Lincoln Electric SPEEDTEC 405S User manual

IM3048
12/2013
REV03
SPEEDTEC
405S, 405SP, 505S & 505SP
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
www.lincolnelectric.eu

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I
Declaration of conformity
13
Lincoln Electric Bester Sp. z o.o.
Declares that the welding machine:
SPEEDTEC 505S
SPEEDTEC 505SP
SPEEDTEC 405S
SPEEDTEC 405SP
conforms to the following directives:
2006/95/CEE, 2004/108/CEE
and has been designed in compliance with the
following standards:
EN 60974-1, EN 60974-10:2007
31.05.2013
PawełLipiński
Operations Director
Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
12/05

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II
12/05
THANKS! For having choosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications .................................................................................................................................................. 1
Electromagnetic Compatibility (EMC) .............................................................................................................................. 2
Safety .............................................................................................................................................................................. 3
Intoduction ....................................................................................................................................................................... 4
Installation and Operator Instructions .............................................................................................................................. 4
WEEE.............................................................................................................................................................................. 9
Spare Parts...................................................................................................................................................................... 9
Electrical Schematic ........................................................................................................................................................ 9
Accessories Suggested ................................................................................................................................................... 9

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1
Technical Specifications
NAME INDEX
SPEEDTEC 405S K14117-1
SPEEDTEC 405SP K14117-2
SPEEDTEC 505S K14116-1
SPEEDTEC 505SP K14116-2
INPUT
Input Voltage U1EMC Class Frequency
405S, 405SP 400V ± 10%
3-phase A 50/60Hz
505S,505SP
Input Power at Rated Cycle Input Amperes I1max PF
405S, 405SP 19,1 kVA @ 80% Duty Cycle
(40°C) 27,6A 0,95
505S,505SP 26,1 kVA @ 50% Duty Cycle
(40°C) 37,7A 0,93
RATED OUTPUT
Open Circuit
Voltage
Duty Cycle 40°C
(based on a 10 min. Output Current Output Voltage
405S, 405SP GMAW 60Vdc 80% 400A 34Vdc
100% 390A 33,5Vdc
FCAW 60Vdc 80% 400A 34Vdc
100% 390A 33,5Vdc
SMAW 60Vdc 80% 400A 36Vdc
100% 390A 35,6Vdc
GTAW 60Vdc 80% 400A 26Vdc
100% 390A 25,6Vdc
505S,505SP GMAW 60Vdc 50% 500A 39Vdc
100% 390A 33,5Vdc
FCAW 60Vdc 50% 500A 39Vdc
100% 390A 33,5Vdc
SMAW 60Vdc 50% 500A 40Vdc
100% 390A 35,6Vdc
GTAW 60Vdc 60% 500A 30Vdc
100% 390A 25,6Vdc
WELDING CURRENT RANGE
GMAW FCAW SMAW GTAW
405S, 405SP 20A÷400A 20A÷400A 5A÷400A 5A÷400A
505S,505SP 20A÷500A 20A÷500A 5A÷500A 5A÷500A
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse Type gR or Circuit Breaker Type Z Power Lead
400V
405S, 405SP 32A 4 Conductor, 4mm2
505S,505SP 32A 4 Conductor, 4mm2
DIMENSION
Weight Height Width Length
405S, 405SP 50 kg 535 mm 300 mm 635 mm
505S,505SP 50 kg 535 mm 300 mm 635 mm
Protection Rating Operating Humidity (t=20°C) Operating Temperature Storage Temperature
IP23 ≤90 % from -10 ºC to +40 ºC from -25 ºC to +55 ºC

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2
Electromagnetic Compatibility (EMC)
01/11
This machine has been designed in accordance with all relevant directives and standards. 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. 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
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.
WARNING
EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and
therefore the product is designed to be used in an industrial environment only.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those
locations, due to conducted as well as radiated disturbances.

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3
Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. 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.
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 shall consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN
12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective
Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169
Standard.
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.
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.
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or
transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,
work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located
away from areas where they may be subjected to physical damage or the welding process including
sparks and heat sources.

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4
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which can
cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an
environment with increased hazard of electric shock.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Intoduction
SPEEDTEC 405S, 405SP, 505S and 505SP inverter
sources have been designed to work with wire feeders
PF24, PF40, PF42, PF44, PF46, LF45, LF45S. For
communication, inverter source-wire feeder is using
ArcLink®protocol.
Inverter source-wire feed configuration allows the
welding:
GMAW (MIG/MAG)
FCAW-GS / FCAW-SS
SMAW (MMA)
GTAW (arc ignition using lift TIG).
SPEEDTEC 405S, 405SP, 505S and 505SP work with
the water cooler COOLARC 46.
The complete packaging includes the following items:
Inverter source
CD with Operator’s Manual
Work lead - 3m
Slow-blow fuse – 2A (2 units)
Slow-blow fuse – 6,3A (1 unit)
Slow –blow fuse – 12.5A (1 unit).
Recommended equipment, which can be bought by
user, was mentioned in the chapter "Accessories".
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.
Do not use this machine for pipe thawing.
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.
Example: 60% duty cycle
Welding for 6 minutes. Break for 4 minutes.
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
Minutes or decrease
duty cycle

