Lincoln Electric POWER WAVE 405M IM917-A User manual

POWER WAVE®405M
OPERATOR’S MANUAL
For use with machines Code 11379, 11491
IM917-A
June, 2009
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, thin before you act
and be careful.
WARNING
WARNINGAVISODE
PRECAUCION
ATTENTION
!!
!!
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WARNING
REMOTEPOWER
OFF
ON
PO W ERWAVE405
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. T L: 216.481.8100 FAX: [phone] W B SIT : www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.

FOR ENG NE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c.Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELD NG CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSS BLE SER OUS NJURY OR DEATH.
KEEP CH LDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT W TH THE R DOCTOR BEFORE OPERAT NG.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet 205 is available
from the Lincoln lectric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL NSTALLAT ON, OPERAT ON, MA NTENANCE AND REPA R PROCEDURES ARE
PERFORMED ONLY BY QUAL F ED ND V DUALS.
WARN NG
Mar ‘95
ELECTR C AND
MAGNET C F ELDS
may be dangerous
2.a. lectric current flowing through any conductor causes
localized lectric and Magnetic Fields ( MF). Welding
current creates MF fields around welding cables and
welding machines
2.b. MF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. xposure to MF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to MF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2.Never coil the electrode lead around your body.
2.d.3.Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CAL FORN A PROPOS T ON 65 WARN NGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel ngines The Above For Gasoline ngines

ii
SAFETY
ii
A C AYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECT IC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with educed Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and 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.
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.
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.
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

iii
SAFETY
iii
FO ELECT ICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDE may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. eep 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.
WELDING and CUTTING
SPA KS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
Jan ‘09
Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv
SAFETY
iv
Mar. ‘93
PRÉCAUT ONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. viter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. loigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de 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.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUT ONS DE SÛRETÉ POUR
LES MACH NES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

v
SAFETY
v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction 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

vi
SAFETY
vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s 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
_________________________
1Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
L10093 3-1-96H

viivii
Thank You 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!
ead 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:
WA NING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
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 egistration
- 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.
CUSTOME 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.

viii
viii TABLE OF CONTENTS Page
nstallation.......................................................................................................Section A
Technical Specifications - POW R WAV ® 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 lectrode Polarity ...................................................................................A-3
Voltage Sensing ................................................................................................... A-4
POW R WAV ® to Semi-automatic Power Feed Wire Feeder Interconnections A-5
System Description................................................................................................A-5
System Set-Up...............................................................................................A-6, A-7
Welding with Multiple POW R WAV ®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 quipment ...........................................................B-1
Recommended Processes..............................................................................B-1
Required quipment .......................................................................................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 quipment...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Compatible Lincoln quipment
________________________________________________________________________
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 ....................................................................... -1
Using the Status L D to Troubleshoot System Problems..................................... -2
Troubleshooting Guide............................................................................. -3 thru -7
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagram....................................................................................Section F-2
Dimension Print............................................................................................Section F-3
________________________________________________________________________
Parts Lists...............................................................................................................P-551
________________________________________________________________________

