machines may not yield satisfactory  
weld performance. To ensure optimal performance,  
the calibration of output Voltage and Current should  
be checked yearly.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
EXPLODING PARTS can cause  
injury.  
CALIBRATION SPECIFICATION  
•
Failed parts can explode or cause other  
parts to explode when power is applied.  
Output Voltage and Current are calibrated at the fac-  
tory. Generally speaking the machine calibration will  
not need adjustment. However, if the weld perfor-  
mance changes, or the yearly calibration check  
reveals a problem, contact the Lincoln Electric  
Company for the calibration software utility.  
•
Always wear a face shield and long  
sleeves when servicing.  
------------------------------------------------------------------------  
See additional warning information  
throughout this Operator’s Manual  
-----------------------------------------------------------  
The calibration procedure itself requires the use of a  
grid, and certified actual meters for voltage and cur-  
rent. The accuracy of the calibration will be directly  
affected by the accuracy of the measuring equipment  
you use. Detailed instructions are available with the  
utility.  
CAPACITOR DISCHARGE PROCEDURE  
1. Obtain a power resistor (25 ohms, 25 watts).  
2. Hold resistor body with electrically insulated glove.  
DO NOT TOUCH TERMINALS. Connect the resis-  
tor terminals across the two studs in the position  
shown. Hold in each position for 1 second. Repeat  
for all four capacitors.  
RESISTOR  
CAPACITOR  
TERMINALS  
3. Use a DC voltmeter to check that voltage is not  
present across the terminals on all four capacitors.  
ROUTINE MAINTENANCE  
Routine maintenance consists of periodically blowing  
out the machine, using a low pressure airstream, to  
remove accumulated dust and dirt from the intake and  
outlet louvers, and the cooling channels in the  
machine.  
POWER WAVE® 405M  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
POWER WAVE® 405M  
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E-2  
E-2  
TROUBLESHOOTING  
charts for both machine and weld performance.  
USING THE STATUS LED TO  
TROUBLESHOOT SYSTEM PROBLEMS  
The STATUS LIGHT is a two color light that indicates  
system errors. Normal operation is a steady green  
light. Error conditions are indicated in the following  
chart.  
The POWER WAVE® / Power Feed are best diag-  
nosed as a system. Each component (power source,  
user interface, and feed head) has a status light, and  
when a problem occurs it is important to note the con-  
dition of each. In addition, errors displayed on the user  
interface in most cases indicate only that a problem  
exists in the power source, not what the problem may  
be. Therefore, prior to cycling power to the sys-  
tem, check the power source status light for error  
sequences as noted below. This is especially  
important if the user interface displays "Err 006"  
or "Err 100" .  
NOTE: The POWER WAVE® 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.  
Included in this section is information about the power  
source Status LED, and some basic troubleshooting  
LIGHT CONDITION  
MEANING  
Status LED is solid green (no blinking).  
1. System OK. Power source communicating normally  
with wire feeder and its components.  
Status LED is blinking green.  
2. Occurs during a reset, and indicates the POWER  
WAVE® 405M is mapping (identifying) each compo-  
nent in the system. Normal for first 1-10 seconds  
after power is turned on, or if the system configura-  
tion is changed during operation.  
Status LED is blinking red and green.  
3. Non-recoverable system fault. If the PS Status light  
is flashing any combination of red and green, errors  
are present in the POWER WAVE® 405M. Read  
the error code before the machine is turned off.  
Error Code interpretation through the Status light is  
detailed in the Service Manual. 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.  
Status LED is solid red (no blinking).  
Status LED is blinking red.  
Non recoverable hardware fault. Generally indicates  
nothing is connected to the POWER WAVE® 405M  
wire feeder receptacle. See Trouble Shooting Section.  
Not applicable.  
POWER WAVE® 405M  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
ERROR CODES FOR THE POWERWAVE  
The following is a list of possible error codes that the POWER WAVE® 405M can output via the status light (see  
"Troubleshooting the POWER WAVE® / Power Feed System Using the Status LED." If connected to a PF-10/11  
these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.  
Error Code #  
CAN communication bus off.  
User Interface time out error.  
Indication  
11  
12  
Probably due to excessive number of communication errors.  