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5
Input Supply Connection
WARNING
Only a qualified electrician can connect the welding
machine to the supply network. Installation the outlet
plug to power lead and connecting the welding machine
had to be made in accordance with the appropriate
National Electrical Code and local regulations.
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. SPEEDTEC 405S, 405SP, 505S and
505SP can only be connected to a mating grounded
receptacle.
Input voltages is 3x400V 50/60Hz. For more information
about input supply refer to the technical specification
section of this manual and to the rating plate of the
machine.
Make sure that the amount of mains power available
from the input supply is adequate for normal operation of
the machine. The type of protection and cable sizes are
indicated in the technical specification section of this
manual.
WARNING
The welding machine can be supplied from a power
generator of output power at least 30% larger than input
power of the welding machine.
See "Technical Specifications" chapter.
WARNING
When powering welder from a generator be sure to turn
off welding machine first, before generator is shut down,
in order to prevent damage to welding machine!
Refer to points [1], and [8] of the images below.
Output Connections
Refer to points [5], [6] and [7] of the Figures below.
Controls and Operational Features
1. Power Switch ON/OFF (I/O): Controls the input
power. Be sure the power source is properly
connected to the mains supply before turning power
on ("I").
2. Status Light: A two color light that
indicates system errors. Normal
operation is steady green light. Error
conditions are indicated, per Table 1.
NOTE: The status light will flash green, and sometimes
red and green, for up to one minute when the machine is
first turned on. When the power source is powered it can
take as long as 60 seconds for the machine to be ready
to weld. This is a normal situation as the machine goes
through initialization.
Table 1.
LED Light
Condition
Meaning
Only machines which using ArcLink®
protocol for communication
Steady Green
System OK. Power source is
operational, and is communicating
normally with all healthy peripheral
equipment.
Blinking Green
Occurs during power up or a system
reset, and indicates the power source
is mapping (identifying)
each component in the system.
Normal for first 1-10 seconds after
power is turned on, or if the system
configuration is changed during
operation.
Alternating Green
and Red
If the status lights are flashing any
combination of red and green, errors
are present in the power source.
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 green
light. Read the error code before the
machine is turned off.
If occurs, to clear the error try to turn
Off the machine, wait for a few
seconds, then turn ON again. If the
error remains, a maintenance is
required. Please contact the nearest
authorized technical service center or
Lincoln Electric and report the error
code read.
Steady Red
Indicate no communication between
the power source and device which
has been connected to this power
source.
3. Thermal Overload Indicator: It indicates
that the machine is overloaded or that
the cooling is not sufficient.
4. Replaceable Panel: User Interface can be installed,
in place of the replaceable panel, which allows to
adjust the welding parameters from the power
source. Panel with User Interface Kit can be
purchased separately (see "Accessories" chapter).
5. Negative Output Socket for the Welding
Circuit: Depending on the configuration
of power source, for connecting a work
lead, the electrode holder with lead or the
source/wire feeder welding cable.
6. Positive Output Socket for the Welding
Circuit: Depending on the configuration
of power source, for connecting a work
lead, the electrode holder with lead or the
source/wire feeder welding cable..
7. Control Receptacle: 5 pins receptacle for
wire feeder or remote controller
connection. To communication wire
feeder or remote controller with power
source is used ArcLink®protocol.

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6
1
3
4
5 6
7
2
Figure 1.
8
14
910
13
12 11
Figure 2.
8. Power lead (5m): 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 by a qualified person only.
9. Fuse F3: Use the 12,5A/400V (6,3x32mm) slow-blow
fuse. See "Spare Parts" chapter.
10. Fuse F4: Use the 6,3A/400V (6,3x32mm) slow-blow
fuse. See "Spare Parts" chapter.
11. Fuse F2: Use the 2A/400V (6,3x32mm) slow-blow
fuse. See "Spare Parts" chapter.
12. Fuse F1: Use the 2A/400V (6,3x32mm) slow-blow
fuse. See "Spare Parts" chapter.
13. Cooler Power Supply Socket: Socket
supplies 400VAC for power circuit
cooler. The circuit is protected by a slow-
blow fuse [12].
WARNING
Read and understand the cooler manual before
connecting it to the machine.
14. Gas Heater Socket: Usup = 24VAC, Pmax = 80W.
User Interface
User Interface can be installed, in place of the
replaceable panel [4], which allows to adjust the welding
parameters from the power source. Panel with User
Interface Kit can be purchased separately (see
"Accessories" chapter).
Description of the User Interface is available in the
operator’s manual od wire feeder IM3028, IM3034,
IM3045, IM3046, IM3052, IM3053 and the Guide
supplied with a Replaceable Front Panel.
Welding Cables Connection
Insert the plug of the work lead into the socket [5]. The
other end of this lead connects to the work piece with the
work clamp.
Connect the wire feeder to the power source:
Insert the positive welding cable into the output socket
[6].
Insert the wire feeder control cable into the socket [7]
(see "Accessories" chapter, Source/wire feeder cable
K10349-PG-xM or K10349-PGW-xM).
Use the shortest possible cable lengths.
Water Cooler Connection
SPEEDTEC 405S, 405SP, 505S and 505SP work with
the water cooler COOLARC 46 (see "Accessories"
chapter).
WARNING
Read and understand the cooler manual
before connecting it to the power source.
Before connecting cooler, refer to the
manual of wire feeder.
The COOLARC 46 is supplied by welding power source
using 9-PIN socket.
Input voltages is 400V, 50/60Hz. Make sure that the
supply voltage of the unit matches the cooler’s rated
voltage.
13
Figure 3.