A-1
NSTALLAT ON
POWER WAVE® 405M
A-1
TECHN CAL SPEC F CAT ONS - POWER WAVE® 405M
NPUT AC VOLTAGE & DC OUTPUT
OUTPUT CABLES, CONNECT ONS AND L M TAT ONS
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
5500//6600 HHzz (continuous)
335500AA // 3344VV // 6600%% 1144..77””xx1122..55””xx
PPoowweerr220000--222200// 33 PPhhaassee 2277..88””**
WWaavveeKK 22336699--22 338800--440000// 332200AA // 3333VV // 6600%% AAMMPPSS8866..55llbbss((337733xx331188xx
440055MM44115511 PPhhaassee 55--442255((3377..44 gg)) 770066**))mmmm
5500//6600 HHzz
227755AA // 3311VV //110000%%
11 PPhhaassee
330000AA // 3322VV // 110000%%** IInncclluuddeess
33 PPhhaassee hhaannddlleess
* Overall Length Including Handle, 21.6” (549mm) without handle.
Insulation Class 180 (H)
Select the output cable size based upon the following chart.
Cable sizes for Combined Length of lectrode and Work Cable (Copper) 75°C rated:
DUTY CYCL CURR NT L NGTH UP 61m (200 FT) 61-76m (200-250 FT)
100% 275 1/0 1/0
60% 350 1/0 2/0
POWER WAVE® 405M NPUT CURRENT
2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
1. Not rated is indicated by 4-x's in the box on the rating plate
Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Voltage Phases 300Amps@ 350Amps@ Line Cord Size Fuse Size Notes
32Volts(100%) 34Volts(60%) AWG SIZ S
200 3 41 48 6 80A Note 2
220 3 37 48 6 80A Note 2
380 3 23 28 8 50A
400 3 22 27 8 50A
415 3 22 26 8 50A
Voltage Phases 275Amps@ 320Amps@ Line Cord Size Fuse Size Notes
31Volts(100%) 33Volts(60%)
200 1 ---- ---- --- ----- Note 1
220 1 64 82 4 125A Note 2
380 1 44 55 6 80A Note 2
400 1 40 50 8 80A
415 1 38 48 8 80A

A-2
NSTALLAT ON
POWER WAVE® 405M
A-2
SELECT SU TABLE LOCAT ON
The Invertec POW R WAV ® 405M will operate in
harsh environments. ven so, it is important that sim-
ple preventative measures are followed in order to
assure long life and reliable operation.
• 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.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
• DO NOT MOUNT OVER COMBUST BLE SURFACES.
Where there is a combustible surface directly
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .06”(1.6mm) thick, which shall extend not
less than 5.90”(150mm) beyond the equipment on
all sides.
----------------------------------------------------------------------
STACK NG
POW R WAV ® 405M cannot be stacked.
T LT NG
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.
NPUT AND GROUND NG CONNECT ONS
• Only a qualified electrician should connect the
Invertec POW R WAV ® 405M. Installation should
be made in accordance with the appropriate
National lectrical Code, all local codes and the
information detailed below.
• 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.
SAFETY PRECAUT ONS
ELECTR C 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.
• 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.
----------------------------------------------------------------------
WARN NG
• 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.
• For higher voltages: Position the large switch to
greater than 380.
• Move the "A" lead to the appropriate terminal.
POWER CORD CONNECT ON
A 10ft.(3.5m) power cord is provided and wired into
the machine. Follow the power cord connection
instructions.
• ncorrect connection may result in equipment
damage.
----------------------------------------------------------------------
Single Phase nput
Connect green/yellow lead to ground per National
lectrical Code.
Connect blue and brown leads to power.
Wrap blue lead with tape to provide 600V insulation.
Three Phase nput
Connect green/yellow lead to ground per National
lectric Code.
Connect black, blue and brown leads to power.
UNDERCARR AGE MOUNT NGS
WARNING
WARNINGAVISODE
PRECAUCION
ATTENTION
!!
!!
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WARNING
REMOTEPOWER
OFF
ON
POWERWAVE3 5 5


GREEN / YELLOW
BLUE
BLACK
BROWN
14.79
12.44
3.44 21.60
27.82
5.50
10.00
MOUNTING HOLE LOCATIONS
M19527
13.10
1/4-20 NUT (4 PLACES)
NOTE: MOUNTING SCREWS CA
10/01
N NOT PROTRUDE MORE THAN
0.5 INCHES INSIDE THE MACHINE.
11.84
3.50
CAUT ON
CAUT ON

