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1. LOW _PWR_TEST Negative Supply 15 Volts 0 66 Amp JZ6N 126 Aux Buck Supply 15 Volts 05 Amp 19 Buck Supply E lt e 11 POWER TEST Lig 2937 QUT CG Jobs G5915 2F 0NG5914 Ssbk O3 17 Thu Apr 02 12 57 25 2009 GND L c6 E Y GND NOTE This diagram is for reference only PROPRIETARY amp CONFIDENTIAL SINCE COMPONENTS OR CIRCUITRY ON lt PRINTED CIRCUIT BOARD MAY CHANGE DESIBN INEOBHATIDN WITHOUT AFFECTING THE INTERCHANGE DRAWN BY PW MK HIS ABILITY OF A COMPLETE BOARD GENERAL INFORMATION G 22 SEE PAGE UNLESS OTHERW LESS OTHERWISE VOLTAGE NET O POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONN EQUIPMENT TYPE POWER WAVE BJECT SCHEMATIC CTRL amp PWR SPLY DIAGRAM MAY NOT SHOW THE EXAC ENGIN
2. x55 LM11171 ADJ x56 LM1117I ADJ CF COMM CF ENETO AX CF SC2 TXD CLUSTER 1 CF SCZ RXD DS24808 VOD POL 1 IBUTTON_DATA GND I BUTTON REA IBUTTON COM NF ORMATION ELECTRICAL SYMBOLS PER E RESISTORS Ohms t 1 44 S 1A400V COMMUNICATION PROPRIETARY amp CONFIDENTIAL SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INEQRM ATION EQUIPMENT TYPE CAPACITORS V UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 77 3 FRAME CONNECTION EARTH GROUND CONNECTION SHEET 2 OF 2 POWER WAVE WITHOUT AFFECTING THE INTERCHANGE DRAWN EF 8 009 ABILITY OF A COMPLETE BOARD THIS 2 ENGINEER EF DIAGRAM MAY NOT SHOW THE EXAC manual SCHEMATIC DIGITAL CONTROL SUBJECT REFERENCE COMPONENTS OR CIRCUITRY OF CONT
3. TO TRANSFORMER CENTER TAP TO TRANSFORMER 1 gt GND SEC CENTER TAP Return to Section TOC Return to Master TOC GND_PRI V 2 INPUT OUTPU onoi 2 gurPurz A4451BN AUXILLARY WINDINGS ELECTRONIC MODULE GNO PRI eio gt 2 Of c 5 5 oD K 216 v 2 INPUT OUTPU anoi X22 purpur2 4451BN 60218 OTHERWISE S
4. V 15 ENABLE GENERAL INFORMATION SEE PAGE 1 LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION MAIN POWER cons awo NS PROPRIETARY 1 USED FOR ANY PU SINCE COMPONENTS OR CIRCUITRY ON amp PRINTED CIRCUIT BOARD MAY CHANGE 2 FECTINC N DRAWN BY EF 8 ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC ENGINEER COMPONENTS OR CIRCUITRY OF CONTROLS sz HAVING COMMON CODE NUMBER AFPRDVED CNJobsNGA800 4LINPOWER SUPPLIES sDK 1317 Aug 17 11 25 33 2009 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN POWER WAVE 350 G 18 ELECTRICAL DIAGRAMS G 18 SCHEMATIC 3 STAGE INVERTER PC BOARD G4769 PG 1 Return to Master TOC Return to Section TOC PRIMARY AND SECONDARY B37
5. DG201ADY a URRENT Al FPGA_ANALOG TURN OFF N FEEDBACK DJUST NTEGRATOR 600 OHMS V 5BUS 5 O CPLD ANALOG lt CPLD ANALOG lt gt gt VPOLARITY LTAGE VOLTAGE ADJUST CURRENT 13074 lt x 8 4 9 6 DSP_ ANALOG gt 0SP D A CS 74 ADT OLTAGE FEEDBACK GH ADJUST CLR CAP2 gt Pos M CLR CAP1 LEM URRENT FEE lb HIGH ADJUST CLUSTER 1
6. READY _OUT 1 ANODE vec E Ki voi 2 001 yoz ANODEZ GN HCPL 0631 PARALLEL G 16 5 HDI yy PCAN L DE BE PCAN RX READY IN INVERT PCAN RX IN FPGA INVERT READY IN IN FPGA FPGA COMM PCAN SW 8 AN0DE1 1 0012 27 GND AN0DE2 HCPL 0631 RO LOW HIGH RO HIGH YO LOW OUTPUT HIGH 5101 as 6 gt PCAN_t gt READY DE B 2 485 E gt READY t CLOSED MASTER OPEN SLAVE READY H READY_SW FPGA_COMM gt FPGA_COMM ETHERNET PORT 0 25MHZ SYS RESET 2 EORXER EOTXCLK 47 EOTXD1 2 EOTXD3 EOCOL EOCRS EOMDIO EOMDC CF_ETHERNETO Aug 17 11 25 34 2009 NOTE This diagram is for reference only It may not be accurate for all machines covered by this ADD ADDR 1 ADDRO J PWROWN TPFOP TPFON TPFIP TPFIN REFCLK x1 1 REFCLK XO 1 LED CFG1 LED CFGZ LED CFG3 paras P PAUSE SLEEP 1 971 0 06 IW 3 32K
7. Return to Section TOC LED 188 LED 2 FUNCTION GREEN BOOST IGBT DRIVE FUNCTIONING WHEN ON STATUS yOKy GREEN 3 VDC POWER FUNCTIONING PROPERLY WHEN STATUS yERRORy CHECK CODE FOR SPECIFIC ERROR GREEN CHOPPER IGBT 4 DRIVE FUNCTIONING WHEN ON OUTPUT ENABLE GREEN CHOPPER IGBT 2 DRIVE FUNCTIONING WHEN ON 9 aon J1 L LED 4 SINGLE PRASE DETECT GREEN IGBT DRIVE FUNCTIONING WHEN ON LED 38 OLED 6 SENSE LED 5 J1C1 gt GREEN CHOPPER IGBT 4 DRIVE FUNCTIONING WHEN ON a GREEN CHOPPER IGBT DRIVE FUNCTIONING WHEN SIONS GREEN CHOPPER IGBT DRIVE FUNCTIONING WHEN ON 9 427 aLED2 ETHERNET STATUS GREEN BUCK IGBT DRIVE FUNCTIONING WHEN ON e BUZZER b is INPUT SUPPLY VDC TO VDC DEVICENET Description of LED functions Power Wave S350 For reference only G5915 PFC CONTROL P C BOARD FUNCTION VDC POWER SUPPLY FUNCTIONING PROPERLY WHE
8. HF _EN C ARC EST F SUPERP_EN_F ACTIVE SNUB_F CAPA_OV_C gt ARC_ESTABLISHED CAPAUV CAPA_UV_C CAPB_UV_C CAPBOV CAPB_OV_C CAPBUV gt SUPERPOSITION ENABLE gt ACTIVE SNUBBER 805 BUS CHOP_ 5V DSP_DIGITAL LEVEL IN CHOP CLK MOSI_B CHOP MOSI MOST_A CHOP MISO MISO_B MISO_A LEVEL FPGA_DIGITAL FPGA DIGITAL 100 GND ENCLA ENC_1A_F ENC_1B_F V 5BUS ENC_2A_F ENC2A ENC_2B_F ENC2B C Jobs G4800 4L1 DIGITAL_10 sbk 04 17
9. GND_SEC 556N Return to Section TOC Return to Master TOC RESET 1 556N OUT TRIG z DISCHG CNTVOLT z TRIG THRESH 0 DISCHG 7 THRESH 7 BLA CHOKES 3 3V SUPPLY 8 SENS 3 SHUTDOWN FEEDBACK LP2951CN 33 5 o E 2 r e 09 2 8L6 CHOKE6 SEE PAGE 1 UNLESS OTHERWISE SPECIFIED _ DTHERWISE SPECIFIED LABELS 6 OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 7 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION ED COMMUNICATED INC SINCE COMPONENTS OR CIRCUITRY A ni ATINI gt PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORM ALON EQUIPMENT 02 OF 02 3 THE INTERCH m OF A COM LETE BOARD HIS UBJECT SCHEMATIC 3 STAGE INVERT
10. V433BUS 3DANLG 190 C Jobs G4800 4L1 DSP sbk 07 17 on Aug 17 11 25 34 2009 CLUSTER 1 V 3 3BUS G4 K1 L2 P4 K6 P8 1011 PROPRIETARY amp CONFIDENTIAL COMP PRINTED WITHOUT AF EF ABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC ENGINEER EF COMPONENTS HAVING A COMMON CODE NUMBER NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC ONENTS OR CIRCUITRY ON A RCUIT BOARD MAY CHANGE FECTING THE INTERCHANGE DRAWN BY 5 OR CIRCUITRY OF CONTROLS DESIGN INFORMATION GENERAL INFORMATION ELECTRICAL OLS PER E153 CAPACITORS MFD 022 50 UNLESS RESISTOR C1 UNLESS OTHERWIS DIODES DSP SHEET 01 OF 01 PROPRIETARY INFORMATION OWNED BY LINCOLN Gl RE FOR ANY PURPOSE WITHOUT THE EQUIPMENT TYPE G 11 USED PAGE 1 LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNEC TION Z FRAME CONNECTION L EARTH GROUND CONNECTION INC AND MAY N
11. R39 DETECT AC DROPOUT 208VAC 15V UVLO 15V UNDER VOLTAGE LOCK OUT PRIM_OC 13075 ADT C Jobs G5915 2F 0 G5914 sbk 01 17 Thu Apr 02 12 57 24 2009 LINCOLN amp ELECTRIC PRIMARY OVER CURRENT NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ABIL PROPRIETARY amp CONFIDENTIAL SINCE COMPONENTS OR CIRCU PRINTED CIRCU WITHOU NG Y OF A COMPLE DIAGRAM MAY NO COMPONENTS OR DOCUMENT CONTA TIES 0 DESIGN INFORMATION DRAWN BY ENGINEER M APPROVED BOARD MAY CHANGE SHOW RY OF CONTROLS HAVING A COMMON CODE NUMBER GENERAL INFORMATION ELECTRICAL SYMBOLS PER CAPACITORS MFD 00 UNLESS OTHERWISE SPECIFIED t UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED RESISTORS 0 FOR ANY PURP EQUIPMENT TYPE AINS PROPRIETARY INFORMATION OWNED BY LINCOLN GL L THOUT THE EXPRE LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECT ION INC TTEN PERM POWER WAVE 35
12. FPGA DIGITAL FDSP AWE SDWE FDSP_ CS_TPM TPM FDSP_ INT FDSP_ ARE_ SDCAS CAPA UV C CAPB_UV_C CAPB_OV_C FETA C FETB C SSOUT_C CAPA_OV_C OVR_CUR TURN OFF SEL I ON LFL STT 67 5 67 NEG VPOLARITY RESET RAMPIN CLR_CAP_IN Mon Aug 17 11 25 33 2009 FPGA CPLD FPGA_ANALOG MISCO_F MISC1_F FAN CONTROL F HF EN C NC LEVEL SUPERP_EN_F STT ON F DPCLKS FDSP GPO FDSP FOSP_GP7_ INT7 MNOUT_C 2 2 VCCA PLL FETD C GNDA_PLL2 GNDG PLL2 PLL2 0UTp 1 0 PLL2 OUTn ACTIVE SNUB F CLUSTER 5 CLKXIFD DSP_DIGITAL FDSP FPGA V 15B FPGA TDI 342K 0 063 FPGA TDO FPGA_TMS FPGA TCK F SPLCLK F SPI MO TDI EH TMS TCK CLK DATAO InCONFIG MSELO MSELt EP1
13. w gt 9 5 Dio Return to Section Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal cover and discharging the DC link capacitor making it safe for the technician to work on the machine MATERIALS NEEDED 5 16 Inch Nut Driver 25 1000 Ohm resistor 25 Watts minimum POWER WAVE S350 LINCOLN B F 13 Return to Section TOC Return to Master TOC Return to Section TOC OJO w 91 gt o s 5 Dio clo Return to Section TOC Return to Master TOC Return to Master TOC F
14. B 3 Recommended Processes and Equipment B 3 Equipment Limitations ekle ocu Boeke Ape need B 3 Design Features sci x nde tia eked PUR RP EORR ONERE x PEG PRODR B 4 Case Front Controls ta ton B 5 Case Back Controls cc s Y WEAR B 5 Common Welding Procedures 1 B 6 B 8 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO OTe 05 gt ol 5 Dio amp Return to Section TOC Return to Master TOC SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE ELECTRIC SHOCK CAN KILL Do not touch electrically live part or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Do not operate with covers panels or guards re moved or open FUMES AND GASSES can be dangerous Keep your head out of fumes Use ventilation or exhaust to re move fumes from breathing zone WELDING SPARKS can cause fire zx or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protec QF tion SE
15. FPGA_ANALOG x36 vlog E SPI MOSI CF SPLCLK POT_ CS spony aT 9 osl CLR CAP SYS RESET 05263 20k gt CLR_CAPI gt CLR_CAP2 gt CLR CAP3 s CURRENT FEEDBACK LOW ADJUST LOW ADJUST INTG LINTG VOLTAGE FEEDBACK FPGA ANALOG lt 7 FPGA_ANALOGE FPGA_ANALOG VPOLARITY AUTO 67_SENSING 2 ANALOG 67 13074 0 C Jobs G4800 4L1 ANALOG_IO sbk 02 17 LINCOLN 8 Mon Aug 17 11 25 33 2009
16. Mon Aug 17 11 25 33 2009 NOTE This diagram is for reference only It may not be accurate for all machines covered by this G 8 FETA C SIN 0017 X gurel MICLLS2YM 6055 DRIVE CLUSTER 4 0017 vS1 58 MIC4452YM GNDSI 2 0017 9 gt FETB_ORIVE MICAL52YM GNDSP gt FETC_ORIVE X9 8 IN 0017 MICALS2YM GND5 tc gt DRIVE THERMAL LED_F STT_ON F FAN CONTROL F CPLD DIGITAL PROPRIETARY amp CONFI e RED_LED GRN LED ANODE RED GREEN gt ANODE OF GRN MISCO SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLE E BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC COMPONENTS OR RY 0F CONTROLS HAVING A COMMON COD
17. Gu eed oe 4 Location sass eee Q B 4 LACKING gcse ee 4 Nn 225 sua has amas uyata s aa w ea A 4 e Input and Ground Connections A 4 Machine Grounding A 4 o High Frequency Protection Seta AREE ees A 4 Input Connection uoo pep A 5 gt Input Fuse and Supply Wire s uia duke Peewee 5 Input Voltage Selection 2 REN OG eR RES A 5 Power Cord Replacement 7 2 7 A 5 Connection Diagram ss ssu LEUR dopo A 6 Recommended Work Cable Sizes A 8 O Cable Inductance and its Effects Welding A 9 o Remote Sense Lead Specifications A 9 z 8 Voltage Sensing Considerations for Multiple Arc Systems A 11 5 2 Control Cable Connections tea RA ne
18. J46 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL PARTIES OR USED FOR ANY PURPOSE WITHOUT THE E PRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC TERIS EDT feowrrcr cueverano SCALE UIPMENT TYPE POWERWAVE Ss pace Bor A 12 OF PLACE DEGAS BE DOCUMENT NONE MA Ee esee SUBIECT MACHINE SCHEMATIC NUMBER REVISION WITH PUBLISHED STANDARDS Tra APPROVAL 7 06535 TO NOT SCALE THIS DRAWING INCH UF pare 3242 CRM43 _ 4 Gi 428 Insight SOLID EDGE EN 32 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 350 Return to Section TOC Return to Section TOC Return to Master TOC 2 Return to Master 5 o E 2 r G 5 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 1 VBUS VBUS 2ND_LEM V433BUS 2ND_LEM MAIN LEM MAIN LEM STUD STUD STUD STUD 67 21 21 PRI_CUR_AL PRI CUR_A PRI_CUR CLUSTER 4 PRI_CUR_B1 PRI_CUR_B PRI_CUR_B2 ENCLA
19. 09 2 1 ARCLINK RECEPTACLE AN e 418 OUTPUT ON 417 32632 32 ARCLINK gt 7463 32 5 162 445 FANON ep EIS 3J62 gt GND4 4 62 55462 52 ELECTRODE SENSE VOLTAGE LOCATED LEFT SWITCHING AUX BOOST POSITIVE REAR BIE te NDS Ul D 40VDC SENSE RECEPTACLE MAIN BOOST NEGATIVE B37 B1 Mien svoe Front lower right B2 MAIN BOOST POSITIVE RECTIFIES INPUT LINE PRE 6J61 412 5 L FULL CONTROLS PRIMARY ona 22461 E end OPT MAIN RELAY POSITIVE BRIDGE AUX AND WELDING OUTPUT ASSEMBLY 66571 gt 7 61 414 MAIN RELAY NEGATIVE MOUNTED ON OUTPUT CHOKE i FULL BRIDGE PULSE XFRMR FULL BRIDGE PULSE XFRMR AUX BUCK NEGATIVE RIGHT REAR DIVIDER PANEL AUX BUCK POSITIVE Kaasar LA pe gt INPUT VOLTAGE RANGE 3 1 4 200VAC 600VAC 41 MAIN BUCK NEGATIVE 2207 12A n SINGLE PHASE amp MAIN BUCK POSITIVE 6441 1 THREE PHASE ud L3A 2 FRONT RIGHT MIDDLE LINE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATI ECE SWITCHBOARD
20. 9 5 Dio amp c Return to Section TOC Return to Master TOC Return to Master TOC A INSTALLATION iii FIGURE A 4 STICK WITH S SERIES USER INTERFACE USER INTERFACE CONTROL PANEL REMOTE CONTROL BOX K2828 1 K857 TO NEGATIVE L TO POSITIVE STUD STUD ELECTRODE HOLDER KIT K2394 1 KIT INICLUDES GROUND CLAMP WORK CLAMP 9 WORK FIGURE 5 MIG PROCESS REGULATOR FLOWMETER ARCLINK CABLE K1543 XX TO NEGATIVE STUD WORK CLAMP TO POSITIVE STUD _ WORK PIECE POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o OTe gt 9 5 Dio amp Return to Section TOC Return to Master TOC ms INSTALLATION ms RECOMMENDED WORK CABLE SIZES FOR ARC WELDING Connect the electrode and work cables between the ap propriate output studs of the Power Wave S350 per the following guidelines Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire drive feed plate and the positive output stud on the power source Connect a work lead from the negative power source output stud to the work piece When negative electrode polarity is required such as in some Innershield applications reverse the output connections
21. MISCO ANODE GRN ANODE RED MISC1 THERMAL_LED LEVEL IN SUPERPOSITION ENABLE STT_ON CHOP_BUS FAN CONTROL HF ENABLE ACTIVE SNUBBER V 5BUS V 33BUS 15 LEM SUPPLIES lt lt COMMON COMMON K ELECTRICAL DIAGRAMS DSP_ANALOG FPGA V 3 3BUS V 5BUS FPGA ANALOG CF_CPLD FPGA_DIGITAL DSP_DIGITAL FPGA_COMM FPGA_CPLD was CPLD 3 3805 FPGA_CPLD CPLD_ANALOG CPLO_DIGITAL CPLD COMM CLUSTER 1 V433BUS DSP ANALOG FPGA DIGITAL DSP_DIGITAL DSP_CPLD DSP_FOSP FAST_DSP v 33BUS DSP_FDSP FDSP_MEM SYSTEM FDSP_FPGA COLDFIRE V433BUS 15 V 1 2R V LSBUS CF CPLD CHOP_BUS V 33BUS SHTUWN OE SUSPNI CLKC CLKB Ly CLK CPUCLK XBUF lt XTALOUT CPLD_CLK DSP_CLK FOSP_CLK ENET_CLK i2MHz 22 50V Bye ABS g SOV4R ISOV C V 33BUS ISOV P V 5BUS COMMUNICATI V 5BUS V USB SOV4P USB DATA V433BUS USB DATA G6682 1L0 DEVNET BUSS H DEVNET COM DEVNET BUSS I DEVNET SUPPLY PCAN L PCAN H READY READY H ESP ESPLCSI ESPL CS2 ESPI_CS3 ESPI_MISO ESPLCLK ESPI MOS CF COMM CF COMM CAN BUS H CAN_BUS_L BUTTON DATA FPGA
22. PLUG J27 O POWER WAVE S350 LINCOLN 5 LELECTRIC FIGURE F 12 PLUG J23 FIGURE F 13 SWITCH BOARD TEST POINTS TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE continued F 37 DOL Je1Se N uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL 5 ol UNH DOL 5 DOL uonoes DOL Uonoes UNH NOTES R POWER WAVE 5350 LINCOLN D F 38 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR F 39 CURRENT AND VOLTAGE CALIBRATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For
23. es E 7 Pulse Width Modulation Minimum Maximum Output Insulated Gate Bipolar Transistor IGBT Operation E 9 o 5 o 8 tc FIGURE E 1 BLOCK LOGIC DIAGRAM SWITCH BOARD SECOND STAGE INPUT HIGH FRQUENCY INVERTER QUTPUT WITH PLANER TRANSFORMER RECTIFIER mum OUTPUT POSITIVE 60KHZ CAPACITORS TERMINAL 2 RELAY 4009 THIRD STAGE 9 MAIN INPUT DCLINK FIRST STAGE FULL WAVE MULTE PHASE BUCKS 9 SWITCH RECTIFIER 400 Ohm CAPACITOR BUCK BOOST BRIDGE CURRENT L TRANSDUCER NEGATIVE TERMINAL lt t 120KHz E 2 CHOPPER CONTROL BOARD CURRENT VOLTAGE FEEDBACK FEEDBACK Y CHOPPER COMMUNICATION FAN INPUT CONTROL FAN elia POWER FAN BOARD mE 48 VDC Y IGBT FAN D DRIVES ens 40 VDC e l ONLED THERMAL LED PFC CONTROL DC BUS THERMOSTATS BOARD BOARD CONTROL is NABER BOARD gt ETHERNET ARCLINK COMMUNICATION BUZZER OPTIONAL ARCLINK COMMUNICATION o CONTROL i REMOTE i ARC LINK REMOTE CONTROL L CONTROL L2 ERROR gt RECEPTACLE RECEPTACLE COMMUNICATION Y Y o STATUS STATUS LIGHT ERROR c LIGHT 2 POWER WAVE S350 LINCOLN B E 2 E 2 THEORY OF OPERATION FIGURE E 2 GENERAL DESCRIPTION SWITCH BOARD Return to Section TOC Return to