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7
To connect the water cooler COOLARC 46 to the power
source:
Turn off the power source and disconnect input
plug.
Remove the cap from the Water Cooler Supply
Socket.
Insert 9-pin plug of the water cooler power lead into
the Water Cooler Power Supply Socket [13].
WARNING
Do not switch on the welding power source with the
cooler applied if the reservoir was not filled and the
torch’s/gun’s hoses are disconnected from the cooling
unit. The no observance of this warning may be cause
internal damages at the cooler unit.
User Interface Connection
To connect the User Interface to the power source:
Unscrew the Replaceable Panel [4].
4
Figure 4.
Connect the plug X8 of the power source with the
socket X100 of the User Interface.
X100
X8
Figure 5.
Screw down the User Interface to the power source.
Figure 6.
Machine and Circuit Protection
Power Source is protected against overheating, overload
and accidental short-circuits.
If the machine is overheated, the thermal protection
circuit will decrease the output current to 0. The thermal
protection indicator [3] will turn on.
The Power Source is also electronically protected
against overload and accidental short-circuit. The
overload and short-circuit protection circuit automatically
reduces the output current to a safe value when it
detects an overload.
Transport & Lifting
WARNING
Falling equipment can cause injury and
damage to unit.
Figure 7.
During transportation and lifting with a crane, adhere to
the following rules:
Power source does not include the eye bolt which
can be used to transport or lifting the machine.
To lift use of suitable lifting equipment capacity.
To lifting and transport use a travers and minimum
two belts.
Lift only power source without gas cylinder, cooler
and wire feeder, or/and any other accessories.

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8
Maintenance
WARNING
For any repair operations, modifications or
maintenances, it is recommended to contact the nearest
Technical Service Center or Lincoln Electric. Repairs
and modifications performed by unauthorized service or
personnel will cause, that the manufacturer’s warranty
will become null and void.
Any noticeable damage should be reported immediately
and repaired.
Routine maintenance (everyday)
Check condition of insulation and connections of the
work leads and insulation of power lead. If any
insulation damage exists replace the lead
immediately.
Remove the spatters from the welding gun nozzle.
Spatters could interfere with the shielding gas flow
to the arc.
Check the welding gun condition: replace it, if
necessary.
Check condition and operation of the cooling fan.
Keep clean its airflow slots.
Periodic maintenance (every 200 working hours but
at list once every year)
Perform the routine maintenance and, in addition:
Keep the machine clean. Using a dry (and low
pressure) airflow, remove the dust from the external
case and from the cabinet inside.
If it is required, clean and tighten all weld terminals.
The frequency of the maintenance operations may vary
in accordance with the working environment where the
machine is placed.
WARNING
Do not touch electrically live parts.
WARNING
Before the case of welding machine will be removed, the
welding machine had to be turned off and the power lead
had to be disconnected from mains socket.
WARNING
Mains supply network must be disconnected from the
machine before each maintenance and service. After
each repair, perform proper tests to ensure safety.

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9
WEEE
07/06
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
Part List reading instructions
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service
Department for any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular
code machine.
Use only the parts marked "●" in the column under the heading number called for in the assembly page (# indicate
a change in this printing).
First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that
contains a picture-descriptive part number cross-reference.
Electrical Schematic
Refer to the "Spare Part" manual supplied with the machine.
Accessories Suggested
K10349-PG-xxM Source/wire feeder cable (gas). Available in 5, 10, 15m.
K10349-PGW-xxM Source/wire feeder cable (gas and water). Available in 5, 10 or 15m.
K14033-1 Work Lead, 3m - GRD-600A-70-3M.
K14105-1 Cooler COOLARC 46.
K14096-1 SPEEDTEC CART.
K14072-1 LF45 – Digital Wire Feeder.
K14083-1 LF45S – Digital Wire Feeder.
K14106-1 PF40 – Digital Wire Feeder.
K14107-1 PF42 – Digital Wire Feeder.
K14108-1 PF44 – Digital Wire Feeder.
K14109-1 PF46 – Digital Wire Feeder.
K14110-1 PF24 – Digital Wire Feeder.
K14121-1 Replaceable Front Panel with User Interface, A+.
K14122-1 Replaceable Front Panel with User Interface, B.
K14123-1 Replaceable Front Panel with User Interface, B+.
K14124-1 Case of remote control (PENDANT).
K2429-1 ArcLink®"T" Connector Kit.