5
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Product Description
The PW405 is a semiautomatic multi-process DC arc
welding machine offering CV and CC DC welding. It is
rated for 400 Amps at 35%. Power Wave 405 can only
be used with Linc-Net compatible semi-automatic wire
feeders (PF10 or LF40). In addition, semi-automatic
wire feeders may require optional equipment to access
certain weld modes in the Power Wave. Other
models of Lincoln feeders, or any models of non-
Lincoln wire feeders, cannot be used.
All welding programs and procedures are selected
through the wire feeder user interface. Correctly
equipped, this machine is able to weld CC-Stick, CC-
GTAW, CV-FCAW, synergic and non-synergic CV-
GMAW / synergic GMAW-P processes. The digital
microcomputer based control system allows easy and
accurate adjustment of weld parameters through the
multi-process panel located on the wire feeder.
It is available with :
- 230 VAC/ 3.5 amp auxiliary power for water cooler.
For a quick and easy handling within the welding area,
it may be factory mounted on an undercarriage
equipped with a platform for a gas cylinder.
Undercarriage mounting:
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 IP23S.
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.
Input Supply Connection
Check the input voltage, phase, and frequency supplied
to this machine before turning it on. The allowable input
voltage is indicated in the technical specification section
of this manual and on the rating plate of the machine.
Verify the connection of grounding wires from the
machine to the input source.
The frame of this machine must be grounded. A ground
terminal located on the base of the generator is
provided for this purpose.
This machine is factory 3ph-400V connected. To
connect it in 3ph-230V:
• Open the access panel on the rear of the machine.
• Position the large switch to 200-230.
• Move the "A" lead to the appropriate terminal.
Power cord connection
A 5 meter power cord is provided and wied into the
machine. Follow the power cord connection
instructions.
Single phase Input :
•
Connect green/yellow lead to ground.
•
Connect blue and brown leads to power
•
Wrap blue lead with tape to provide 600V
insulation.
Three phase Input :
•
Connect green/yellow lead to ground.
•
Connect black, blue and brown leads to power
NOTA
: The rating plate is located on the rear panel of
the machine
.
Output connections
Ground cable delivered with the machine has Twist-
mate plugs for connection to the POWER WAVE 405.
Use the shortest possible cable lengths.
When using an inverter type power source like the
PowerWaves, use the largest welding (electrode
and work) cables that are practical, even if the
average output current would not normally require
it. When pulsing, the pulse current can reach very
high levels. Voltage drops can become excessive,
leading to poor welding characteristics, if
undersized welding cables are used.
Changing Polarity
Connect the output lead to the desired polarity and the
ground lead to the other terminal.
The positive terminal marked (+) is the standard
configuration. This polarity is mainly used on GMAW
and FCAW-GS welding mode.
The negative terminal marked (-) is mainly used on
FCAW-SS ( Innershield) welding mode.
Negative electrode polarity :
When operating with electrode polarity negative the