24. _ _ PRIM OC OUTPUT TCK GCLK2 UNES 18 OUTPUTZ TDI GCLK3 MES 2 E d 1 5 1 JST IGBT DRIVE TMS 25 START CHECK A 4451BM INTEGRATORA INTEGRA _ CURRENT SI EPM570 THERMOSTAT OUTPUT 2 INPUT OUTPUT X DUTPUT2 3 3 4451BM 0802 a 52 1 6 245 gt 6 TO THERMOSTAT A REFERENCED TO GROUND AUDIBLE INDICATOR V ono FULL BRIDGE PULSE TRANSFORMER OUTPUT 216 4451BM CND2 eio gt 2 0 olg 5 5 oD K amp IAC LOW PWR LED INDICATOR BANK PRIMARY READY AC LOSS AUX BUCK DRIVE MAIN BOOST IGBT DRIVE AUX BOOST IGBT DRIVE FULL BRIDGE DRIVE B FULL BRIDGE DRIVE A GENERAL INFORMATION MAIN BUCK DRIVE ELECTRICAL SYMBOLS PER E1537 SEE PAGE 1 MAIN RELAY MAIN RELAY CAPACITORS 022 50V 5 OTHERWISE SPECIFIED
25. 2 MAINTENANCE MAJOR COMPONENT LOCATION POWER WAVE S350 LINCOLN 5 LELECTRIC 1 FRONT PANEL ASSEMBLY 2 BASE AND POWER ASSEMBLY 3 VERTICAL DIVIDER PANEL ASSEMBLY 4 OUTPUT CHOKE ASSEMBLY 5 CASE BACK AND FAN ASSEMBLY 6 ROOF AND SIDES ASSEMBLY D 3 DOL Je1Se N 0 DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL 5 ol UNH ODOL 5 unie DOL uonoes OOL uonoes uunjeg D 4 NOTES POWER WAVE 5350 LINCOLN D D 4 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg E1 TABLE CONTENTS THEORY OF OPERATION SECTION o 5 Theory of Operation 1 8 221 2 General Descriptio asas inei bee Peden ka him s RE Y Ga gp n rV aaa da pu EN DE Qam E Q E 2 Main Input Switch Input Rectifier Soft Start Input Relay DC Link Capacitor Buck Boost and Power Factor Correction Board E 3 Planar Transformer Output Rectification and Filtering Multi Phase Chopper Chopper Control Board Current Transducer and Control Board DC Bus Board and Optional User Interface Board E 6 Machine Protection us sk c a e y I k p de
26. Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC D 1 ____ OF CONTENTS MAINTENANCE SECTION 7 Maintenance u u asua iato dera Cn aede DR as C RB e e icu BR e Q analy D 1 Safety Precalltiols ker e rx tau deed RR u ba a u EGER ER DU D 2 Routine Maintemance 14 mime Iq D 2 Periodic Maintenance esc u u enu hue D 2 Calibration Specification u ugr u u dE Lex EE D 2 Major Component Location 52 25 55596 dee u puhu sews D 3 POWER WAVE S350 LINCOLN MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Do not operate with covers re moved Turn off power source before in stalling or servicing Do not touch electrically hot parts Turn the input power to the welding power source off at the fuse box before working in the terminal strip Only qualified personnel should install use or service this equipment Return to Section TOC Return to Master TOC ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a
27. CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 2 CAPACITOR LOCATION Return to Section TOC Return to Master TOC CHOPPER CONTROL BOARD PLANAR TRANSFORMER o lt 2 Be E Return to Master TOC DC LINK CAPACITOR CURRENT TRANSDUCER 2 Be careful not to make contact with capacitor ter power is applied to the machine minals located on the left side of chassis as shown in Figure F 2 INPUT CHOKE CAPACITOR DISCHARGE PROCE 5 5 DURE i WARNING 5 3 ELECTRIC SHOCK can E 1 Disconnect the input power to the Power Wave 350 machine High voltage is present when input 212 3 Carefully check for DC voltage at the capacitor DO NOT TOUCH THE CAPACITOR TERMINALS terminals See Figure F 3 WITH YOUR BARE HANDS 4 f the capacitor voltage is present discharge the capacitor as follows NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 5 Using a high wattage resistor 25 1000 ohms 25 watts minimum electrically insulated gloves and pliers hold the resistor terminals across the capacitor terminals for 10 seconds 6 Recheck the voltage across the capacitor termi nals The voltage should be zero If any voltage remains repeat the procedure NOTE Any volt age present after discharge has been performed is an abnormal condition and may indicate a Switch board
28. BLK WHT BLKMWHT lt B GRN 200000 BLK GRN lt D 55 SYNCRONIZED CONNECTOR OPTIONAL 894 1 2 2 VDC 893 3 21 GND 892 714 CAN H 891 lt 5 L 54 DEVICENET CONNECTOR OPTIONAL CABLE R4 ETHERNET RJ45 353 gt BA aS 353C 351C 351B 353B lt SOLENOID OPTIONAL Pr Cy 554 554 4 55 553 351 4 GROUND BOND CIRCUIT ND1 VERTICAL PANEL fr gus CASEFRONT EARTH GROUND PER THE NATIONAL ELECTRIC CODE CHOPPER CONTROL BOARD gt 8 gt gt 6 gt 5 4 gt 3 2 gt 8 gt 348 4 gt 7 gt 347 gt 6 gt 346 5 gt 345 0 350 9 gt 65A 8 gt 358 gt 7 gt 66 gt 6 gt _ 356 55 355 gt 4 gt gt 3 gt _ 353 gt 2 gt gt 1 gt _ 351 Bee OUTPUT CHOKE BLio A 20 2 4 gt 344 3 gt 343 4 gt 2 gt 3424 1 gt 341 1 Bo OB37 B410 J41 3 STAGE INVERTER G47
29. I 56A HI I lt 56A LO CPLD_ANALOG BUS FEEDBACK ADJ gt AV INTG CLR CAP3 5V SUPP DSP_D A_ CS SAWTOOTH GENERATOR _ DSP DX 33076 DSP_CLKX pIN 00 ASCLK cs REF DSP FSX 4 5 CLUSTER 4 TLVS636100K GND LE 301610 PROPRIETARY amp CONFIDENTIAL CONTA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC ORAWN BY ____ BY 8 17 ENGINEER C Jobs G4800 4L1 ANALOG_I0 sbk 03 17 LINCOLN 8 Mon Aug 17 11 25 33 2009 NOTE This diagram is for reference only COMPONENTS OR CIRCUITRY
30. gt 2 Of c 5 5 oD K 216 Return to Section Return to Master TOC G 15 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 11 LINCOLN 8 CLUSTER 1 CLUSTER 2 USB 2 0 gt V USB V USB USB_DATA gt USB DATA USB DATA gt US8 DATA EXTERNAL CPLD_COMM MOSI MOSI SCLK CLK MISO C Jobs G4800 4L1 COMMUNICATION sbk 11 17 Mon Aug 17 11 25 34 2009 NOTE This diagram is for ELECTRICAL DIAGRAMS ISOV C CF CAN RXO BUS CAN BUS_L CF CAN TXO G 15 gt CAN BUS_ Visosc FPGA COMM DEVICENET ARCLINK SW ISOV R 5232 8 RS
31. x c ee oe Current Weld Mode 200 Adgustmenbs Vokage Current Adjust Output is ON Reset to Factory Defaults Connected to 169 254 68 210 y POWER WAVE S350 LINCOLN B NOTES pas POWER WAVE S350 LINCOLN E F 42 DOL Je1Se N 01 DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes UNH DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 43 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test
32. 65 4 OUTPUT RECTIFIER Located behind front door panel ARCLINK 1540 54A i PRIMARY GND FILTERED AC 200 OHM 100 Wangan On Vertical 207 1 Divider Panel d ARCLINK 153D 53A THERMOSTAT PULL DOWN MULTIPHASE 65 J46 1 RE 1 LEDS lt J46 2 AC INPUT VOLTAGE RECTIFIED BOARD 446 3 P F C CONTROL BOARD LED LEGEND 4004 BUS SIGNAL T LED1 ERROR CODE LED7 EE k LED2 15V POWER SUPPLY FUNCTIONING SHUNT SIGNAL AC SIDE L I LEDS EE 40VDC POWER gt J47 4 gt 474 SHUNT SIGNAL CONTRL GND LED9 Eg COMMON J47 5 gt 475 N PFC CONTROL CTSIGNAL AAA M LED10 BOARD saevo sere 52 r 7 67A for LED information 7 1 gt SCHEMATIC G5914 MAIN LED4 E A AUX BUCK 15V SUPPLY TRANSFORMER SECONDARY COMMON LOCATED LEFT SIDE AUX BUCK 15V COMMON B38 INNER CASE FRONT B9 MAIN BUCK 15V COMMON LED1 LEDi MAIN BUCK 15V SUPPLY Ia 48V SWITCHBOARD P C BOARD OPTIONAL REGULATES PRIMARY VOLTAGE SS SCHEMATIC G4769 1J68 1 33 located on CONTROLS DEVICE AUX BOOST NEGATIVE 5463 33A y 5 o E 2 r e
33. D mE ARC LINK I tampa ics ERROR RECEPTACLE RECEPTACLE COMMUNICATION T mE STATUS STATUS LIGHT ERROR LIGHT The 100 volt output of the weld winding is rectified and filtered by three capacitors and an inductor This filtered DC voltage is applied to the multi phase output chopper circuit The 48 volt output from the Planar Transformer s auxil iary winding is also rectified and filtered and is used to provide power for the Fans the Control Board the DC Bus Board and the optional User Interface Board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO 05 gt ol 5 Dio amp Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 5 CHOPPER CURRENT TRANSDUCER AND CONTROL BOARDS SWITCH BOARD 60KHZ INPUT RELAY INPUT DC LINK FIRST STAGE RECTIFIER 100 Ohm CAPACITOR BUCK BOOST BRIDGE SECOND STAGE HIGH FRQUENCY INVERTER WITH PLANER TRANSFORMER peotiricr gt e OUTPUT E 5 POSITIVE TERMINAL CAPACITORS THIRD STAGE MULTI PHASE BUCK CONVERTER CURRENT TRANSDUCER NEGATIVE TERMINAL 120KHz CHOPPER CONTROL BOARD lt CURRENT VOLTAGE FEEDBACK FE
34. FIGURE F 34 DC BUS BOARD LOCATIONS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC DC BUS BOARD PROCEDURE 1 Disconnect the input power to the Power Wave Carefully remove the DC Bus Board from the S350 machine four mounting studs 2 To gain access to the DC Bus Board see the 7 Install the new DC Bus Board onto the mounting Case Cover Removal and DC Link Capacitor studs Discharge Procedure Remove the right case 8 Secure with the four nuts previously removed cover 3 Locate the DC Bus Board See Figure F 34 OJO gt mi gt 2 5 Dio amp 9 Install the two molex plugs 4 Label and remove the two molex plugs from the DC Bus Board See Figure F 35 5 Using the 3 8 wrench remove the four nuts se curing the DC Bus Board to the vertical divider panel Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B es TROUBLESHOOTING AND REPAIR ree DC BUS BOARD REMOVAL AND REPLACEMENT continued Qolo JE 5 5 FIGURE 35 DC BUS BOARD LOCATIONS 0 ols HE J47 OUTPUT Qolo 8 c 5 s 16 plz cle 513 LED 1 INDICATES OUTPUT olo i S 14 gt ele 2 ila INPUT olo e c k SIG gt ele 215 eic POWER WAVE 6 S350 LINCOLN B NOTES dida
35. 2 F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting u uu u cene Rr 34440454 eerste Ray Pew F A F 12 Test Procedures xls gae Ra PER DER odd ODER RERO eR Re EROR EORR EORR F 13 Case Cover Removal and DC Link Capacitor Discharge Procedure F 13 Control Board Test seu suy be ees hee Ty eee aS F 17 Switch Board Test 2s sedie F 23 Power Factor Control Board F 31 Current amp Voltage Calibration ssec eR nee gee ete debe reve seer need F 39 Optional User Interface Board F 43 Input R etifi r 16 F 49 Planar Transformer Resistance Test F 53 Output Rectifier TeSt rr pid 57 Current Transducer odes F 59 DC Bus Board Testes uu F 65 Removal and Replacement Procedures 1 F 69 Power Factor Correction Control F 69 Current Transducer i 3 23
36. ENB K ENC2A ENCIB ENC2A ENC2B ENC2B THERMOL 2 ARC_ESTABLISHED THERMOL 02 3 THERMO2 _ lt NPUT CONTROL MNDUT CAPAUY lt 3 CAPBUV lt 4 CAPBOV lt 5 FETA DRIVE 6 FETC DRIVE lt 7 15V_RELA ART CA INTL_3PH MNOUT CAPAUV CAPBUV CAPBOV FETA DRIVE FETC DRIVE 15V RELAYS SSOUT FETB DRIVE FETB_DRIVE FETD DRIVE FETD DRIVE SWITCH MISCO CONTROL 1 ANODE_OF_GRN ANODE OF GRN ATUS LED ANODE OF RED ANODE OF RED STATUS LED MISCL AC SWITC CONTROL AL LED THERMAL LED LEVEL IN N SUPERPOSITION ENABLE OUTPUT C lt SUPERPOSITION ENABLE STT ON STT_ON 13 FAN CONTROL lt 16 HF ENABLE OUTPUT A 4 ACTIVE SNUBBER 3 FAN CONTROL HF ENABLE ACTIVE SNUBBER OUTPUT D ANALOG_I V 33BUS VBUS VBUS DSP_ANALOG AIN LEM DSP FDSP STUD STUD CUR_AL RI CUR_A2 X CUR B CUR B2 V SBUS FPGA ANALOG 15 vals CF CPLD ANALOG SYSTEM DIGIT AL_IO ENCLA FPGA DIGITAL FPGA DIGITAL ENCIB ENC2A ENC2B ARC_ESTABLISHED THERMOL DSP_DIGITAL THERMO2 NT1 3PH MNOUT CAPAUV CAPBUV FETA DRIVE FETC DRIVE 15V RELAYS SSQUT CPLO_DIGITAL CPLO_DIGITAL FETB DRIVE DRIVE
37. computer Use the Ethernet cable to connect the computer to the Power wave S350 Connect a resistive load bank to the output studs Energize the Power wave S350 5 Launch the Diagnostic Utility and establish com munication with the Power wave S350 Refer to the Software Documentation to determine proper connection Click on the Calibration Tab A screen similar to Figure F 14 should appear and you are ready to begin the calibration check NOTE The Calibration Screen may look slightly different depending on the Soft ware version Calibration can only be done under Static Load conditions Do not at tempt to calibrate while welding NOTE Incorrect calibration can and will affect weld ing performance It is strongly recom mended to use the Diagnostics screen to run and save a Snapshot before making any calibration adjustments This will allow returning to original settings if necessary Refer to the Software Documentation for in structions on using the Snapshot feature CALIBRATION PROCEDURE 1 Once in the Calibration screen make sure that the machine output is OFF light is BLACK and connect a resistive load bank to the output studs 2 Set load bank for 200 Amps 3 On the Calibration screen select the 200 Amps Current Set Point NOTE If the meters on the load bank are not certi fied connect calibrated and traceable me ters to the machine output See
38. A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o lt 09 ios tc o 5 o 2 8 F 5 The POWER WAVE S350 does not have welding output The Thermal LED is ON The machine regularly overheats There is no welding output OUTPUT PROBLEMS Make sure the input voltage is correct If the symptom is accompanied by an error code see the Status LED Troubleshooting section There may be an external short in the external output circuitry Remove all loads from the output terminals and restart the machine Make sure the wire feeder gun trigger circuit is functioning properly When the gun trigger is activated the fans should go to high speed If the thermal LED is lit the unit may be overheated Adjust the welding load and or duty cycle to coincide with the output limits of the PW S350 Also see the symptom The Thermal LED is ON in this section The welding application may be exceeding the recommended duty cycle and or current limits of the machine Dirt and dust may have clogged the cooling channels inside the mach
39. 13 1 11 SP_DATALO DATAS DATAS 7 6 DATAS DATAL DATA3 DATA2 DATA DATAO FOSP_ CS_TPM FOSP_ CS_SDRAM V 3 3BUS 2uF 0 2207 0 22uF C152 C209 C151 C150 10213 BOOTMODE A22A21 01 HPI BOOT BASED ON TOUTO PIN CLOCK MODE SELECT FOR EMIFA AECLKIN SELIAZ0 A19D 01 CLOCK RATE 500 7 125MHZ 019 CLUSTER 5 25223 2FDSP 816 lt EMU2 EML EMUS EMU EMUT EML EMUS EMUt EMUL FOSP_EMU1 gt 1B 2 S nc gt Nc ABIS gt NC DOMH DOML B G 12 26 25 23 DATA22 21 DATAL DATA18 17 DATA16 FDSP BAO DOML DOMH TIRAS CASA cs Mid wawi GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD RESISTORS 1 UNLE DIODES UNLES PROPRIETARY INFORMATION 0 PROPRIETARY amp CONFIDENTIAL th OTHER PARTES DR SINCE COMPONENTS OR CIRCUITRY ON A 22 50V U FDSP DATAO FOSP_DATAt FO
40. 2 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 2 DUE TO VOLTAGE DROPS ACROSS Sense 1 THE WORKPIECE VOLTAGE BE LOW CAUSING NEED FOR DEVIATION FROM STANDARD PROCEDURES BEST BOTH SENSE LEADS OUT OF THE CURRENT PATHS BOTH SENSE LEADS DETECT ARC VOLTAGE ACCURATELY NO VOLTAGE DROP BETWEEN ARC AND SENSE LEAD 2 2 fear BEST STARTS BEST ARCS Sense 1 MOST RELIABLE RESULTS Sense 2 POWER WAVE S350 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO w OTe 0 o 5 2 Return to Section TOC Return to Master TOC A 13 CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times except where noted otherwise Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed systems Most are designed to be connected end to end for ease of extension Generally it is recommended that the total length not exceed 100ft 30 5m The use of non stan dard cables especially in lengths greater than 25 feet can lead to communication problems system shut downs poor motor acceleration poor arc starting and low wire driving force wire feeding problems Always use the sh
