Lincoln Electric LINC 405 User manual

IM3001
04/2004
Rev. 3
LINC 405
OPERATOR’S MANUAL
MANUALE OPERATIVO
BEDIENUNGSANLEITUNG
MANUAL DE INSTRUCCIONES
MANUEL D'UTILISATION
BRUKSANVISNING OG DELELISTE
GEBRUIKSAANWIJZING
BRUKSANVISNING
INSTRUKCJA OBSŁUGI
BESTER S.A.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
www.lincolnelectriceurope.com

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Declaration of conformity
Dichiarazione di conformità
Konformitätserklärung
Declaración de conformidad
Déclaration de conformité
Samsvars erklæring
Verklaring van overeenstemming
Försäkran om överensstämmelse
Deklaracja zgodności
BESTER S.A.
Declares that the welding machine:
Dichiara che Il generatore per saldatura tipo:
Erklärt, daß die Bauart der Maschine:
Declara que el equipo de soldadura:
Déclare que le poste de soudage:
Bekrefter at denne sveisemaskin:
Verklaart dat de volgende lasmachine:
Försäkrar att svetsomriktaren:
Deklaruje, że spawalnicze źródło energii:
LINC 405-S, LINC 405-SA s/n
conforms to the following directives:
è conforme alle seguenti direttive:
den folgenden Bestimmungen entspricht:
es conforme con las siguientes directivas:
Est conforme aux directives suivantes:
er i samsvar med følgende direktiver:
Overeenkomt conform de volgende richtlijnen:
överensstämmer med följande direktiv:
spełnia następujące wytyczne:
73/23/CEE, 93/68/CEE, 89/336/CEE, 92/31/CEE
and has been designed in conformance with the following norms:
ed è stato progettato in conformità alle seguenti norme:
und in Übereinstimmung mit den nachstehenden Normen hergestellt wurde:
y ha sido diseñado de acuerdo con las siguientes normas:
et qu'il a été conçu en conformité avec les normes:
og er produsert og testet iht. følgende standarder:
en is ontworpen conform de volgende normen:
och att den konstruerats i överensstämmelse med följande standarder:
i że zostało zaprojektowane zgodnie z wymaganiami następujących norm:
EN 50199, EN 60974-1
inż. Stanisław Filipiuk
Technical Director
BESTER S.A., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
06/02

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Safety
08/03
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified individuals. Read and understand this manual before operating this
equipment. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to
this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not
responsible for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker should consult their physician before operating this
equipment.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
CE COMPLIANCE: This equipment complies to the European Communities directives.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

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Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Location and Environment
This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation.
•Do not place or operate this machine on a surface
with an incline greater than 15° from horizontal.
•This machine must be located where there is free
circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover
the machine with paper, cloth or rags when
switched on.
•Dirt and dust that can be drawn into the machine
should be kept to a minimum.
•This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
•Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.
•Do not operate in areas with an ambient
temperature greater than 40°C.
Duty cycle and Overheating
The duty cycle of a welding machine is the percentage of
time in a 10 minute cycle at which the welder can
operate the machine at rated welding current.
60% duty cycle:
Welding for 6 minutes. Break for 4 minutes.
Excessive extension of the work duty cycle will cause
the thermal protection circuit to activate.
The welding machine is protected from overheating by a
thermostat. When the machine is overheated the output
of the machine will turn “OFF“, and the Thermal Indicator
Light will turn “ON“. When the machine has cooled to a
safe temperature the Thermal Indicator Light will go out
and the machine may resume normal operation.
Minutes or decrease
duty cycle
Input Supply Connection
Installation and mains outlet socket shall be made and
protected according to appropriate rules.
Check the input voltage, phase, and frequency supplied
to this machine before turning it on. Verify the
connection of grounding wires from the machine to the
input source. The allowable input voltages are 3x230V
and 3x400V 50Hz (400V: factory default). For more
information about input supply refer to the technical
specification section of this manual and to the rating
plate of the machine.
If it is necessary to change the main supply voltage:
•Ensure that the input cable must be disconnected
from the main supply and the machine switched
OFF.
•Remove the top panel from the machine.
•Reconnect X12 according to the diagram below.
•Replace the top panel.
Make sure the amount of power available from the input
connection is adequate for normal operation of the
machine. The necessary delayed fuse (or circuit breaker
with ”D” characteristic) and cable sizes are indicated in
the technical specification section of this manual.
Refer to points 1, 3, 12 and 13 of the images below.
Output Connections
Refer to points 5, 10 and 11 of the images below.
Controls and Operational Features
1. Power Indicator: After input power is connected and
the power switch is turned on, this lamp will light up