UI is no longer responding to the Power Source. The most likely  
cause is a fault/bad connection in the communication leads or con-  
trol cable.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
Contact the Service Department for instructions on reloading the  
Welding Software.  
21  
22  
23  
Unprogrammed Weld Mode.  
Empty Weld Table.  
Weld Table checksum error.  
Excessive Primary current present. May be related to a short in the  
main transformer or output rectifier.  
Low voltage on the main capacitors. May be caused by improper  
input configuration.  
When accompanied by an overvoltage error on the same side, it  
indicates no capacitor voltage present on that side, and is usually  
the result of an open or short in the primary side of the machine.  
Excess voltage on the main capacitors. May be caused by improp-  
er input configuration.  
31  
32  
33  
Primary overcurrent error.  
Capacitor "A" under voltage  
Capacitor "B" under voltage  
34  
35  
Capacitor "A" over voltage  
Capacitor "B" over voltage  
When accompanied by an under voltage error on the same side, it  
indicates no capacitor voltage present on that side, and is usually  
the result of an open or short in the primary side of the machine.  
Indicates over temperature. Usually accompanied by Thermal LED.  
Check fan operation. Be sure process does not exceed duty cycle  
limit of the machine.  
36  
Thermal error  
37  
41  
Soft start error  
Capacitor precharge failed. Usually accompanied by codes 32-35.  
The secondary (weld) current limit has been exceeded. When this  
occurs the machine output will phase back to 100 amps, typically  
resulting in a condition referred to as "noodle welding"  
Secondary overcurrent error  
NOTE: The secondary limit is 570 amps for the standard stud, and  
325 amps for all single phase operation.  
The maximum voltage difference between the main capacitors has  
been exceeded. May be accompanied by errors 32-35.  
43  
Capacitor delta error  
Error codes that contain three or four digits are defined as fatal  
errors. These codes generally indicate internal errors on the  
Control Board. If cycling the input power on the machine does not  
clear the error, try reloading the operating system. If this fails,  
replace the control board.  
Other  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
POWER WAVE® 405M  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local authorized  
is evident when the sheet metal  
covers are removed.  
Lincoln Electric Field Service  
facility for technical assis-  
tance.  
Input fuses keep blowing, or input  
breaker keeps tripping.  
1. Make certain that fuses or  
breakers are properly sized.  
See Installation section of this  
manual for recommended  
fuse and breaker sizes.  
2. Welding procedure is drawing  
too much output current, or  
duty cycle is too high.  
Reduce output current, duty  
cycle, or both.  
3. There is internal damage to  
the power source. Contact an  
authorized Lincoln Electric  
Service facility.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Machine will not power up (no  
lights, no fan, etc.)  
1. Make certain that the Power  
Switch (SW1) is in the “ON”  
position.  
Authorized Field Service Facility.  
2. Circuit Breaker CB1 (on Case  
Front) may have opened.  
Reset an over load on the 40V  
Wire Feeder supply may  
cause this to trip.  
3. Circuit breaker CB3 (in recon-  
nect area) may have opened.  
Reset. Also, check input volt-  
age selection, below.  
4. Input voltage selection made  
improperly. Power down,  
check input voltage reconnect  
according to diagram on  
reconnect cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.  
POWER WAVE® 405M  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Thermal LED is lit.  
1. Fan thermostat has opened.  
Check for proper fan operation.  
(Fan should run whenever out-  
put power is on.) Check for  
material blocking intake or  
exhaust louvers, or for excessive  
dirt clogging cooling channels in  
machine. Blow air in rear louvers  
to remove dirt around the fan.  
2. Secondary rectifier or Choke  
thermostat has opened. After  
machine has cooled, reduce  
load, duty cycle, or both. Check  
for material blocking intake or  
exhaust louvers.  
3. DC Bus PC board thermostat  
has opened check for excessive  
load on 40VDC supply.  
Machine won’t weld, can’t get any  
output.  
1. Input voltage is too low or too  
high. Make certain that input  
voltage is proper, according to  
the Rating Plate located on the  
rear of the machine.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Authorized Field Service Facility.  
2. If the Thermal LED is also lit,  
see “Yellow Thermal LED is Lit”  
section.  
3. Primary current limit has been  
exceeded. Possible short in out-  
put circuit. Turn machine off.  