41. Control and Power Supply PC Board 05914 G 20 thru G 22 Schematic 40 VDC Buss Power Supply PC Board M19330 G 23 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi layered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided Return to Master TOC o 5 o 2 tc Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Section TOC Return to Master TOC 2 Return to Section TOC Return to Master TOC Return to Master TOC 5 o E 2 r G 2 WIRING DIAGRAM COMPLETE MACHINE G6536 LINCOLN 8 ELECTRICAL DIAGRAMS POWER WAVE S350 12 OPTIONAL i 4 Lake 115 VAC 413 26 61 INVERTER 411 ASSEMBLY 66571 A A 345 341 343 344 348 347 125 1 358 gt 2 gt 4 356 gt 3 gt gt 361 gt 4 gt 362 35 E 37H 82 416 9 363 10 553 3 54 gt 7 gt 8 gt 9 gt 10 10 854 gt 4 357 1 gt 25 34 gt gt 3 2x 53 gt 3 4 95
42. POWER WAVE S350 LINCOLN E F 88 DOL Je1Se N 01 DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes UNH DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 89 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in testing the Power wave S350 output after the repair or replacement of a part or PC board MATERIALS NEEDED Diagnostic Utilities Software Laptop or other Suitable Computer Ethernet Cross Connect Cable LE Co M19969 7 Resistive Load Bank
43. Two 2 Welding Cables 20ft 4 0 Calibrated Ammeter and Voltmeter POWER WAVE S350 LINCOLN B F 89 TROUBLESHOOTING AND REPAIR r RETEST AFTER REPAIR continued PROCEDURE 1 Be certain that the machine is properly con nected for the input voltage being applied Return to Section TOC Return to Master TOC 2 Turn the Power Switch ON and see that it goes through the Start up routine and the Status Light is steady Green 3 Turn the Power Switch OFF and connect a re sistive load across the Output Studs and a com puter to the Ethernet be sure that the machine will pro duce proper weld output Return to Section TOC Return to Master TOC OJO OTe 1 o 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B TABLE OF CONTENTS DIAGRAM SECTION valk o 9 Electrical 55224240 0 205 EAE G 1 gt S9 c 2 8 b 5 Wiring Diagram Complete Machine 06536 G 2 Schematic Complete Machine 06535 1 G 3 G 4 Schematic Digital Control PC Board 04799 G 5 thru G 17 Schematic Stage Inverter PC Board 4769 G 18 G 19 Schematic
44. YN A 13 o 5 o gt 9 25 c POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO gt 05 8 gt ol 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC ia INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 5350 POWER SOURCE INPUT VOLTAGE AND CURRENT Duty Cycle Input Voltage 10 Input Amperes Idle Power Factor 1 Phase in parenthesis Rated Output 4096 unl 39 35 20 17 14 5 NA 65 37 32 25 K2823 1 460 575 100 rating 50 60 Hz 30 28 16 14 11 56 51 29 25 20 RATED EE INPUT VOLTAGE PHASE 200 208 1 50 60 300 Amps 29 Volts 250 Amps 30 Volts 230 1 50 60 380 415 1 50 60 460 1 50 60 575 1 50 60 200 208 3 50 60 230 3 50 60 380 4 15 3 50 60 460 3 50 60 575 3 50 60 On 230 Volt 1 phase inputs the max rating is at a duty cycle of 30 except for GTAW processes RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT MAXIMUM CORD SIZE TIME DELAY FUSE VOLTAGE PHASE INPUT AMPERE RAT AWG SIZES OR BREAKER FREQUENCY ING AND DUTY CYCLE AMPERAGE 200 208 1 50 60 60A 100 200 208 3 50 60 39A 40 230 1 50 60 67A 30 230 3 50 60 35A 40 380 41 5 1 50 60 38A 40 380 41 5 3 50 60 19A 40 460 1 50 60 34A 40 460 3 50 60 17A 40 575 1 50 60 27A 40 575 3 50 60 14A 40
45. a corresponding voltage is preprogrammed into the machine through special soft ware at the factory The nominal preprogrammed voltage is the best aver age voltage for a given wire feed speed but may be ad justed to preference When the wire feed speed changes the Power Wave S350 automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range Non Synergic CV In non synergic modes the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments Therefore to maintain the arc characteristics the operator must ad just the voltage to compensate for any changes made to the WFS All CV Modes Pinch adjusts the apparent inductance of the wave shape The pinch function is inversely proportional to inductance Therefore increasing Pinch Control greater than 0 0 results in a crisper arc more spatter while de creasing the Pinch Control to less than 0 0 provides a softer arc less spatter PULSE WELDING Pulse welding procedures are set by controlling an over all arc length variable When pulse welding the arc voltage is highly dependent upon the waveform The peak current back ground current rise time fall time and pulse frequency all affect the voltage The exact voltage for a given wire feed speed can only be pre dicted when all the pulsing waveform parameters are known Using a preset voltage becomes impr
46. bustible surfaces Where there is a combustible sur face directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides LIFTING Both handles should be used when lifting POWER WAVE S350 When using a crane or overhead device a lifting strap should be connected to both handles Do not attempt to lift the POWER WAVE 5350 with accessories attached to it WARNING Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lifting Do not operate machine while suspended when lifting FALLING EQUIPMENT can cause injury STACKING The POWER WAVE S350 cannot be stacked TILTING Place the machine directly on a secure level surface or on a rec ommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUND CONNECTIONS Only a qualified electrician should connect the POWER WAVE 350 Installation should be made in accordance with the ap propriate National Electrical Code all local codes and the infor mation in this manual MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with a ground symbol is located next to the input power connection block See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PRO
47. input power is also connected through a blocking diode to the Power Factor Correction Board Initially the DC relay is not activated and the incoming DC voltage is applied to the DC Link Capacitor via the 100 ohm resistor This resistor functions as a current limiting device allowing the DC Link Capacitor to charge slowly The PFC board uses the incoming DC voltage to create three separate 15VDC supplies These auxil iary voltages are used to power the circuitry for the con trol circuits as well as the 15 volts for the Buck Boost IGBTs and the soft start relay REMOTE 1 ARC LINK cor RECEPTACLE REMOTE CONTROL CONTROL BOARD 7 RECEPTACLE uc STATUS STATUS LIGHT ERROR LIGHT Under normal operating conditions the PFC board acti vates the soft start relay 50ms after input power is ap plied to the machine The 100 ohm resistor will be shorted out by the relay s contacts and the full input potential will be applied to the DC Link Capacitor The DC Link Capacitor also functions as a voltage clamp for the Buck Boost circuit The Buck Boost circuit located on the switch board consists of a buck converter followed by a boost con verter The boost switch is active when the input voltage is at 230VAC input or less Under this condition the Buck switch is held on the entire time The Buck switch is active when the input voltage is at 325VAC or more Under this condition the Boost switch is not active for
48. set to the diode test mode to perform the tests detailed in 5 If the Input Rectifier does not meet the expected readings replace the Switch Board POWER WAVE S350 LINCOLN B rt TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST PROCEDURE continued FIGURE F 18 INPUT RECTIFIER LEAD LOCATIONS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TABLE F 11 PROBE READINGS Probe RED Probe BLACK RESULT Terminal B32 Terminal B10 0 3V 1 0V Terminal B31 Terminal B10 0 3V 1 0V OJO ol lz 9 5 EIX Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B NOTES pos POWER WAVE S350 LINCOLN E F 52 DOL Je1Se N 01 DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 53 TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in
49. sible symptoms that the machine may exhibit Find the listing that best describes the symp tom that the machine is exhibiting Symptoms are grouped into the following categories output problems welding problems and eth ernet problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In gen eral these tests can be conducted without re moving the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely compo nents that may have failed in your machine It also specifies the appropriate test proce dure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are de scribed in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring dia grams and schematics Refer to the Electrical Diagrams Section Table of Contents to locat
50. test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid in the removal and replacement of the Power Factor Correction Control Board MATERIALS NEEDED 3 8 Nutdriver Return to Section TOC Return to Master TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B e lt 09 is E tc Return to Master TOC LINCOLN B rO TROUBLESHOOTING AND REPAIR Ee AM POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE continued 5 5 FIGURE F 28 CAPACITOR amp PFC CONTROL BOARD LOCATION e 2 PFC CONTROL BOARD DC LINK CAPACITOR ele PROCEDURE 912 lt 1 Disconnect the input power to the Power Wave Remove the five molex type plugs from the 5350 machine board Label locations for reassembly d ele 2 To gain access to the PFC Control Board see Install the new board and replace the molex Cover Removal and DC Link Ca type plugs previously removed ayo pacitor Discharge Procedure Replace the three nuts previously removed Locate the PFC Control Board and using the 8 Replace the left
51. 70 95 mm cable Order K852 95 Twist Mate Cable Receptacle For connecting welding cable to Twist Mate Cable Plug Order K1759 70 for 1 0 2 0 50 70 mm2 cable Order K1759 95 for 2 0 3 0 70 95 2 cable Twist Mate to Lug Adapter For connection of lugged cable to Twist Mate connec tors 18 457 mm long Order K2176 1 Inverter and Wire Feeder Cart Rear wheeled cart includes front casters and no lift gas bottle platform Convenient handles allow for easy cable storage while full length side trays store parts and tools Shipped fully assembled Small footprint fits through 30 762 mm door Order K1764 1 Dual Cylinder Kit Dual Cylinder Kit Permits side by side mounting of two full size gas cylin ders with easy loading For use with K1764 1 cart Order K1702 1 Coaxial Welding Cable Optimum weld cables for minimizing cable inductance and optimizing welding performance Order K1796 25 for 25 feet 25 ft 7 6 m cable length Order K1796 50 for 50 feet 50 ft 15 2 m cable length Order K1796 75 for 75 feet 75 ft 22 9 m cable length Order K1796 100 for 100 feet 100 ft 30 5 m cable length Welding Fume Extractors Lincoln offers a wide range of fume extraction environ mental system solutions ranging from portable systems easily wheeled around a shop to shop wide central sys tems servicing many dedicated welding stations Request Lincoln publication E13 40 See www lincolnelectric com
52. APPROVED oisposition NA NUMBER 5011992 POWER WAVE S350 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 09 2 Return to Section TOC Return to Master TOC 5 o E 2 r G 16 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 12 LINCOLN amp ELECTRIC EOMDIO EOMDC EOTXCLK EOTXEN EOTXDO EOCOL EORXCLK EORXDV EORXDO EOCRS E0TXD3 E0TXD2 E0TXD1 EORXD3 EORXDZ EORXD1 EORXER CF TO 9 2 EOTXCLK COLDFIRE ETHERNET EOMDC E1TXCLK EOTXEN E1TXEN E1TXDO EOCOL E1COL EORXCLK EORXDV EOCRS EOTXD3 torxpz EOTXER EORXD3 EORXDZ 13 E0RXD1 EORXER SBVBUS U USB USBCLKOUT U SUSBCLKIN MCFS484 E1RXER AE gt DSES AG n VCC X48 LXT971AB GND C3 C6 EA F3 F C Jobs G4800 4L1 COMMUNICATION sbk 12 17 USB_DATA Mon EORXD3 2 EORXD1 EORXDO EORXDV EORXCLK ELECTRICAL DIAGRAMS V SBUS LED ON OUTPUT LOW LED OFF OUTPUT HIGH
53. COMM BUTTON COM CPLD COMM SYSTEM SORC 5050 505 SORC 15050 1505 RESISTORS Ohms 4 0100 5 14 406 DEVELOPMENT G 5 CLUSTER 2 V USB USB DATA USB DATA USB 2 0 DEVNET BUSS H DEVNET COM DEVNET_BUSS 1 DEVNET_SUPPLY PCAN L LDEVICENET ETHERNETO PCAN H READY L READY H PARALL SPI ESPLCLK ESPI_MOS XTERNA RS232_RXD RS232_1XD CAN BUS H RS 232 LINK CAN_BUS_L BUTTON DATA BUTTON COM CLK_A CLK B MOSIA MOSI_B MISO_A MISO_B CHOP_ 5V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED MAIN SHEET SHEET 01 OF 01 THIS DOCUMENT CONT PI TION OWNED BY LINCOLN GLOB PROPRIETARY amp CONFIDENTIAL ori 0 D FOR ANY THOUT THE EXPRESS WRITTEN YYYYYYYY OPPER 1 0 I BUTTON AR LABELS 4 SUPPLY VOLTAGE NET Q POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION D MAY NOT DUPL ON OF LINCOLN GLOB 4 gt KEYING PLUG KEYING PLUG PRINTED CIRCUIT BOARD M POWER WAVE WITHOUT AFFECTING THE IN DRAWN EF 8 17 2009 DOCUMENT 2 KEYING PLUG ABILITY OF
54. Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le re froidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder SAFETY iv PRECAUTIONS DE SURETE 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauf fement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de s
55. J31 on the User Interface Board and Plug J47 on the DC Bus Board Also check the continuity of the CAN communication leads 153D and 154D between Plug J31 and Plug J11 on the PFC Board See the wiring diagram 8 Make sure the green ground lead is securely connected to the user interface board OJO gt OTe 05 o s 5 Dio amp c 9 Replace the case covers plugs and P C Boards previously removed Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B TROUBLESHOOTING AND REPAIR pas OPTIONAL USER INTERFACE BOARD TEST PROCEDURE continued Table F 10 Description of LED Functions Optional User Interface Board RED PREWELDCONTROLSEECT _ Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o OTe 0 gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B TROUBLESHOOTING AND REPAIR re OPTIONAL USER INTERFACE BOARD TEST PROCEDURE continued FIGURE 15 U I FRONT VIEW 04760 Series Return to Section TOC Return to Master TOC ollo LED 11 LED 1 5 5 LED1 LED 1 15 2 12 Lle ala LED 11 216 LED 9 LED 2 LED 6 LED
56. Lebe b a hed IY v aq a c p O ua F 71 Control Board ses sudes apa p aa F 73 Switch Board Assembly dues ER ERG nb RU NOSE EN We ERE F 77 satan S as F 81 Remote PO Board z uqa uso Oy a daw F 85 Retest After suus sess dense diaa du dae heeded due ee pedes REN F 89 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC w OTe 9 a Dio clo Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Per sonnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos
57. Observe Safety Guidelines detailed in the beginning of this manual INPUT CONTROL BOARD 331 Peak input current limit Input current limit has been exceeded Typically indicates short term power overload If problem persists contact Service Department Return to Section TOC Return to Master TOC 15 VDC supply on Input control board too low Verify input voltage 333 Under voltage lockout is within the acceptable range If problem persists contact service de partment Thermostat on primary module tripped Typically caused by bottom 336 Thermal Fault fan not working Problem with start up sequence If problem persists contact Service 337 Pre charge timeout Department Transformer current too high Typically indicates short term power 346 Transformer primary over current overload If problem persists contact service department Contact the Service Department Other Return to Section TOC Return to Master TOC w gt 9 5 Dio a A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC
58. Order K960 1 POWER WAVE S350 LINCOLN B p ACCESSORIES TIG Mate 17V Air Cooled TIG Torch Starter Pack Get everything you need for TIG welding in one com plete easy to order kit packaged in its own portable car rying case Includes PTA 17V torch parts kit Harris flowmeter regulator 10 ft 3 0 m gas hose and work clamp and cable Order K2265 1 TIG Mate 17 Air Cooled TIG Torch Starter Pack Get everything you need for TIG welding in one com plete easy to order kit packaged in its own portable car rying case Includes PTA 17 torch parts kit Harris flowmeter regulator 10 ft 3 0 m gas hose Twist mate adapter and work clamp and cable Order K2266 1 Return to Section TOC Return to Master TOC TIG Mate 20 Water Cooled TIG Torch Starter Pack Get everything you need for TIG welding in one com plete easy to order kit packaged in its own portable car rying case Includes PTW 20 torch parts kit Harris flowmeter regulator 10 ft 3 0 m gas hose Twist Mate adapter work clamp and cable and 10 ft 3 0 m water hose Order K2267 1 Return to Section TOC Return to Master TOC MIG OPTIONS Work and Feeder Welding Cables 350 amps 60 duty cycle with Twist Mate connectors and Ground Clamp Order K1803 1 COMPATIBLE LINCOLN EQUIPMENT Any Arclink compatible wire feeding equipment See www lincolnelectric com OJO OTe o s 5 Dio amp
59. P C BOARD LED LEGEND SWITCH PROPRIETARY amp CONFIDENTIAL 76 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOB LED1 48V AUXILIARY CLEVELAND SCALE pace tor2 BOOSTIGET DRIVE ND1 VERTICAL PANEL st NONE POWERWAVE 5350 paa Lori LED4 15V SUPPLY ECHAS S ewm moy LED5 LED10 CHOPPER IGBT DRIVES pM seem See SUBJECT MACHINE SCHEMATIC genes CASEFRONT WITH PUBLISHED STANDARDS DONOT SCALE THIS DRAWING INCH Mee 1671 Ge128 LED11 BUCK IGBT DRIVE EN 170 SOLID EDGE Insight Return to Section TOC Return to Master TOC manual LINCOLN ELECTRIC POWER WAVE S350 E ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE G6535 PG 2 mu SWITCHBOARD PFC CONTROL CONTROL P C BOARD P C BOARD mE uu Description of LED functions on Power Wave 350 Description of LED functions For reference only CONTROL 8 PWR ri E 88242200 on Power Wave 5350 For reference only 64770 SWITCHBOARD P C BOARD COLOR FUNCTION TU m J26 EA J G4800 CONTROL P C BOARD GREEN 48 VDC AU ILIARY POWER FUNCTIONING WHEN Return to Master TOC
60. POWER WAVE S350 LINCOLN B F 23 Return to Section TOC Return to Master TOC s 2 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC F 24 TROUBLESHOOTING AND REPAIR F 24 SWITCH BOARD TEST PROCEDURE continued TABLE F 4 SWITCH BOARD LED s Description Indicates Light Conditions LED 1 48VDC Supply ON Power applied to PW C300 LED 4 15VDC Supply ON Power applied to PW C300 LEDS Boost Circuit When high input Active voltage is applied 460 and higher LED3 may be very dim or off LED11 Buck Circuit ON Brilliance may Active vary with load LEDs 5 thru 10 Chopper IGBTs ON Brilliance will activated vary with load and output PROCEDURE 1 Disconnect the input power to the Power Wave S350 machine 2 Perform the Case Cover and DC Link Capac itor Discharge Procedure WARNING 0 High voltages are present on and around the switch board Take the appropriated safety precautions when performing the following procedures 3 Locate the switch board on the left side of the machine See Figure F 7 4 Carefully apply the correct input power to the Power Wave S350 Check the LEDs per Table F 4 See Figure F 8 for LED locations 9 If the LEDs are not indicating a properly func tioning switch board per Table F 4 proceed with the following steps C
61. Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag Ifthe PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Com pany for credit it must be in the static shielding bag This will prevent further damage and allow proper fail ure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to
62. Return to Master TOC F 58 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST PROCEDURE continued FIGURE F 22 TEST POINTS 9 4 HHA amar aes 9 23 9 B38 25 Cy PROCEDURE 1 Disconnect the input power to the Power Wave S350 machine To gain access to the Output Rectifier test points first perform the Case Cover and DC Link Capacitor Discharge Procedure Locate test points B51 B38 and B39 See Fig ure F 22 Disconnect lead 207 from the 200 ohm 100 watt output resistor See wiring diagram Using the ohmmeter check the resistances from B51 to B38 B39 Polarity of the ohmmeter is important With the positive meter probe on B51 and the negative meter probe on B38 B39 the resistance reading should be very high With the positive meter probe on B38 B39 and the negative probe on B51 the resistance read ing should be very low Thus a forward diode drop If the meter readings indicate a very low resistance is both directions the output rectifier may be shorted If the meter readings indicate a very high resistance in both directions the out put rectifier may be open If the Output Rectifier is faulty
63. TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO w OTe 05 91 9 5 Dio clo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR r Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S The Real Time Clock no longer functions The S350 will not produce full output OUTPUT PROBLEMS The Control Board Battery may be faulty Replace if necessary Type 52032 The input voltage may be too low See the Check for error codes See Troubleshooting in this section Make certain the input voltage is correct for the machine RECOMMENDED COURSE OF ACTION The Control Board may be faulty Perform the Transducer Test Perform the Voltage Calibration The Control Board may be faulty Perform the Board Test A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE S350 LINCOLN B E TROUBLESHOOTING AND REPAIR 20 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF AC
64. WIRE CONSIDERATIONS Refer to Specification Section for recommended fuse wire sizes and type of the copper wires Fuse the input circuit with the recommended super lag fuse or delay type breakers also called inverse time or thermal magnetic circuit breakers Choose input and grounding wire size according to local or national elec trical codes Using input wire sizes fuses or circuit breakers smaller than recommended may result in nui sance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE SELECTION The POWER WAVE S350 automatically adjusts to work with different input voltages No reconnect switches settings are required A WARNING 9 The POWER WAVEG S350 ON OFF switch is not intended as a service disconnect for this equipment Only a qualified electrician should con nect the input leads to the POWER WAVE S350 Connections should be made in accordance with all local and national electrical codes and the connec tion diagram located on the inside of the reconnect access door of the machine Failure to do so may result in bodily injury or death POWER CORD REPLACEMENT A WARNING Only a qualified electrician should connect the input leads to the POWER WAVE S350 Connections should be made in accordance with all local and national electrical codes and the connection diagrams Fail ure to do so may result in bodily injury or death o0 I
65. and DC Link Capacitor Discharge Procedure Remove the right case side cover 3 Locate the DC Bus Board See Figure F 26 4 Carefully apply the correct input voltage to the 5 Power wave S350 machine Locate LED1 on the DC Bus Board See Figure If LED1 is bright red and steady the DC Bus Board is OK If the LED1 is dim or not steady remove the input power and disconnect Plug J47 When power is reapplied if the LED1 is bright and steady check for a heavy load or short on leads 51 52 and check the resistor at leads 474 and 475 The re sistance should be 250 ohms See wiring dia gram If LED1 is not ON proceed to the next steps DC BUS BOARD 7 Carefully check to ensure that the correct input voltage 48VDC is being applied to the DC Bus Board Plug J46 Pin 1 lead 65 to Plug J46 lead 66 See Figure F 27 8 If the correct input voltage is not present 48VDO check the circuit breaker and associ ated wiring between the DC Bus Board and the Switch Board See the wiring diagram 9 If the correct input voltage is being applied to the DC Bus Board check for the correct output volt ages 10 Check for the presence of 40VDC at Plug J47 Pin1 Lead 51 to Plug 447 Pin 8 Lead 52 See Figure F 27 11 Check for the presence of 40VDC at Plug J47 Pin5 Lead 475 to Plug J47 Pin4 Lead 474 See Figure F 27 12 If the correct input voltage is being applied to the DC Bu
66. 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 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 t
67. at the power source electrode cable to the negative stud and work cable to the positive stud CAUTION Negative electrode polarity operation WITHOUT use of a remote work sense lead 21 requires the Neg ative Electrode Polarity attribute to be set See the Remote Sense Lead Specification section of this document for further details For additional Safety information regarding the elec trode and work cable set up See the standard SAFETY INFORMATION located in the front of the In struction Manuals GENERAL GUIDELINES Select the appropriate size cables per the Output Cable Guidelines below Excessive voltage drops caused by undersized welding cables and poor con nections often result in unsatisfactory welding perform ance Always use the largest welding cables electrode and work that are practical and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates un dersized cables and or bad connections Route all cables directly to the work and wire feeder avoid excessive lengths and do not coil excess cable Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit Always weld in a direction away from the work ground connection Table A 1 shows copper cable sizes recommended for different currents and duty cycles Lengths stipulated are the distance from th
68. current transducer feedback voltages are incorrect the current transducer or wiring from the current transducer to the control board may be defec tive See the wiring diagram 13 Click on Turn Output Off 14 Disconnect the laptop computer 15 Remove the input power to the PW S350 ma chine 16 Replace the case covers POWER WAVE S350 LINCOLN B F 60 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE continued FIGURE F 23 PLUG LOCATIONS ON CONTROL BOARD J12 Chopper Control Board Communication Return to Section TOC Return to Master TOC J5 Secondary Thermostat Connection e O Switch Bank 1 5 5 J6 Primary Error Communications ala 2 J7 Inverter Shutdown Command Fan Control Status LED J8 Current Feedback J9 Voltage Feedback OJO w 0 91 9 5 Dio a Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B inis TROUBLESHOOTING AND REPAIR po CURRENT TRANSDUCER TEST PROCEDURE continued FIGURE F 24 CURRENT TRANSDUCER LOCATION Return to Section TOC Return to Master TOC lt 2 Be E Return to Master TOC CURRENT TRANSDUCE
69. flex ible welding system Like existing POWER WAVES the software based architecture allows for future upgrade ability One significant change from the current range of Power Wave units is that the Ethernet communica tion feature is standard on the Power Wave S350 which allows for effortless software upgrades through Powerwavesoftware com The Ethernet communication also gives the Power Wave amp S350 the ability to run Production Monitoring 2 Also a Devicenet option which will allow the Power Wave S350 to be used in a wide range of configurations Also the Power Wave 5350 is designed to be compatible with future ad vanced welding modules like STT RECOMMENDED PROCESSES AND EQUIPMENT The Power Wave S350 is recommended for semiautomatic welding and may also be suitable for basic hard automation applications The Power Wave amp S350 can be set up in a number of configurations some requiring optional equipment or welding programs RECOMMENDED EQUIPMENT The Power Wave S350 is designed to be compatible with the current range of Power Feed systems in cluding future versions of ArcLink feeders RECOMMENDED PROCESSES The Power Wave S350 is a high speed multi process power source capable of regulating the current voltage or power of the welding arc With an output range of 5 to 350 amperes it supports a number of standard processes including synergic GMAW GMAW P FCAW FCAW SS SMAW GTAW and GTAW P on var
70. found on the Web site www lincolnelectric com FACTORY INSTALLED None Available FIELD INSTALLED OPTIONS GENERAL OPTIONS Stick Tig User Interface Kit Mounts inside the front panel of the Power Wave S350 Allows stick and Tig operation without having a wire feeder Order K2828 1 115 VAC Auxiliary Power Kit Mounts inside the back of the Power Wave S350 Adds 115 VAC 60 Hz auxiliary power capability to the Power Wave S350 only compatible with the K2823 1 power source Order K2829 1 DeviceNet Kit Mounts inside the back of the Power Wave S350 lows Devicenet objects to communicate with the Power Wave S350 Order K2827 1 Work Voltage Sense Lead Kit Required to accurately monitor voltage at the arc Order K940 25 for 25 ft 7 6 m Order K1811 75 for 75 ft 22 9 m Deluxe Adjustable Gas Regulator amp Hose Kit Accommodates Argon or Argon blend gas cylin ders Includes a cylinder pressure gauge dual scale flow gauge and 4 3 ft 1 3 m gas hose Order K586 1 Work and Wire Feeder 2 0 Weld Cable Package Includes Twist Mate connectors work clamps 15 ft 4 5 m work cable and 10 ft 3 0 m electrode cable Rated 350 amps 60 duty cycle Order K1803 1 Twist Mate Cable Plug For connecting welding cable to output terminal recep tacles For 1 0 2 0 50 70 mm cable Order K852 70 Twist Mate Cable Plug For connecting welding cable to output terminal recep tacles For 2 0 3 0
71. gt gt 0 O008 0 A 1 Based on U S National electrical Code 2 Also called inverse time or thermal magnetic circuit breakers circuit breakers that have a delay in tripping action that decreases as the magnitude of the current increases 3 Type SO cord or similar in 30 C ambient 4 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO gt OTe 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC Aa INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE AMPERES GMAW GMAW Pulse FCAW 5 350 100V GTAW DC SMAW PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2823 1 20 40 in 518 mm 14 00in 356 mm 24 80in 630mm 85 Ibs 39 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE Environmentally Hardened 4 F to 104 F 20C to 40C Environmentally Hardened 40 F to 185 F 40C to 85C IP23 155 F Insulation Class Weight does not include input cord POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO OTe gt 2 5 Dio amp c Return to
72. input fuses repeatedly fail or the input circuit breakers keep tripping The machine will not power up no lights or displays The machine appears to be off electrical damage is evident when the S350 OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Service Facility Make certain the fuses or breakers are properly sized The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding current and or reduce the duty cycle Check for error codes See Status LED Troubleshooting in this section Make sure the proper input voltage is being applied to the machine check fuses or breakers Make sure the input supply disconnect has been turned ON Make certain the input power switch SW1 is in the ON position Check for error codes See Status LED Troubleshooting in this section RECOMMENDED COURSE OF ACTION Contact the Lincoln Electric Service Department at 1 888 935 3877 Perform the Input Rectifier Perform the Switch Board Perform the PFC Control Check the input switch SW1 for proper operation Also check the associated leads for loose or faulty connections See the Wiring Diagram Check to make sure that 40VDC is being applied to the optional User Interface Board at leads 52D to lead 51D See the wiring diagram Perform the Bus Board Perform the Input Rectifier Perform the PFC Control