Output connections on some POW R WAV ®s are
made via 1/2-13 threaded output studs located
beneath the spring loaded output cover at the bottom
of the case front.
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.
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAF -
TY INFORMATION" located in the front of the
Instruction Manuals.
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
----------------------------------------------------------------------
NEGAT VE ELECTRODE POLAR TY
When negative electrode polarity is required, such as
in some Innershield applications, reverse the output
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
When operating with electrode polarity negative the
" lectrode 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.
A-3
NSTALLAT ON
POWER WAVE® 405M
A-3
OUTPUT CABLES, CONNECT ONS AND
L M TAT ONS
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.
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.
----------------------------------------------------------------------
CABLE NDUCTANCE, AND TS EFFECTS
ON PULSE WELD NG
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).
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.)
CAUTION
CAUTION
B
A
C
FIGURE A.3
POWER
WAVE
WORK
A
C
B
POWER
WAVE
FIGURE A.4
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
C
A
B
WORK
SLIDING WORK

A-4
NSTALLAT ON
POWER WAVE® 405M
A-4
VOLTAGE SENS NG
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.
f 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 L CTROD 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 POW R WAV ® at the four pin
connector. By default the WORK voltage is monitored
at the output stud in the POW R WAV ® 405M. For
more information on the WORK sense lead (21), see
"Work Voltage Sensing” in the following paragraph.
nable the voltage sense leads as follows:
TABLE A.1
Process Electrode Voltage Work Voltage
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional
GMAW-P 67 lead required 21 lead optional
FCAW 67 lead required 21 lead optional
GTAW
Voltage sense at studs Voltage sense at studs
GMAW Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional
CAC-C Voltage sense at studs Voltage sense at studs
* The electrode voltage 67 sense lead is integral to
the control cable to the wire feeder.
Work Voltage Sensing
The standard POW R WAV ® 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
POW R WAV ® 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. nable the work voltage sensing in the
POW R WAV ®. (See Dip Switch Settings and
Locations in Installation Section of this manual.)
CAUTION
ELECTRODE VOLTAGE SENS NG
nabling 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.
mportant: 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

A-5
NSTALLAT ON
POWER WAVE® 405M
A-5
POWER WAVE® TO SEM -AUTOMAT C
POWER FEED W RE FEEDER NTERCON-
NECT ONS
The POW R WAV ® 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 POW R
WAV ® 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 DESCR PT ON
The POW R WAV ® 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.
ach "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

A-6
NSTALLAT ON
POWER WAVE® 405M
A-6
CONF GUR NG THE SYSTEM
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.
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.
POWER WAVE®
405M
ROBOT
PLC CONTROLLER
ANALOG NTERFACE
etc.
POWER WAVE® 405M
POWER WAVE®
405M
POWER WAVE®
405M
FEED HEAD
FEED HEAD 1
CONTROL BOX
S NGLE HEAD FEEDER DUAL HEAD FEEDER
S NGLE HEAD BOOM FEEDER
PF-10R
S NGLE HEAD BOOM FEEDER
UP TO 4 W RE FEEDERS
ALLOWED
UP TO 4 FEED HEADS
ALLOWED
WIR
DRIV
MODUL

A-7
NSTALLAT ON
POWER WAVE® 405M
A-7
In this case the individual feed heads need to be assigned to the dual head control and the POW R WAV ®
405M auto mapping disabled and the quipment Groups set on (See Figure A-8). (See the Feeder documenta-
tion for information on setting the feeder DIP switches)
System that is NOT "Auto Mappable"
POWER WAVE® 405M
POWER WAVE® 405M
POWER WAVE®
405M
DUAL HEAD
DUAL HEAD
ALTERNATE HARD AUTOMAT C APPL CAT ON
(using a User nterface, Wire Drive Module, and POWER FEED-10R)
COMB NAT ON HARD AUTOMAT ON APPL CAT ON
(w/ Semi-Auto Feeder, Wire Drive Module, and POWER FEED-10R)
DUAL HEAD BOOM FEEDER
(using two single heads)
PF-10R
FH-1 FH-2
PF-10R
W RE
DR VE
MODULE
(FH1)
W RE
DR VE
MODULE
(FH1)