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to indicate the machine is ready to weld.
2. Thermal Overload Indicator: This lamp will light up
when the machine is overheated and the output has
been turned off. This can occur if the ambient
temperature is above 40°C or the duty cycle of the
machine has been exceeded. Leave the machine
on to allow the internal components to cool, when
the lamp turns off normal operation is possible.
•Thermostatic fan: the fan is additionally
controlled by the thermal protection circuit.
This feature saves energy and also minimizes
the amount of dirt and other air borne particles
being drawn into the machine.
The fan is operating only while cooling is
needed.
3. Power on/off Switch: Controls the input power to
the machine.
4. Hot Start Control (LINC 405-SA only): Hot Start is a
temporary increase in the output current during the
start of stick (MMA) welding that helps ignite the arc
quickly and reliably. The potentiometer is used to
set the level of the increased current.
5. Negative Quick Disconnect: Negative output
connector for the welding circuit.
6. Digital Welding Current Meter with memory feature
(LINC 405-SA only): Shows present the value of
the welding current during welding; after welding it
continues to display the average welding current.
7. Output Current Control: Potentiometer used to set
the output current (also during welding), from 15A to
400A.
8. Local/Remote Switch: Remote Control Unit
K10095-1-15M and K870 can be used with this
machine. It changes control of the Output Current
from the machine Output Control (point 7) to the
K10095-1-15M or K870 and vice versa.
9. Arc Force Control (LINC 405-SA only): It is a
function used during stick (MMA) welding in which
the output current is temporarily increased to clear
short circuit connections between the electrode and
the weld puddle that occur during normal welding.
10. Remote Control Connection: If a remote control is
used, it will be connected to the remote connector.
11. Positive Quick Disconnect: Positive output
connector for the welding circuit.
12. Fuse: This fuse protects the Fan Circuit.
13. Power Input Socket: Connect the supply plug to the
existing input cable, that is rated for the machine as
indicated in this manual, and conforms to all
applicable standards. This connection shall be
performed only by a qualified person.
Stick Welding (MMA)
For starting welding process with MMA method you
should:
•Insert welding cable plugs into output sockets and
twist to lock them in place.
•Connect the work cable to the welding piece with the
work clamp.
•Fasten a correct coated electrode into the electrode
holder.
•Connect the main plug to the outlet mains socket.
•Set the Local/Remote Switch in required position:
local or remote.
•Turn the Power on/off Switch on.
•Set required welding current by knob of the Output
Current Control.
•Obeying appropriate rules you can begin to weld.
Electromagnetic Compatibility (EMC)
02/02
This machine has been designed in accordance with all relative directives and norms. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
•Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

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machine.
•Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
•Safety and control equipment for industrial processes. Equipment for calibration and measurement.
•Personal medical devices like pacemakers and hearing aids.
•Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
•The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
•Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
•The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
•Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
Technical Specifications
INPUT
Input Voltage
230 / 400V ±10%
Three Phase
Input Power at Rated Output
34 kVA @ 35% Duty Cycle
Frequency
50 Hertz (Hz)
RATED OUTPUT AT 40°C
Duty Cycle
(Based on a 10 min. period)
35%
60%
100%
Output Current
400A
315A
240A
Output Voltage
36.0 Vdc
33.0 Vdc
29.0 Vdc
OUTPUT RANGE
Welding Current Range
15 – 400 Amps
Maximum Open Circuit Voltage
78 Vdc
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or Circuit Breaker Size
63A Superlag (230V input)
40A Superlag (400V input)
Input Power Cable
4 Conductor, 6 mm2
PHYSICAL DIMENSIONS
Height
640 mm
Width
580 mm
Length
1150 mm
(700 mm without handles)
Weight
126 Kg
Operating Temperature
–10°C to +40°C
Storage Temperature
-25°C to +55°C
For any maintenance or repair operations it is recommended to contact the nearest technical service center or Lincoln
Electric. Maintenance or repairs performed by unauthorized service centers or personnel will null and void the
manufacturers warranty.