73. is correct A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B is TROUBLESHOOTING AND REPAIR Fs Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The welding starting is poor Make sure the driver roll tension on the wire feeder is adjusted correctly Also the welding wire should travel freely through wire feeding path Check the welding tip for blockage Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt OTe 05 91 9 5 Dio amp c A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJU
74. low pressure air stream to re move accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine PERIODIC MAINTENANCE Return to Section TOC Return to Master TOC Calibration of the Power Wave amp S350 is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly cal ibrated machines may not yield satisfactory weld per formance To ensure optimal performance the calibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the factory Generally the machine calibration will not need adjust ment However if the weld performance changes or the yearly calibration check reveals a problem use the cal ibration section of the Diagnostics Utility to make the appropriate adjustments OJO C gt S 2 0 9 5 Dio EIX The calibration procedure itself requires the use of a grid and certified actual meters for voltage and current The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use The Diagnostics Utility includes detailed instructions it is refered to on the Service Navigator DVD or is available at www powerwavesoftware com Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B D 3
75. material to be welded Select the weld mode that best matches the desired welding process The standard weld set shipped with the Power Wave S350 encompasses a wide range of common processes that will meet most needs If a spe cial weld mode is desired contact the local Lincoln Electric sales representative All adjustments are made through the user interface Because of the different configuration options your sys tem may not have all of the following adjustments See Accessories Section for Kits and Options available to use with the Power Wave S350 Definition of Welding Modes NON SYNERGIC WELDING MODES A Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES Synergic welding mode offers the simplicity of sin gle knob control The machine will select the correct voltage and amperage based on the Wire Feed Speed WFS set by the operator Basic Welding Conirols Weld Mode Selecting a weld mode determines the output charac teristics of the Power Wave power source Weld modes are developed with a specific electrode material elec trode size and shielding gas For a more complete de scription of the weld modes programmed into the Power Wave S350 at the factory refer to the Weld Set Ref erence Guide supplied with the machine or available at www powerwavesoftware com Wire Feed Speed WFS In synergic welding modes synergic CV GMAW P WFS is
76. or Power Feed 25M wire feeder Alternatively an optional Stick TIG UI K2828 1 can be installed into the power source to control these settings locally In a SMAW STICK mode Arc Force can be adjusted It can be set to the lower range for a soft and less pen etrating arc characteristic negative numeric values or to the higher range positive numeric values for a crisp and more penetrating arc Normally when welding with cellulosic types of electrodes E6010 E7010 E6011 a higher energy arc is required to maintain arc stability This is usually indicated when the electrode sticks to the work piece or when the arc becomes unstable during manipulative technique For low hydrogen types of elec trodes E7018 E8018 E9018 etc a softer arc is usu ally desirable and the lower end of the Arc Control suits these types of electrodes In either case the arc control is available to increase or decrease the energy level de livered to the arc GTAW TIG WELDING The welding current can be set through a Power Feed 10M or Power Feed 25M wire feeder Alternatively an optional Stick TIG UI K2828 1 can be installed into the power source to control these settings locally The TIG mode features continuous control from 5 to 350 amps with the use of an optional foot amptrol K870 The Power Wave S350 can be run in either a Touch Start TIG mode or Scratch start TIG mode CONSTANT VOLTAGE WELDING Synergic CV For each wire feed speed
77. problem Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt OTe 05 9 5 Dio amp c Return to Section TOC Return to Master TOC Fas TROUBLESHOOTING AND REPAIR pm CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE continued A WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine 7 Also carefully check for a DC Voltage at B48 B49 See Figure F 9 If a voltage is present wait for it to decay before proceeding FIGURE F 3 CAPACITOR TERMINALS AND ASSOCIATED LEADS OGL POWER WAVE 5350 DC LINK CAPACITOR TERMINALS CAPACITOR TROUBLESHOOTING REPAIR FH CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Linc
78. test point locations 4 Using the Ohmmeter check the resistances per Table F 12 5 f the resistances are correct per Table F 12 then the Planar Transformer is OK OJO gt 5 QJ gt 9 5 2 EIX 6 Replace the Case Cover Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE continued ojo e S 5 TABLE F 12 RESISTANCE CHECKS Test Points Expected Resistance Comments dc B37 to B41 Zero ohms Continuity of Primary Winding B39 to B40 Zero ohms Continuity of 1 2 of Secondary Winding B40 to B38 Zero ohms Continuity of 1 2 of Secondary Winding B8 to B7 Zero ohms Continuity of 1 2 of 48V 5 Winding B7 to B9 Zero ohms Continuity of 1 2 of 48V E Winding B37 to B40 Infinity Isolation between Primary 5 E and Secondary Winding B37 to B7 Infinity Isolation between Primary and 48V Winding B40 to B7 Infinity Isolation between Secondary and 48V Windings All Test Points to Chassis Infinity Isolation fr om all olo Ground windings to chassis ground 5 5 o 3 ele ala 2 2 ojo e 912 o 3 cle 5 5 8 8 POWER WAVE 5350 LINCOLN B NOTES pon POWER WAVE S350 LINCOLN E F 56 DOL Je1Se N 01 DOL Je1Se N 01 uunjeH DOL 0 D
79. the entire Switch Board must be replaced Replace lead 207 Replace the case covers F 58 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 59 TROUBLESHOOTING AND REPAIR F 59 CURRENT TRANSDUCER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Current Transducer and associated wiring is functioning correctly MATERIALS NEEDED Misc Hand Tools Lap top computer Diagnostic Utilities Software Ethernet Cross Connect Cable LE 19969 7 Resistive Load Bank Optional 50 ft 4 0 weld cable Calibrated Ammeter Volt Ohmmeter Note The Diagnostic Utility Softwa
80. 0 DEVICENET amp c POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO mi gt 9 5 Dio amp Return to Section TOC Return to Master TOC inia TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE continued FIGURE F 5 TEST POINT LOCATIONS Switch J12 Chopper Control Board Communication Bank 2 J15 CAN Communication J11 J5 Secondary Thermostat Connection Switch Bank 1 J2 ee J6 Primary Error Communications 48 Volt DC Connection J7 Inverter Shutdown Command Fan Control Status LED J8 Current Feedback J9 Voltage Feedback J10A J10B POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC lt 2 B E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC r TROUBLESHOOTING AND REPAIR re CONTROL BOARD TEST PROCEDURE continued FIGURE F 6 PLUGS amp LEAD LOCATIONS PLUG J4 PLUG J5 358 356 410 409 LTEHE TEE SED 1 PLUG J6 PLUG J7 355 LILIEIEJEIEJEJE jul IL L ID ID 404 406 350 PLUG J8 PLUG J9 21
81. 0 MATERIAL APPROVAL NA DISPOSITION DATE SUBJECT SCHEMATIC CTRL amp PWR SPLY DOCUMENT 5038040 JG 5914 2F0 POWER WAVE 5350 ELECTRICAL DIAGRAMS 6 21 SCHEMATIC 3 STAGE INVERTER PC BOARD 65914 2 2 OUTPUT 18 QUTPUT2 44518M 2 vsi 52 8 INPUT output 7 1 A4 amp S BM GND2 t Return to Master MAIN BUCK DRIVE Return to Section TOC INVERTER SHUTDOWN INPUT PRIMARY FAULT LOW_PWR_TEST 51 Y 0 ua 1 2 OUTPUT Xi DUTPUT2 INVERTER SHUTDOWN BANK 1 069 LOW PWR TEST vm t 4451BM zl THERMAL FAULT ogg L00 AUDIBLE INDICATOR 123 0 1 068 s gt AC_DROPOUT p PK LIMIT CAP UV 208VAC 57 7 T MAIN BOOST IGBT DRIVE Return to Section TOC Return to Master TOC DE V CLRN GCLKO
82. 14 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 1 CASE COVER SCREW LOCATION PROCEDURE 1 Disconnect the input power to the Power Wave 5350 machine Using the 5 16 inch nut driver remove the four top corner end caps as shown in Figure F 1 Keep the screws and flat washers for reassem bly To gain access to the left side internal compo nents use the 5 16 inch nut driver to remove the six remaining screws from the left side See Figure F 1 Locate the DC Link Capacitor and carefully check the voltage across it If any voltage is present discharge the capacitor using the high wattage resistor 25 1000 ohms 25 watts minimum electrically insulated gloves and pliers Hold on the resistor terminals on the capacitor terminals for 10 seconds Recheck the voltage across the capacitor ter minals The voltage should be zero If any volt age remains repeat the procedure Note Any voltage present after discharge has been per formed is an abnormal condition and may indi cate a switch board problem To gain access to the right side portion of the unit remove the six remaining screws from the right cover When replacing the case side and or top be sure to secure all screws When replacing the corner end caps be certain to replace the flats washers previously re moved POWER WAVE S350 LINCOLN B F 14 TROUBLESHOOTING AND REPAIR
83. 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC 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 ma chines 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 in structions 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
84. 2 213 206 202 214 PLUG J12 341 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO lz 9 5 Dio amp Return to Section TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Switch Board is receiving the correct voltages and also ifthe Switch Board is functioning properly The Switch Board has many functions and com ponents Testing of the Planar Transformer the Input Rectifier and the Output Diodes are addressed with individual testing procedures See the F Section Table of Contents MATERIALS NEEDED Voltmeter Ohmmeter Multimeter 7 16 Inch Wrench
85. 232_TXD CF SCO RXD n voa2 CF_CAN_RX 4 3 6 OCHO Vin DEVICENET gt DEVNET_BU 6 02 0720 009 gt DEVNET BUSS DEVNET SUPPLY GND1 DEV COM HCT1G126DCK CF_CAN TX1 PROPRIETARY amp SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER reference only It may not be accurate for all machines covered by this manual DEVNET COM DEV COM ELECTRICAI CAPACIT SEE PAGE 1 OV UNLESS OTHERWISE SPECIFIED UNLESS RWISE SPECIFIED LABELS UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION HEET 1 OF 2 EARTH GROUND CONNECTION CATED COMMUNICATED INC N INFORMATION EQUIPMENT TYPE POWER WAVE SUBJECT SCHEMATIC DIGITAL CONTROL PCB ENGINEER EF REFERENCE ATERIAL APPROVAL PROJECT 50110
86. 3 4 349 6 gt 352 gt 12 342 4 CONTROL BOARD G4800 J12 J8 56 4e s lt 6 0226 2645 lt h mit 21 1 6 lt 5 67 lt 4 202 lt 36 206 lt 1 lt 417 lt 76 214 lt 6 2134 4336 2124 0426 2114 0016 350 066 418 06 415 9 lt 372 gt J7 373 355 6 401 8 lt gt J6 7 3594 lt 5 403 46 402 lt 36 4065 44 4054 0816 409 410 CAPACITOR NOT PRESENT EARLIER MODELS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODING B BLACK R RED N BROWN V VIOLET G GREEN N A PIN NEAREST THE FLAT EDGE OF LED LENS ANODE ALIGNS WITH WHITE LEAD OF LED SOCKET CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF P C BOARD J10A1 J2 J5 J11 55 J9 J13 J16 J10B1 J31 J46 J26 J27 J62 J811 451 111 J112 J8 J24 J28 4 429 443 447 463 43 7000 0000 5 n d J12 J23 J25 J42 OPTIONAL A ARCLINK B ARCLINK C ELECTRODE SENSE D 40VDC E 0VDC 51 ARCLINK RECEPTACLE WHT 20000
87. 3 LED 7 OJO OTe mei gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 91 lz 9 5 Dio amp Return to Section TOC Return to Master TOC M TROUBLESHOOTING AND REPAIR did OPTIONAL USER INTERFACE BOARD TEST PROCEDURE continued FIGURE F 16 PLUG J31 LOCATION ON USER INTERFACE BOARD rear view 51D 1530 PLUG J 31 52D 1540 NOTE Leads connect to user interface harness 4 pin connection to 6 pin connection POWER WAVE S350 LINCOLN B NOTES POWER WAVE 5350 LINCOLN D F 48 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes uunjeg ODOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR F 49 INPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipm
88. 50 LINCOLN B F 74 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 0 91 lz 9 5 Dio amp Return to Section TOC Return to Master TOC Fm TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 31 BOARD PLUG REMOVAL Switch Bak J15 J12 Chopper Control Board Communication an CAN Communication J11 45 Secondary Thermostat Connection J13 Switch Bank 1 J2 J6 Primary Error Communications 48 Volt DC Connection J4 47 Inverter Shutdown Command Fan Control Status LED J8 Current Feedback 49 Voltage Feedback J10A 10 POWER WAVE S350 LINCOLN B NOTES rte POWER WAVE 5350 LINCOLN D F 76 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes UNH DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 77 TROUBLESHOOTING AND REPAIR SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE A WARNING Service and repa
89. 6 17 CPLD_ANALOG FPGA CPLD CLR CAP IN RESET_RAMP_IN FPGA_CPLD ELECTRICAL DIAGRAMS CLUSTER 1 IN PWR_ INT 5 1 51 CF _SPI_MOSI CF_SPI_MISO CF Si CPLD ANALOG RESET RAMP CLK_SOMHZ RESET DSP 1 BLOCK 2 CPLD_CLK CLR CAP RESET FDSP VDSP_GOOI CPLD COMM Mon Aug 17 11 25 34 2009 ACT541 VSPI xh IN PWR SPILENABLE DSP_CPLD KILL STOP CLUSTER 5 MISO DSP_ RESET FDSP_KILL_STOP FD ET LBS V 33BUS 15 gt CPLD TCK FDSP_CPLD 16 CPLD TDI RED LED GRN LED CPLD_DIGITAL CPLD_TDO CPLD TMS 18 PROPRIETARY amp CONFIDENTIAL SINCE COMPONENTS OR CIRCUITF PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INEDRMATION EQUIPMENT TYPE G 10 SS OTHERWISE SPECIFIED THERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 7 FRAME CONNECTION EARTH GROUND CONNECTION POWER WAVE WITHOUT AFFECTING THE INTERCHANGE DRAWN BY EF HIS SUBJECT ABILITY OF A COMPLETE BOARD
90. 70 309 lt 9 lt 308 8 lt 807 lt 7 lt 306 6 lt 305 lt 5 lt ASSEMBLY 65663 USER INTERFACE PCB 1530 1540 lt 2 54D r3 lt 331 520 ae L J STATUS RED GREEN LED 424 INPUT CONTROL BOARD 5915 214 lt 4 lt 211 lt 3 lt 213 lt 2 lt Lem 212 lt 1 lt CURRENT TRANSDUCER 425 Hc 1 4 14 DE Kee He Kae t2 08 4 486 406 lt 6 lt 405 lt 5 lt 404 lt 4 lt 403 lt 3 lt 402 lt 2 lt 326 lt 6 lt 331 lt 4 lt 401 338 335 334 lt 5 lt 24 9 lt REMOTE CONTROL ASSEMBLY G6572 4112 L 15V TRIGGER 4 525304 5 G6536PRINT NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine POWER WAVE S350 G 3 ELECTRICAL DIAGRAMS G 3 SCHEMATIC COMPLETE MACHINE G6535 PG 1 MANUFACTURER No STUD STUD LEM COMMON LEM FEEDBACK LOCATED ON 15VDC LEM SUPPLY CASE FRONT 15