CONTROL CABLE SPEC F CAT ONS
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 POW R WAV ®/ Power Feed™system.
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.
WELD NG W TH MULT PLE POWER
WAVES®
Special care must be taken when more than one
POWER WAVE® is welding simultaneously on a
single part. Arc blow and arc interference may
occur or be magnified.
ach 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 POW R
WAV S®. When these parameters are identical, the
pulsing frequency will be the same, helping to stabilize
the arcs.
very 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)
A-8
NSTALLAT ON
POWER WAVE® 405M
A-8
Connect All Work
Sense Leads at the End
of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
Travel
Direction
POWER WAVE®405M
POWER WAVE®405M
TWO POWER WAVES®
CAUTION
CAUTION
F GURE A.6

A-9
NSTALLAT ON
POWER WAVE® 405M
A-9

MULT PLE ARC UNSYNCHRON ZED SENSE LEAD AND WORK LEAD PLACEMENT GU DEL NES

A-10
NSTALLAT ON
POWER WAVE® 405M
A-10
/ O RECEPTACLE SPEC F CAT ONS
TABLE A.2
W RE FEEDER RECEPTACLE
P N LEAD# FUNCT ON
A 53 Communication Bus L
B 54 Communication Bus H
C 67A lectrode Voltage Sense
D 52 0vdc -
51 +40vdc +
TABLE A.3
VOLTAGE SENSE RECEPTACLE
P N LEAD# FUNCT ON
3 21A Work Voltage Sense
TABLE A.4
RS232 RECEPTACLE
P N LEAD# FUNCT ON
2 253 RS232 Receive
3 254 RS232 Transmit
4#Pin5
5#Pin4
6 # # Pin20
20 # # Pin6
7 251 RS232 Common
D P SW TCH SETT NGS AND LOCAT ONS
DIP switches on the P.C. Boards allow for custom configuration of
the POW R WAV ®. To access the DIP switches:
ELECTR C SHOCK can kill.
1. Turn off power to the power source at the dis-
connect switch.
• nsulate 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.
CONTROL BOARD D P SW TCH:
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)
switch 8* work sense lead
off work sense lead not connected
on work sense lead connected
*Factory setting for Switch 8 is OFF.
switch 7 auto mapping
off auto mapping enable-default
on auto mapping disabled
CONTROL BOARD (DIP Switch Location)
F GURE A.7
WARN NG
}40VDC
F GURE A.8

GENERAL DESCR PT ON
The POW R WAV ® 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.
The POW R WAV ® 405M power source is
designed to be used with the semi automatic family of
Power Feed wire feeders, operating as a system.
ach 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.
The POW R WAV ® 405M is a high performance,
digitally controlled inverter welding power source
capable of complex, high-speed waveform control.
Properly equipped, it can support the GMAW, GMAW-
P, FCAW, SMAW, GTAW, and CAC-A processes. It
carries an output rating of 350 Amps, 34 Volts at 60%
duty cycle and 300 Amps, 32 volts at 100% duty
cycle.
RECOMMENDED PROCESSES AND
EQU PMENT
RECOMMENDED PROCESSES
The POW R WAV ® 405M can be set up in a num-
ber of configurations, some requiring optional equip-
ment or welding programs. ach 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.
The POW R WAV ® 405M is recommended for
semi-automatic welding, and may also be suitable for
basic hard automation applications.
• This POW R WAV ® is not recommended for
processes other than those listed.
B-1
OPERAT ON
B-1
POWER WAVE® 405M
SAFETY PRECAUTIONS
Read this entire section of operating instr ctions
before operating the machine.
ELECTR C SHOCK can kill.
• Unless sing cold feed feat re, when
feeding with g n trigger, the elec-
trode and drive mechanism are
always electrically energized and
co ld remain energized several sec-
onds after the welding ceases.
• Do not to ch electrically live parts or electrodes
with yo r skin or wet clothing.
• Ins late yo rself from the work and gro nd.
• Always wear dry ins lating gloves.
-----------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep yo r head o t of f mes.
• Use ventilation or exha st to remove
f mes from breathing zone.
-----------------------------------------------------------
WELD NG SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on containers that have
held comb stibles.
-----------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional g idelines detailed in the
beginning of this man al.
WARNING