Remove all loads from the out-  
put of the machine. Turn back  
on. If condition persists, turn  
power off, and contact an autho-  
rized Lincoln Electric Field  
Service facility.  
4
. This problem will normally be  
accompanied by an error code.  
Error codes are displayed as a  
series of red and green flashes by  
the  
status  
light.  
See  
"Troubleshooting the POWER  
WAVE® / Power Feed System  
Using the Status LED" section of  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.  
POWER WAVE® 405M  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine often “noodle welds” (out- 1.Secondary current limit has been  
put is limited to approximately 100  
amps) when running a particular  
procedure, especially a procedure  
with high WFS.  
exceeded, and the machine has  
phased back to protect itself.  
2. Adjust procedure or reduce load  
to lower current draw from the  
machine.  
Machine won’t produce full output. 1. Input voltage may be too low,  
limiting output capability of the  
power source. Make certain that  
the input voltage is proper,  
according to the Rating Plate  
located on the rear of the  
machine.  
2. Secondary current or voltage not  
be properly calibrated. Check  
values displayed on the Power  
Feed 10/11 verses readings on  
an external meter.  
If all recommended possible areas  
of misadjustments have been  
checked and the problem persists,  
contact your local Lincoln  
Auxiliary receptacle is “dead” no 1. Circuit breaker CB1 (on case  
auxiliary voltage .  
front) may have opened. Reset.  
2. Circuit breaker CB3 (in recon-  
nect area) may have opened.  
Reset.  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.  
POWER WAVE® 405M  
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E-7  
E-7  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
General degradation of the weld per- 1.Check for feeding problems, bad  
formance  
connections, excessive loops in  
cabling, etc.  
2. Verify weld mode is correct for  
processes.  
3. The power source may require  
calibration.  
4. Check the actual current dis-  
played on the Power Feed 10 vs.  
actual current measured via exter-  
nal meter.  
5. Check the actual voltage dis-  
played on the Power Feed 10 vs.  
actual voltage measured via exter-  
nal meter.  
6. Check the actual WFS displayed  
on the Power Feed 10 vs. actual  
WFS measured via external  
meter.  
Excessively long and erratic arc.  
1. Check for proper configuration  
and implementation of voltage  
sensing circuits.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
POWER WAVE® 405M  
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F-1  
F-1  
WIRING DIAGRAMS  
POWER WAVE® 405M  
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F-2  
F-2  
DIAGRAMS  
POWER WAVE® 405M  
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F-3  
F-3  
CONNECTION DIAGRAM  
Connection Diagram Semi-automatic "Simple System"  
(Electrode Positive, CV/Pulse Configuration shown)  
POWER WAVE  
WIRE  
FEEDER  
TO  
WORK  
CONTROL CABLE K1543  
POWER WAVE® 405M  
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F-4  
F-4  
DIMENSION PRINT  
POWER WAVE® 405M  
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NOTES  
POWER WAVE® 405M  
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NOTES  
POWER WAVE® 405M  
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G Do not touch electrically live parts or  
electrode with skin or wet clothing.  
G Insulate yourself from work and  
ground.  
G Keep flammable materials away.  
G Wear eye, ear and body protection.  
WARNING  
Spanish  
G No toque las partes o los electrodos G Mantenga el material combustible  
G Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
G Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
G Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
G Gardez à l’écart de tout matériel  
inflammable.  
G Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
G Isolez-vous du travail et de la terre.  
German  
G Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
G Isolieren Sie sich von den  
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
G Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
G Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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G Keep your head out of fumes.  
G Use ventilation or exhaust to  
remove fumes from breathing zone.  
G Turn power off before servicing.  
G Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
G Los humos fuera de la zona de res-  
piración.  
G Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
G Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
G No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux  
tien.  
G Gardez la tête à l’écart des fumées.  
G Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
G Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
G Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
G Vermeiden Sie das Einatmen von  
Schweibrauch!  
G Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
G Não opere com as tampas removidas.  
G Desligue a corrente antes de fazer  
serviço.  
G Mantenha-se afastado das partes  
moventes.  
G Não opere com os paineis abertos  
ou guardas removidas.  
G Mantenha seu rosto da fumaça.  
G Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
G Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• 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  
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