91. ALA DDATA12 DDATAtt 10 DDATAS DDATAB DDATAT DDATAS DDATAS DDATA4 DDATA3 DDATAZ ODATAL soc oL M CF SDCLKO DDATAQ d CF DADDR12 Return to Section TOC Return to Master TOC DADDR12 A DADDR11 DADUR10 DADDR9 CF_DDATA31 DADDRS 301 5 CF DDAT DADDR7 3113 50 CF_DDATA29 DADDR6 NN 8 28 DADDRS 30 ia 22 CF_DDATAZ7 DADDR4 9 CF_DDATAZ6 DADDR3 2613 CF_DDATA25 DADDR2 Bl a gt a CF DDATA24 DADUR Sud CF_DDATAZ3 DADDRO CF_DDATA SDCLKO 1 MTABECAMIS 1 CF DDATAZ SDCKE 8 CF_DDATAZ0 0 MI CF DDATA19 CF DDATA18 CF_DDATA17 CF_DDATAL6 DDATA10 SDDATA9 VREF CF_SDWE CF_SDCKE MCFSABA Return to Section TOC Return to Master TOC BAO DOML CF_DDATAt CF_DDATAZ CF_DDATAS LIES CLUSTER 1 CF DDATAS MTABLCAMI 10 CF_DDATAS CF_DDATA7 CF_DDATAS CF_DDATAS CF_DDATA1O CF_ODATAI1 CF_DDATAIZ CF DDATA13 CF_DDATAL eio gt 2 0 olg 5 5 oD K
92. B DIAGRAM MAY NOT SHOW THE ENGINEER EF REFERENCE COMPONENTS OR CIRCUITRY OF CONTROLS f MATERIAL APPROVAL HAVING COMMON CODE NUMBER oisposition NA pate NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual DOCUMENT SCHEMATIC DIGITAL CONTROL PCB 64799 411 POWER WAVE 5350 Return to Section TOC Return to Section TOC 09 2 Return to Section TOC Return to Master TOC Return to Master TOC 5 o E 2 r Return to Master TOC G 11 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 7 ELECTRICAL DIAGRAMS FTP8 FTP7 6 DSP_MEM DSP_MEM ADDRS ADDRB ADDRT ADDR ADDRS DSP CPLD DSP_ADDR2 008 ADD 09 08 07 06 05 04 03 02 m 00 ANAT ANA ANAS ANAL ANA3 ANA2 ANAL 0 ANB7 ANB6 ANBS 2 ANBI ANB0 5 15 OSP_DATAI4 DSP DATA13 DSP_DATA11 DSP_DATA10 OSP_DATAS DSP DATA8 DSP DATA6 DSP DATAS DATAS 5 DSP_DATAZ SP_DATAL DATAO O O 0 2 DSP_CMPO 05 _ 2 DSP CMPA FPGA DIGITAL FPGA DIGITAL OSP_TMR1_QUT OSP_TMR2_OUT FETA C FETB_C DSP CPLD C
93. C6F25618 FPGA_INIT_DONE INIT_DONE CLKUSR CF PCIBR CF PCIBRO CF_PPSCL2 FPGA_CONF_DONE nSTATUS FPGA_RDY_ FAULT DEV_OE DEV CLRn FPGA_PROG_ RS CAPAC RES PROPRIETARY amp CONFIDENTIAL To PARTE WITHOUT AFFEC OR CIRCUITRY ON A BOARD MAY CHANGE NG THE INTERCHANGE ABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual MON CODE NUMBER EQUIPMENT TYPE OV UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED UNLES CF_FPGA OLTAGE R SUPPLY SOURCE POIN COMMON CONNECTION 7 7 FRAME CONNEC PERMI POWER WAVE APPROVED RAWN B 9 SUBJECT ENGINEER EF REFERENCE MATERIAL DISPOSITION SCHEMATIC DIGITAL APPROVAL NA CONTROL PCB PROJECT G 4799 4L1 NUMBER DOCUMENTI REVISION 01 5350 Return to Section TOC Return to Section TOC Return to Master TOC eio f gt 2 0 Of c cre 5 5 oD 216 Return to Section Return to Master TOC Return to Master TOC G 10 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 6 LINCOLN 9 ELECTRIC C Jobs G4800 4L1 CPLD sbk 0
94. COMPLETE BOARD THIS SUBJECT SCHEMATIC DIGITAL CONTROL PCB Nuveen o Sene pue DIAGRAM MAY NOT SHOW THE EXACT ENGINEER REFERENCE YING PLUG COMPONENTS OR CIRCUITRY OF CONTROLS Mopp MATERIAL APPROVAL PROJECT 885 HAVING COMMON CODE NUMBER PROVED DISPOSITION 5011992 799 411 SINCE COMPONE EQUIPMENT TYPE THRU 4750HMS C Jobs G4800 4L1 G4799 sbk 0117 Aug 17 11 25 33 2009 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC POWER WAVE S350 Return to Section TOC Return to Master TOC Return to Section TOC 09 2 Return to Section TOC Return to Master TOC Return to Master TOC 5 o E 9 E E r G 6 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 2 STUD NPUT OIW R39 Ista V433BUS 56 FPGA_ANALOG R50 UL TIPLEXER ELECTRICAL DIAGRAMS ABSOLUTE VALUE AMPLI AND POLARITY DETECTIO INVERTING GAIN
95. CTRIC 3 3 31 i DSP_PWM10 D i 5 DATA3 DOR X19 L 1 1C6F25618 ey 1 i DATA30 DATA29 DATA28 DATA27 F_DATA26 DATA25 DATAZ4 F DATA DATA22 DATAZ1 20 DATA19 DATA18 DATA17 DATAL DSP_SCITXB DSP_SCIRXB THERMAL LED_F F5 DPCLKO VCCA PLL1 GNDA PLL1 GNDG PLL1 PLL1 0UTp PLL1 0UTn TPM CF_ INT CF_ CS_TPM CF CS HPI V 15BUS 4 HPT HRDY SYSTEM SYS_ RESET FPGA_DIGITAL FDSP_DATA14 FDSP_DATA 5 12 FDSP_DATA11 FDSP_DATA FDSP DATAS FDSP DATAB8 FDSP DATAT FDSP_DATA6 FDSP DATAS FDSP_DATAS FDSP DATA3 FDSP DATA2 FDSP DATAt FDSP DATAO ENC_1B_F ENC_2A_F ENC_2B_F ARC_EST_F THERMAL 1 3 DSP FPGA C Jobs G4800 4L1 FPGA sbk 05 17 CF FPGA CF FPGA gt CF TOUTS FDSP HPI CS CF TIN3 2 6 25618 P_ FAULT BANK RTC_CALIB DSP_CMPO DSP CMP2 DSP_CMP4 DSP TMRI DSP 106 OUT DSP_TMR2_QUT OSP_PWM7 DSP_TMR3_OUT DSP_TMR4_QUT DSP_CANTX DSP_CANRX JDPCLKT ARCLINK SW READY_IN READY OUT PCAN TX PCAN RX 7094 2 ADDR4 FOSP_ADDR11 FOSP_ADDR10 FDSP_ADDR9 FDSP_ADDRI FDSP_ADDR7 FDSP_ADDR6 FDSP_ADDR5 FOSP_ADDR4 FDSP_ADDR3
96. DC Low Input power applied signal To To Speed Output enabled for J7 pin 6 Lead 355 10 VDC High high fan speed signal Speed Power supply 48 6 Lead 214 15 VDC Input power applied to to Current To To machine Transducer J8 pin 2 Lead 212 Power supply 48 6 Lead 214 Input power applied to to Current To To machine Transducer J8 pin 3 Lead 213 PROCEDURE 1 Disconnect the input power to the Power Wave 6 If further testing is required proceed to Step 7 5350 machine 7 Using the Voltmeter carefully check the volt 2 Perform the Case Cover and DC Link ages per Table 2 See Figure Figure F 5 for test itor Discharge Procedure point locations and Figure F 6 for lead loca tions 3 Locate the control board on the right side of the machine 8 Using the Ohmmeter check the resistances per Table F 3 See Figure F 5 for test point loca 4 Carefully apply the correct input voltage to the tions and Figure lead locations Power Wave S350 machine 5 See Figure F 4 for LEDs status and functions If Led 9 is green the proper input voltage is being applied to the control board If LED 1 is green the control board s functioning status is OK POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 91 lz 9 5 Dio amp Retur
97. E ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL WARNING OR CAUTION DANGEROUS VOLTAGE POSITIVE OUTPUT NEGATIVE OUTPUT HIGH TEMPERATURE STATUS PROTECTIVE GROUND EXPLOSION Orn POWER UP SEQUENCE When the POWER WAVE 5350 is powered up it can take as long as 30 seconds for the machine to be ready to weld During this time period the user interface will not be active DUTY CYCLE The duty cycle is based on a ten minute period A 40 duty cycle represents 4 minutes of welding and 6 min utes of idling in a ten minute period Refer to the tech nical specification section for the Power Wave S350 s duty cycle ratings POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO OTe 0 gt o s 5 2 amp c Return to Section TOC Return to Master TOC Return to Master TOC PRODUCT DESCRIPTION PRODUCT SUMMARY The Power Wave S350 is a portable multi process power source with high end functionality capable of Stick DC TIG MIG Pulsed MIG and Flux Cored weld ing It is ideal for a wide variety of materials including aluminum stainless and nickel where arc perform ance is critical The Power Wave S350 is designed to be a very
98. E NUMBER manual ENTIAL DESIGN INFORMATION SUBJECT REFERENCE MATERIAL APPROVAL DISPOSITION NA DATE DRAWN BY ENGINEER EF APPROVED CONT PARTIES OR U E gt THERMAL STT_ON FAN CONTROL GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITOR MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 00V UNLESS OTHERWISE SPECIFIED DIGITAL 1 01 01 PROPRIETARY INFI INCOLN GLOBAL INC EQUIPMENT TYPE OWNED BY D FOR ANY PURP ITHOUT THE EXPRESS WRITTEN PERMIS POWER WAVE LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION K EARTH GROUND CONNECTION MAY NOT DUPLI TED COMMUNI ON OF LINCOLN GLOBAL INC SCHEMATIC DIGI PROJECT NUMBER TAL CONTROL PCB DOCUMENT NUMBER 5011992 JG 4799 411 POWER WAVE S350 G 9 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 5 ELECTRICAL DIAGRAMS CLUSTER 1 FOSP_MEM en MEM DSP MEM FDSP_DATALS Return to Section Return to Section TOC 09 2 Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC 5 o E 2 r LINCOLN amp ELE
99. EDBACK 48 VDC COMMUNICATION FAN CONTROL TO SWITCH BOARD 40 VDC POWER ONLED THERMAL LED PFC CONTROL USER INTERFACE BOARD PRECHARGE OPTIONAL RELAY CONTROL ARCLINK COMMUNICATION DC BUS BOARD THERMOSTATS y Y y 4 CONTROL BOARD gt ETHERNET ARCLINK COMMUNICATION gt REMOTE i ERROR COMMUNICATION REMOTE CONTROL RECEPTACLE poe ONTROL RECEPTACLE MULTI PHASE CHOPPER CHOP PER CONTROL BOARD CURRENT TRANSDUCER AND CONTROL BOARD The Multi Phase Chopper is used to control the welding voltage and current output It receives the 100 volt DC from the Planar transformer and produces a regulated output for welding purposes It contains six chopper phases in parallel that turn on 60 degrees out of phase Two or complimentary phases each conduct 180 de grees out of phase through the same output choke as sembly The Chopper Control Board located on the Switch Board receives welding output commands from the Control Board The Chopper Control Board then deter mines the on time of the six chopper IGBTs to meet the requirements set forth from the Control Board Y Y STATUS STATUS LIGHT ERROR LIGHT The Control Board receives commands and feedback information via Arc Link communication from the op tional User Interface Board the Arc Link Receptacle the Remote Control Board a
100. EER PW MK REFERENCE COMPONENTS OR CIRCUITRY OF CONTROLS f MATERIAL APPROVAL PROJECT HAVING COMMON CODE NUMBER APPROVED ciseosition pare NUMBER 3 It may not be accurate for all machines covered by this manual POWER WAVE S350 G 23 SCHEMATIC 40 VDC BUSS POWER SUPPLY PC BOARD M19330 ELECTRICAL DIAGRAMS G 23 40 VDC 45 120 n gt 4 Work Lead Disconnect Protection Circuitry Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ci D3 r27uF 35V 600V oo N C17 C11 0 004 74 0 004 74 A 50V 50V eio gt 2 0 olg 5 5 oD K amp GENERAL INFORMATION ST NO USED 0V 2 2 ELECTRICAL SYMBOLS PER E1537 CAPAC
101. ER PCB M 1 8 ATERIA APPROVA w S seston 0 Mem 5038040 04769 3 0 AOL C NJobsNGA770 3J0NG4769 Sbk O2 17 Fri Oct 16 11 56 28 2009 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 350 Return to Section TOC Return to Section TOC 09 2 Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC 5 o E 2 r G 20 SCHEMATIC 3 STAGE INVERTER PC BOARD G5914 PG 1 125 FIRST STAGE VCAP SIGNAL ELECTRICAL DIAGRAMS SIMULATED DISCONTINUOUS INPUT CURRENT SHUNT SIGNAL J25 Von R85 TTSK 0 063W Vom INTEGRATOR OUTPUT R 102 TTSK SOURCE IMA Von FIRST STAGE WM CONTROL LER VREF PKLMT 10 INVERTED AVERAGE CURRE
102. ET 1 OF 2 LL EARTH GROUND CONNECTION NT C 4 ANY SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE DESKA INFORMATION EQUIPMENT TYPE POWER WAVE AFFECTING THE INTERCHANGE DRAWN cr 8 17 2009 7 DIAGRAM MAY NOT SHOW THE EXACT ENGINEER EF SUBJECT SCHEMATIC DIGITAL CONTROL REVISION COMPONENTS OR CIRCUITRY OF CONTROLS sz MATERIAL APPROVAL PROJECT 01196 HAVING A COMMON CODE NUMBER APPROVED oisposition NA pate NUMBER 2799 41 01 SN16P11P12P13P1 P15P16T11 3114115116123 1423 Y4 C Jobs G4800 4L1 COLDFIRE sbk 09 17 on Aug 17 11 25 34 2009 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN ELECTRIC POWER WAVE S350 G 14 ELECTRICAL DIAGRAMS G 14 SCHEMATIC DIGITAL CONTROL PC BOARD 4799 PG 10 CF_SDRAM COLDFIRE SDRAM CONTROLLER DDATA31 DIM DDATA3O DDATA30 DDATA29 SIDA TOS DDATA28 M 27 00 26 500 26 SDRAM pius a DDATA23 DDATA22 1 DDATAZ DDATAZO DDATAI9 18 17 DDATA16 15 DDAT
103. F 33 2 To gain access to the Switch Board Assembly see the Case Cover Removal and DC Link 8 Using the 7 16 wrench remove the three input Capacitor Discharge Procedure power leads from terminals B30 Lead 2A B31 Lead 1 and B32 Lead See Figure F33 3 Locate the Switch Board See Figure F 32 9 Remove the two thermostat leads 410 and 409 4 Locate label and remove the five molex plugs from the heat sink thermostat See Figure F 33 from the switch board J41 J42 J43 J45 and OJO w 0 ol 5 Dio a J28 See Figure F 33 10 Using the 5 16 nutdriver remove the four screws and washers securing the switch board 5 Using the 7 16 wrench remove the six output assembly to the chassis frame See Figure choke leads from the terminals labeled BL1 thru F 32 BL6 Be sure to label the leads for reassembly See Figure F 33 NOTE To gain access to the rear mounting screws 2 remove the air baffle 6 Using the 7 16 wrench remove the positive out cable from the switch board See 11 Carefully remove the Switch Board Assembly Note washer and lead placement for re assembly Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt mi 9 5 amp c Ret
104. F _PCIBR1 CF_PCIBRO CF_FPGA CLUSTER 5 CF_ TA 1 lt ER 15 15 r CLUSTER 5 15V BUS SUPPLY y p os PWR RESET 202 E 5 2 CF DSCLK 1 S DSCLK TRST 2 2 PSTDDATAT UVLD 4 PSTODATAT LAL a3 5 5 CF BKPT 1 315 BKPT TMS DATAS 82 PWRED 1 STDDATAS 2 PSTODATAS RT 1 6 3 3 1 i CF 08 15 DSI TD STDDATAA PSTDDATAS S SYNC s 0 K 2 Rx V 15_ENABLE om 1 eee J STDDATA2 8 comP VSENSI TS i A PSTODATAZ 1SCANLG DDATA1 DATA 819 PSTDDATAI MCF5484 PSTDDATAO eio gt 2 0 olg 5 5 oD K amp CLUSTER 51 15CANLG AST USED UNLESS OTHERWISE SPECIFIED PLL SUPPLY E 1 UNLESS OTHERWISE SPECIFIED LESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NE O POWER SUPPLY SOURCE POIN 57 COMMON CONNECTION 2 x18 1 2 3 3 FRAME CONNECTION COLDFIRE SHE
105. IGHT ___ 36 Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 54 Secondary Output over current error The long term average secondary weld current limit has been ex ceeded NOTE The long term average secondary current limit is 325 amps 56 Chopper communication error Indicates communication link between main control board and chop per has errors If cycling the input power on the machine does not clear the error contact the Service Department 58 Primary Fault error Review error code from input board status light or status beeper Most likely caused by an over power condition which caused an under volt age on the primary bus If cycling the input power on the machine does not clear the error contact the Service Department Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the Power Source Control Board If cycling the input power on the machine does not clear the error contact the Service Department A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE S350 LINCOLN B m TROUBLESHOOTING AND REPAIR pu
106. ING AND REPAIR eee SWITCH BOARD TEST PROCEDURE continued FIGURE F 8 SWITCH BOARD LED s LED S 5 THRU 10 LED 1 LED 4 CX 5 LED 3 LED 11 LED S 5 Thru 10 These six LED s are used to indicate a turn on of a chopper phase Intensity of each LED is related to the on time of each of the IGBT s LED 4 15 Volt DC power supply for secondary control circuits LED 1 48 Volt DC auxiliary power supply indicator LED 3 Boost IGBT drive LED 11 Buck IGBT drive POWER WAVE S350 LINCOLN B guy Return to Section TOC Return to Master TOC s lt 2 Be E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC per TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE continued TABLE F 5 SWITCH BOARD VOLTAGE MEASUREMENTS F 27 Description Pre charge relay coil voltage 400VDC from Buck Boost and DC Link Capacitor 48 VAC from the Planar Transformer Winding Test Points Plug J41 Pin 6 To Plug J41 Pin5 B48 To B49 B7 To B9 Also B7 to B8 Expected Reading 15VDC 400VDC SOVAC Conditions Correct
107. IRCUIT 3 RESERVED FOR FUTURE DEVELOPMENT 4 DEVICENET KIT OPTIONAL 5 ETHERNET 6 RESERVED FOR FUTURE DEVELOPMENT 7 SOLENOID KIT OPTIONAL 8 INPUT POWER CORD FIGURE B 2 ff 2 2 1 5 2 gt gt 3 gt 4 amp gt gt 8 amp POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO OTe 0 gt 2 5 Dio EIX Return to Section TOC Return to Master TOC di OPERATION COMMON WELDING PROCEDURES WARNING MAKING A WELD The serviceability of a product or structure utilizing he welding programs is and must be the sole re sponsibility of the builder user Many variables be yond the control of The Lincoln Electric Company affect the results obtained in applying these pro grams These variables include but are not limited o welding procedure plate chemistry and temper ature weldment design fabrication methods and service requirements The available range of a elding program may not be suitable for all appli cations and the build user is and must be solely re sponsible for welding program selection Choose the electrode material electrode size shielding gas and process GMAW GMAW P etc appropriate for the
108. ITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED 02 6 A 1 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED LY VOLTAGE NET R SUPPLY SOURCE POINT GROUND CONNECTION CLUSTER NO ENTIAL THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SINCE COMPONENTS OR CIRCUITRY m PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMA REFERENC PMENT TYPE MULTI SYSTEMS 40 BUSS WITHOUT AFFECTING THE INTERCHANGE DRAWN BY TE In ABILITY OF COMPLETE BOARD THIS SCHEMATIC POWER SUPPLY PCB REIS DIAGRAM MAY NOT SHOW THE EXACT ENGINEER T COMPONENTS OR CIRCUITRY OF CONTR AL APPROVAL PROJECT 2 HAVING COMMON CODE NUMBER APPROVED pate 9 8 2006 u a CRM38151 A 19330 2 0 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 POWER WAVE S350
109. J23 Pin 11 Resistance should Input power ele 5 e Plug J23 Pin 12 ohms 9 Switch Board Typical failure is a short Auxiliary Buck Plug J23 Pin 2 Resistance should Input power Gate Drive To be greater than 500 removed Remove LINCOLN Plug J23 Pin 1 ohms Plug J41 from the Switch Board Typical failure is a short o o c is 2 2 5 o al o 3 cle 5 2 POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO OTe 1 9 5 Dio amp Return to Section TOC Return to Master TOC F 36 TROUBLESHOOTING AND REPAIR F 36 POWER FACTOR CONTROL BOARD TEST PROCEDURE continued TABLE F9 POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS continued Main Boost Gate Drive Plug J23 Pin 8 To Plug J23 Pin 7 Resistance should be greater than 500 ohms Input power removed Remove Plug J43 from the Switch Board Typical failure is a short Input power Auxiliary Boost Plug J23 Pin 9 Resistance should removed Remove Gate Drive To be greater than 500 Plug J43 from the Plug J23 Pin 10 ohms Switch Board Typical failure is a short POWER WAVE S350 LINCOLN B F 37 B12 B48
110. L PROTECTION Two normally closed NC thermostats protect the machine from excessive operating temperatures One is con nected to the control board It is located on top of the secondary heat sink The other thermostat is located and integrated into the switch board and is monitored by the Power Factor Correction Board Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond its duty cycle or output rating If ex cessive operating temperatures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the machine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fans are operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fans are not turning or the intake air louvers are obstructed the power must be removed from the machine and the fan condition or air obstruction corrected PROTECTIVE CIRCUITS Protective circuits are designed into the Power Wave S350 to sense trouble and shut down the machine before damage occurs to the machine s internal components Error Codes will be flashed out by the light on the Control Board and will help identify the reason for the shutdown They should all be steady green See the Trou bleshooting Section for more information regarding Error Co
111. LUSTER 5 05 1 3 DSP KILL STOP 5 9 01 u we a LK 1 NC lt 1 ae 332K 00634 3 3 0 06 3wW AV INTG DSP_ TRST 5 _ 2 DSP_TMS 05 4 osp_too s di 5 0 aia ate DSP_EMU0 6 osp_emui lt 148 AUCIGO4 NC GND DSP_CLK 50MHZ DSP_ANALDG DSP D A CS WMS PwM6 T10UT 13 r20UT 10 r2cMp READY TCK rus TDI EMUO 9 2 CLKIN CLKOUT T30UT T4OUT Ics 16 LE OSP_PWM7 NC HB P3 DSP PWMIO NC NC KS SP TMR3 DUT NS DSP TMRA DUT 5 CAPO_D 05 TCLKINB LS LN 5 CMP6 MOST miso N SPCLK SCATX SCARX SCBTX SCBRX MCLK MCLKR DSP SCITXA DSP SCIRXA SP SCITXB V 3 3BUS DSP CF DSP_SCIRXB DSP CLKX SP CANTX CANRX TPS72501 IN OUT x8 ENABLE RST FB VDSP G00D VIO 6000
112. Master TOC OJO w OTe 0 o s 5 Dio clo INPUT CHOKE 60KHZ INPUT 400V RELAY IGBT FULL WAVE BRIDGE MAIN SWITCH DC LINK FIRST STAGE RECTIFIER CAPACITOR BUCK BOOST 100 Ohm SECOND STAGE HIGH FRQUENCY INVERTER WITH PLANER TRANSFORMER RECTIFIER POSITIVE TERMINAL OUTPUT 100V CAPACITORS THIRD STAGE MULTI PHASE BUCK CONVERTER CURRENT TRANSDUCER NEGATIVE TERMINAL 120KHz Y CHOPPER CONTROL BOARD CURRENT FEEDBACK VOLTAGE FEEDBACK CHOPPER COMMUNICATION GENERAL DESCRIPTION The POWER WAVE 5350 is a welder featuring an inverter type power source with Tribrid Converter Technology and Automatic PowerConnect Technology with high end functionality The POWER WAVE S350 machine is a high performance multi process machine with GMAW FCAW MMA DC TIG and pulse capability The S350 is capable of regulating the current voltage and power of the welding arc It offers premier welding performance solutions for specific areas such as aluminum stainless and nickel especially where machine size and weight are considerations FAN INPUT CONTROL FAN CONTROL y TD VDC b Suet DRIVES t sous 40 VDC 9 G POWER ON LED THERMAL LED 0 PFC CONTROL DES CONTROL THERMOSTATS BOARD USE
113. Materials Needed at the beginning of this Section A WARNING The Output Studs of the Machine will be Electrically HOT during Steps 4 thru 7 4 Click on the Turn Output ON button The BLACK light on the screen will flash RED indi cating that the weld output is turned ON Figure F 14 5 Adjust the load bank to 200 Amps at approxi mately 24 Volts as read on the external cali brated meters 6 Using the Calibration Adjustment buttons Ad just the current so that the external ammeter reads 200 Amps 2A Adjust the voltage so that the Output Voltage display window reads the same as the external voltmeter 25volts 7 Click on the Turn Output OFF button Calibra tion is complete Also check at 300 Amps 50 Amps POWER WAVE S350 LINCOLN B Return to Section TOC lt 2 Be E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR CURRENT AND VOLTAGE CALIBRATION PROCEDURE continued FIGURE F 14 CALIBRATION SCREEN Lincoln Electric Diagnostic FE lll Communication Diagnostics System Info Calibration Cable Tests Feed Head DeviceNet Lookup Error rena WARNING Connect welding cables to load bank before testing Da not make changes on this screen while welding Bw
114. N ERROR CODE LED WILL FLASH ERROR AND BU R WILL SOUND SEE TABLE BELOW FOR DETAILS DIGITAL CONTROL O ERROR CODE E PLANATION PEAK INPUT CURRENT LIMIT START UP CURRENT CHECK FAILURE START UP VOLTAGE CHECK FAILURE Return to Section TOC Return to Master TOC THERMAL FAULT NO FIRST STAGE FAN PRECHARGE TIMEOUT TRANSFORMER PRIMARY OVERCURRENT REMOTE BOARD ASSEMBLY G5672 1 J112 I O LED3 B28 5 MOUNTED LED s 244 B11 INVERTER eio gt 2 0 olg 5 5 oD K amp CHOPPER CONTROL J47 DAUGHTER BOARD 27 OUTPUT ER 28 T o 508020 P C BOARD N INDICATES OUTPUT MOUNTED LED s
115. N 5 NOTES ree POWER WAVE 5350 LINCOLN D F 80 DOL Je1Se N 01 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 81 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the DC Bus Board MATERIALS NEEDED 3 8 wrench POWER WAVE S350 LINCOLN B F 81 Eee TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT continued
116. NECTOR 10 VDC FAN HIGH SPEED x THERMAL LED STATUS R RED GREEN LED THERMOSTAT FAN POS LOCATED ON I FAN NEG TOP OF 351B SECONDARY 3B HEAT SINK 8J6 407 lt s lt 554 1 01226 lt s 150 0047uF 553 lt 104 342 343 344 346 347 348 511 8 341 401 yn J51 2 gt 1 3 B Return to Section TOC Return to Master TOC COMMON DATA OUTPUT A DATA OUTPUT B DATAINPUT A DATAINPUT B SUPPLY 5V ISOLATED 45V ISOLATED CLOCK INPUT A CLOCK INPUT B L J50 1 gt WHT WHT gt 200000 E P 480 3 GRN lt 50 4 gt 200000 gi gon fo 55 348 341 342 343 344 345 346 347 THERMOSTAT THERMOSTAT SECONDARY COMMON INPUT BOARD ERROR INVERTER SHUTDOWN FAN CONTROL POSITIVE FAN CONTROL NEGATIVE 48 VDC POSITIVE 48 VDC COMMON 855533 SYNC TANDEM CONNECTOR OPTIONAL SECONDARY 15V THRU 475 OHM 353 mi 48 VDC FAN HIGH 24 VDC FAN LOW LOCATED REAR STAYS ON HIGH SPEED FOR CHOPPER CONTROL BOARD 8 MIN AFTER LAS SCHEMATIC 64747 TRIGGER THEN 55 350 3 36 PIN IN LINE CONNECTOR 5 j 3 2 located on ABA back
117. NT SIGNAL VSENSE 5 js x vec f CAOUT 14 MULTOUT VADUT 7 GTDRV INTEGRATOR INTEGRATOR_B CURRENT_SENSE_CTAL ono E G 20 Vas START CHECK A 8 13075 START UP SYSTEMS CHECK CURRENT PK LIMIT PK INPUT CURRENT LIMIT V ono PRIMARY CAP VOLTAGE gt VCAP SIGNAL CAP UV START CHECK V 15 V RECTIFIED AC LAARA AC DROPOUT DETECT SECOND STAGE CT INPUT
118. 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 competent 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
119. OC OJO gt OTe 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt mi 0 gt ol 5 2 EIX Return to Section TOC Return to Master TOC F 74 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE continued 3 PROCEDURE 1 Disconnect the input power to the Power Wave 5350 machine To gain access to the Control Board see the Case Cover Removal and DC Link Capacitor Remove the right side case cover Locate the Control Board See Figure F 30 Remove the eight molex type plugs and the FIGURE F 30 CONTROL BOARD LOCATION CONTROL PC BOARD Install the new board and replace the molex type plugs and Ethernet cable previously re moved Check the settings of the dip switch making sure they are the same as the old board Replace the four nuts previously removed Replace the right case side cover See the Case Cover Removal and DC Link Capacitor Ethernet cable from the board Label locations Discharge Procedure for reassembly See Figure 31 Using the 3 8 wrench remove the four nuts se curing the control board to the vertical baffle POWER WAVE S3
120. OF CONTROLS HAVING A COMMON CODE NUMBER It may not be accurate for all machines covered by this manual GENERAL INFORMATION UNLESS OTHERWISE SPECIFIED OTHERWISE SPECIFIED ANALOG J OSHEET 02 OF o2 IS PROPRIE FOR URPOSE WITHOUT THE EQUIPMENT TYPE Y INFORMATION OWNED BY LIN POWER WAVE LABELS SUPPLY VOLTAGE NET Q POWER SUPPLY SOURCE POINT V COMMON CONNECTION FT FRAME CONNECTION EARTH GROUND CONNECTION MAY NOT BE DUPLICATED COMMUNIC ATED N OF LINCOLN GLOBAL INC PAGE 03 OF 13 GLOBAL INC IR PRI PERM SCHEMATIC DIGITAL CONTROL PCB SUBJECT REFERENCE APPROVAL M APPROVA APPROVED NUMBER PROJECT NUMBER G 4799 411 DOCUMENT DOCUMENT REVISION A 01 5011992 POWER WAVE S350 Return to Section TOC Return to Section TOC Return to Master TOC 09 2 Return to Section TOC Return to Master TOC Return to Master TOC 5 o E 2 r G 8 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 4 LINCOLN amp ELECTRIC THERMO THERMAL C 02 MNOUT_C ELECTRICAL DIAGRAMS CLUSTER 1 gt 15V RELAYS gt MNOUT gt SSOUT INT 1 3PH F SSOUT_C INT1 3PH
121. OL 0 DOL Uonoes UNH DOL DOL uonoes OOL uonoes uunjeg Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 57 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Output Rectifier is open or shorted MATERIALS NEEDED Voltmeter Ohmmeter Multimeter POWER WAVE S350 LINCOLN B F 57 Return to Section TOC Return to Master TOC Return to Section TOC OJO c 0 1 gt 9 a Dio amp Return to Section TOC Return to Master TOC
122. ONS Power Wave S350 Solenoid Kit Mounts inside the back of the Power Wave 5350 Switches gas flow in the Power Wave S350 through the Twist Mate con nector Includes gas hose and solenoid only compatible with the K2823 1 power source Order K2825 1 Pro Torch TIG Torches A full line of air cooled and water cooled torches avail able Request Lincoln publication E12 150 See www lincolnelectric com Hand Amptrol Provides 25 ft 7 6 m of remote cur rent control for TIG welding 6 pin plug connection Order K963 3 Foot Amptrol amp Provides 25 ft 7 6 m of remote current control for TIG welding 6 pin plug connection Order K870 Arc Start Switch May be used in place of the Foot or Hand Amptrol amp Comes with a 25 ft 7 6 m cable Attaches to the TIG ra eua n acc torch for convenient finger control to start and stop the weld cycle at current set on the machine Order K814 Twist Mate Torch Adapter For connection of Pro Torch TIG torches 1 piece cable to power sources with gas passing through the Twist Mate connection For use with K2825 1 Order K1622 1 For air cooled PTA 9 or PTA 17 torches Order K1622 3 For air cooled PTA 26 torches Order K1622 2 For water cooled torches Twist Mate Torch Adapter For connection of PTA 9 or PTA 17V torches 1 piece cable to power sources without gas passing through the Twist Mate connection
123. OR BUCK BOOS CURRENT carve TRANSDUCER S Ee 5 TERMINAL I A Anais A SIL 5 j o dos CHOPPER CONTROL BOARD CURRENT VOLTAGE FEEDBACK FEEDBACK L a CHOPPER D COMMUNICATION FAN INPUT CONTROL FAN CONTROL is Y Y STAGE DRIVES 40 VDC ON 9 THERMAL LED PFC CONTROL DC BUS THERMOSTATS BOARD BOARD CONTROL OSER INTERFACE BOARD gt ETHERNET ARCLINK COMMUNICATION Le ums OPTIONAL ARCLINK COMMUNICATION CONTROL PEIE CENEL ERROR RECEPTACLE COMMUNICATION DC BUS BOARD AND OPTIONAL USER INTERFACE BOARD The DC Bus Board receives 48VDC supply voltage from the Planar Transformer circuitry This voltage is regu lated to 40VDC and is applied to the ArcLink Receptacle for wire feeder operation The optional User Interface Board receives the operator commands and via ArcLink communications sends the appropriate signals to the Control Board ym STATUS STATUS LIGHT ERROR LIGHT NOTE Unshaded areas of Block Logic Diagram are the subject of discussion E 6 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C gt o s 5 Dio amp Return to Section TOC Return to Master TOC ET THEORY OF OPERATION ET Machine Protection THERMA
124. OT DUPLICATED COMMUNICATE INC TTEN PERMISSION OF LINCOLN GLOBA POWER WAVE SCHEMATIC DIGITAL CONTROL PCB numer SUBJECT REF ERENCE MATERIAL Weit PROJECT ec NUMBER 2011992 DOCUMENT REVISION 64799 4L1 A 01 DOCUMENT POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC 09 2 Return to Section TOC Return to Master TOC 5 o E 2 r Return to Master TOC G 12 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 8 2K 0 063w SETS HPI TO 32 BIT WIDTH ELECTRICAL DIAGRAMS EDSP_FPGA FOSP_FPGA FOSP_GP7_ INT7 CF CF DATAO CF_DATA1 2 5 FIPS FDSP GP3 CF DATA3 CF_DATA4 33FANLG CF DATAS CF DATA CF DATAT CF_DATAS CF DATA9 CF_ADDR2 CF_ADDR3 CF ADDR HPL INT HPI_ HADY HCNTL HCNTLA CLKINSEL ACLKIN CLKMODE3 CLKMODE2 LKMODEt CLKMODE Cp y OSCOUT OSCVOD NMI CF_ SOFTRST SYS_ KILL FOSP_CLK_SOMHZ VFOSP_GOOD t TPM_FOSP_ INT GPOIS OSP_CMPO FOSP_ RESET FDSP KILL STOP DS
125. PECIFIED OTHERWISE SPECIFIED THERWISE SPECIFIED 8 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 117 FRAME EARTH GROU 0018 HCPL 2601 4 29 2 NT SINCE COMPONENTS OR CIRCUITRY ON A 3 PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE 1 TOCUMEI NUMBER ABIL Y OF 1 BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC LL 038020 G 4769 30 COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER APPROVED C Jobs G4770 3J0 G4769 sbk 01 17 Fri Oct 16 11 56 28 2009 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp POWER WAVE 350 G 19 ELECTRICAL DIAGRAMS ens SCHEMATIC 3 STAGE INVERTER PC BOARD G4769 PG 2 vs 15 SUPPLY O Return to Master TOC Return to Section TOC BLZ D 2 GND_SEC
126. POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO w OTe 0 gt o s 5 Dio clo Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES 55 STICK OPTIONS ACCESSORY KIT 150 Amp For stick welding Includes 20 ft 6 1m 6 electrode cable with lug 15 ft 4 6m 6 work cable with lugs headshield filter plate work clamp electrode holder and sample pack of mild steel electrode For use with K2176 1 Twist Mate to Lug Adapter ORDER K875 ACCESSORY KIT 400 AMP For stick welding Includes 35 ft 10 7m 2 0 electrode cable with lug 30 ft 9 1m 2 0 work cable with lugs headshield filter plate work clamp and electrode holder For use with K2176 1 Twist Mate to Lug Adapter ORDER K704 REMOTE OUTPUT CONTROL Portable current control provides the same dial range as the current control on the welder Consists of a 6 pin Amphenol con nector which plugs into the remote control Amphenol 25 foot cable length ORDER K857 ORDER K857 1 for 100 ft 30 m STICK ELECTRODE HOLDER AND CABLE 55 BLY Includes 200A stick electrode holder and Twist Mate connector 12 5 ft cable length ORDER K2374 1 STICK ELECTRODE HOLDER CABLE AND WORK CABLE ASSEMBLY Includes 200A stick electrode holder welding cable work clamp and Twist Mate adapter ORDER K2394 1 TIG OPTI
127. POWER WAVE S350 LINCOLN E F 84 DOL Je1Se N 01 DOL Je1Se N 01 uunjeH DOL 0 DOL 0 DOL Uonoes UNH DOL DOL uonoes OOL uonoes uunjeg 85 TROUBLESHOOTING AND REPAIR res REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Remote PC Board MATERIALS NEEDED Phillips Head Screwdriver Return to Section TOC Return to Master TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Mast
128. P_FPGA L lt B2 apoo FOSP_CPLO CLKXO DSP CLKR DSP FSR DSP DR DSP CLKX DSP FSX DSP DX TOUTO DSP FDSP TINPO SYSTEM OPERATES IN BIG ENDIAN MODE TOUT2 0 HPI IS ENABLED UVLO PWRGD RT S SYNC CLUSTER 1 ENA COMP 15 PHILA LSG VBIAS VSENSE TPS54350 X50 4 AHCLKX0 AFSRO AMUTEINO T 3 C155 C158 212 uF o 1 A10B2 85 88814 1 C Jobs G4800 4L1 F AST_DSP sbk 08 17 on Aug 17 11 25 33 2009 M22 Pi 122 WI YZ Y19 Y22 AB3AB10AB17AB20 CLUSTER 5 3 3805 151 TA 14 SP Ta 14 Fi oc FDSP 1 FDSP_ASDCKE FOSP_ ARE_ SDCAS FOSP_ AQE_ SDRAS E20 FOSP_ AWE_ SOWE AECLKIN AECLKOUT1 AECLK0UT2 1 5 ABUSREQ FDSP FDSP D FDSP DATA29 FDSP DATA28 FDSP_DATA27 FDSP DATAZ6 25 DATA DATA 22 DATA21 20 19 DSP DATA18 FOSP_DATAt FOSP_DATAt FDSP DATALA
129. R olo eye 09 2 5 TABLE 13 OUTPUT CURRENT ACTUAL TRANSDUCER FEEDBACK VOLTAGE 2 3 500 4 0 450 3 6 400 3 2 350 28 300 24 250 20 200 1 6 150 1 2 100 0 8 50 0 4 Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B F 63 ETHERNET RECEPTACLE ZZZZZZZZX2AZzUIB 2Z Z2ZZZZZZ2Z2ZZ2ZAZZZZ N 2 POWER WAVE 5350 LINCOLN E SN FIGURE F 25 ETHERNET RECEPTACLE TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE continued 63 DOL Je1Se N 0 uunjeH DOL Je1Se N uunjeH DOL 0 DOL 0 DOL UNH DOL UNH DOL OOL uonoes uunjeg NOTES POWER WAVE 5350 LINCOLN D F 64 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg 65 TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may re
130. R CONTROL BOARD TEST PROCEDURE continued FIGURE F 10 PFC CONTROL BOARD LOCATION ETHERNET CONNECTOR PFC CONTROL BOARD ARCLINK CONNECTION DC LINK CAPACITOR X PRE CHARGE RELAY INPUT CORD GRIP CONNECTOR POWER WAVE S350 LINCOLN B 8 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE continued FIGURE F 11 PFC CONTROL BOARD PLUGS Return to Section TOC Return to Master TOC BUZZER G5915 PFC CONTROL BOARD P C BOARD COLOR FUNCTION 2 GREEN 15 VDC POWER SUPPLY FUNCTION PROPERLY WHEN ON 1 RED ERROR CODE LED WILL FLASH ERROR AND BUZZER WILL SOUND SEE TABLE BELOW FOR DETAILS Pause before repeating the code 3 5 seconds Pause between digits of the code 1 5 seconds Pause between sounds flashes indicating a specific digit 0 5 seconds ERROR CODE x ss Return to Section Return to Master TOC OJO w 9 5 Dio clo 336 THERMAL FAULT NO FIRST STAGE FAN 337 PRECHARGE TIMEOUT 346 TRANSFORMER PRIMARY OVERCURRENT POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR PN POWER FACTOR CONTROL BOARD TEST PROCEDURE continued TABLE F 8 POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS Return t
131. R INTERFACE BOARD ori ARCLINK COMMUNICATION RELAY BUZZER ARCLINK COMMUNICATION 15 B REMOTE CONTROL I i ARC LINK CONTROL ERROR RECEPTACLE RECEPTACLE c Y y STATUS STATUS LIGHT ERROR LIGHT One significant improvement is that the Ethernet communication feature is standard on the Power Wave S350 machine This allows for effortless software upgrades through PowerWavesoftware com The Ethernet communication also gives the POWER WAVE 5350 the ability to run Production Monitoring 2 The POWER WAVE S350 is designed to be compatible with future advanced welding modules such as STT The POWER WAVE S350 is capable of producing a welding output from 5 to 350 amperes It will operate on single and or three phase input power from 208VAC to 575VAC It is environmentally hardened to an IP23 rating for operating in difficult environments NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO OTe gt ol 5 Dio amp c Return to Section TOC Return to Master TOC THEORY OF OPERATION ES FIGURE E 3 MAIN INPUT SWITCH INPUT RECTIFIER SOFT START INPUT RELAY ETC SWI
132. RESISTOR hr W UNLESS OTHERWISE SPECIFIED LABELS DIODES UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON NECTION O We FRAME CONNECTION EARTH GROUND CONNECTION s m PROPRIETARY amp CONFIDENTIAL 109 8 PARTIES UR ANY PL SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INEGRMATION EQUIPMENT TYPE POWER WAVE S350 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY PW MK 3 30 2 BILITY OF A COMREETE BOARD THIS B SUBJECT SCHEMATIC CTRL amp PWR SPLY PCB DIAGRAM MAY NOT SHOW THE EXAC ENGINEER REFERENCE JMBI REVISION COMPONENTS OR CIRCUITRY OF CONTROLS A APPROVAL mm A HAVING COMMON CODE NUMBER APPROVED NA DATE 01 C NJobsNG5915 2F 0 G5914 sbk 02 17 Thu Apr 02 12 57 25 2009 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN je ELECTRIC POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio f i 2 0 c cre 5 5 oD 216 Return to Section Return to Master TOC G 22 ELECTRICAL DIAGRAMS SCHEMATIC STAGE INVERTER PC BOARD 65914 PG 3 LINCOLN 8 Bootstrap Sup 15 Volts 05 Amps
133. ROLS f AL Al JVAL HAVING COMMON CODE NUMBER APPROVED orsposition NA NUMBER 4799 411 5011992 POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio gt 2 0 olg 5 5 oD K amp Return to Section TOC Return to Master TOC G 17 ELECTRICAL DIAGRAMS G 17 SCHEMATIC DIGITAL CONTROL PC BOARD 4799 PG 13 CLUSTER 1 BULK SUPPLY FOR 3 3V_ ISOLATED 19232 V 5BUS sev V 5BUS SUPPLY FOR SOLATED NK CAN 30 55VDC OPERATION las 92 7 271 eo p SUPPLY FOR 5V ISOLATED PARALLEL SUPPLY VSPI GODD E gt vem h 1 225V a REFERENCE SUPPLY Ea 5 1_
134. RS THIRD STAGE MULTI PHASE BUCK CONVERTER CURRENT TRANSDUCER NEGATIVE 77 TERMINAL SN CHOPPER CONTROL BOARD CURRENT FEEDBACK VOLTAGE FEEDBACK CHOPPER PLANAR TRANSFORMER OUTPUT RECTIFICATION AND FILTERING The Planar Transformer has two secondary windings The 100 volt weld winding is center tapped and rectified The 48 volt auxiliary winding is also center tapped and rectified The term Planar refers to the design and construction of the transformer The windings are cre ated on printed circuit boards and stacked up to create a transformer The primary and secondary connections are oriented at opposite ends of the transformer This type of assembly provides for tighter magnetic coupling between the pri mary and secondary windings resulting in lower leakage inductance higher efficiency cooler operation and re duced size gt 48 VDC COMMUNICATION ojo NE INPUT CONTROL S FAN CONTROL POWER 48 voc TO SWITCH Fae TAN BOARD s lt 09 9 mee o sionas 5 40 VDC Ee POWER ON LED THERMAL LED _ PFC CONTROL DC BUS THERMOSTATS S BOARD BOARD CONTROL ed USER INTERFACE 1 BOARD BOARD la gt ETHERNET ARCLINK COMMUNICATION OPTIONAL ARCLINK COMMUNICATION 513
135. RY amp CONFIDENTIAL OTHER PARTIES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC DRAWN BY EF ENGINEER EF REFERENCE SUBJECT COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT HAVING A COMMON CODE NUMBER APPROVED DISPOSITION NA NUMBER NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC OR FOR ANY PURPOS EXPR DESIGN INFORMAT 10N EQUIPMENT TYPE GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 _ SEE CAPACITORS MFD UNLESS OTHERWISE SPECIFIED RESISTORS 0 LABELS DIODES 1 A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION PAGE 1 UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED ANALOG I OSHEET 01 oF 02 D MAY NOT DUPLICATED COMMUNICATED N OF LINCOLN GLOBAL INC PAGE 02 OF 13 DOCUMENT 00 7 RE A 01 POWER WAVE SCHEMATIC DIGITAL CONTROL PCB NUMBER 5011992 6 4799 411 POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC 09 2 Return to Section TOC Return to Master TOC Return to Master
136. Return to Master TOC Return to Master TOC o 5 0 gt 2 E Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info SVM203 A October 2010 POWER WAVE 5350 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 thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machine code number 11589 SERVICE MANUAL LI NCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC Return to Master TOC o 5 o 2 8 Return to Master i SAFETY i WARNING N CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains chem are known to the State of California to cause cancer icals known to the State of California to cause cancer birth de
137. SP_DATAZ FOSP_DATA3 FOSP_DATAS FOSP_DATAS FOSP_DATA6 FOSP_DATA7 FOSP_DAT AS FOSP_DATAS FOSP_DATALO FOSP_DATAt1 FDSP DATA12 FDSP DAT FOSP_DATALS FOSP_DATALS LESS OTHER SE SPECIFIED BY LINCOLN GLOBAL INC AND MAY NOT BE ITTEN PERMI RI E SPECIFIED 5 OTHERWISE SPECIFIED AST NO USED PAGE 1 LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 3 7 FROME CONNECTION EARTH GROUND CONNECTION PLICATE N OF LINCOLN GLOBAL 1 COMMUNI POWER WAVE PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION EQUIPMENT TYPE WITHOUT AFFECTING THE INTERCHANGE DRAWN BY 2 ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXAC ENGINEER EF SUBJECT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER APPROVED MATERIAL NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC SCHEMATIC DIGITAL CONTROL PCB APPROVAL DOCUMENTI REVISION A 01 DOCUMENT NUMBER 4799 4L1 PROJECT NUMBER 201199 POWER WAVE 5350 G 13 ELECTRICAL DIAGRAMS G 13 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 9 COLDFIRE FLEXBUS A war al COLDFIRE Ag ae INTERRUPTS amp EEPROM ae ar us SERIAL BUSSES 64KBYTE DATAZT 1 pus 26 20 E IN PWR_ INT CF I2C CLK DATAZ 30 195 CF I2C DA
138. STMENT S COURSE OF ACTION ETHERNET PROBLEMS The system will not connect Make sure that the correct patch Use Weld Manager included cable or cross over cable is on the Power Wave Utilities being used and Service Navigator CD s or available at www powerwavesoftware co m to verify the correct IP address information has been entered Return to Section TOC Return to Master TOC Make sure the software is not blocking the connection See the on line Diagnostic Utility Verify that the cables are fully inserted into the bulk head Verify that no duplicate IP connector addresses exist on the Verify that the network device network connected to the Power Wave is either a 10 baseT device or a 10 100 baseT device The LED located under the PC board Ethernet connector will be lit when the machine 1 connected to another network device Return to Section TOC Return to Master TOC The Ethernet connection drops out Make sure all of the connections Make certain that the network while welding are tight and secure cable is not located next to any heavy current carrying conductors This would include input power cables and welding output cables OJO w 0 lz 9 5 Dio clo A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical t
139. Section TOC Return to Master TOC 1 INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before work ing on the equipment e Do not touch electrically hot parts e Always connect the POWER WAVE 5350 grounding lug to a proper safety Earth ground SELECT SUITABLE LOCATION The POWER WAVE S350 will operate in harsh envi ronments Even so it is important that simple preven tative measures are followed in order to assure long life and reliable operation e 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 e Dirt and dust that can be drawn into the machine should be kept to a minimum The use of air filters on the air intake is not recommended because nor mal air flow may be restricted Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown e Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles e Do not mount the POWER WAVE S350 over com
140. TA DATAZS 5 00 20 DATA DATAZ4 00819 1 19 x L8 DATA30 ITAJA 5 001 43 5 29 DATAZ3 AD 2 20 SAND DATAZ2 j R26 DD u 012 12 21 ADDR21 26 00 6 D ADDR2 fe CF_DATA11 20 AD CF_ADDR20 00815 15 510 26 CF_DATALO DATA19 2 DD Do 25 A1 09 2 CF ENETO CF DATAS DATA18 4 8 Doi DDR13 1 DATA24 Er DATAG y 2 I ae c AF20 E gt CF IZC DATA NVRAM RT RTC_CALIB CF_DATA3 DATAL CF_ADDRI6 Dn 11 06 26 DATARS 29 3 5 E 32KRYTE eril DDI 19 21 0 2 S DATA M anori 26 CF_ADDR CF COMM NC SCOTXD D VBAK DATA ADDRI CF ADDRI 5 3 31256S ADDRB 3 19 1 DATA 3 M26 CF_ADDR D CF CAN TX1 AD 12 0087 2 G CF_DATA1 gt 5 DATA aiig 2 CF_ADDR12 7 D2 CF_TIN2 25 AA2 p ids DATAS AC24 roy 1 DSP_SCIRXA CF_DATA9 10 ADDRIO CF_ADDR10 ae AE 4 h SCITXA URES ADDRA 8 DATA Y1 p ADDR9 26 CF_ADDR9 CF_TOUT1 AC2 INAS 5 Se ADDR3 tlas A AF2 CF_DATA2 DATA8 ADRE CF_ADDRS FPGA RDY FAULT AF2 CF_DATAL 7 CF_ADDR7 ADORE 3 a2 RTCLCALIB CF 10010 AF24 ATA pts 5 A ADDR1 4 1 6 CF ADDR js 1 94 u
141. TCH BOARD INPUT RELAY INK FIRST STAGE EU WAVE MAIN C LI BRIDGE SWITCH RECTIFIER 100 Ohm CAPACITOR BUCK BOOST SECOND STAGE HIGH FRQUENCY INVERTER OUTPUT WITH PLANER TRANSFORMER RECTIFIER POSITIVE TERMINAL THIRD STAGE MULTI PHASE BUCK CONVERTER CURRENT TRANSDUCER NEGATIVE TE 120KHz CHOPPER CONTROL CURRENT VOLTAGE FEEDBACK FEEDBACK FAN INPUT CONTROL POWER CHOPPER COMMUNICATION 000 DRIVES sanas 40 VDC POWER ONLED THERMALLED PFC CONTROL BOARD USER INTERFACE BOARD RECHARGE OPTIONAL CONTROL ARCLINK COMMUNICATION DC BUS BOARD CONTROL H THERMOSTATS BOARD gt ETHERNET ARCLINK COMMUNICATION k ERROR COMMUNICATION MAIN INPUT SWITCH INPUT RECTIFIER SOFT START INPUT RELAY DC LINK CAPACITOR BUCK BOOST AND POWER FACTOR CORRECTION BOARD The Power Wave S350 can be connected to a variety of both three phase or single phase input voltages The Power Wave S350 automatically adjusts to operate with different AC input voltages No reconnect switch set tings are required The initial input power is applied through a line switch located on the lower front panel of the machine This AC input voltage is applied to an input rectifier where it is rectified to a DC voltage The DC voltage is then applied to a soft start circuit consist ing of a 100 ohm resistor and a DC relay The rectified
142. TECTION The EMC classification of the POWER WAVE 5350 is Industrial Scientific and Medical ISM group 2 class A The POWER WAVE S350 is for industrial use only See print L10093 for fur ther details Locate the POWER WAVE 5350 away from radio controlled machinery The normal operation of the POWER WAVE 5350 may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO w 0 gt ol 5 2 clo Return to Section TOC Return to Master TOC Return to Master TOC gt INSTALLATION A WARNING Only a qualified electrician should connect the input leads to the POWER WAVE S350 Connections should be made in accordance with all local and national electrical codes and the connection diagrams Failure to do so may result in bodily injury or death 3 0m power cord is provided and wired into the machine For Single Phase Input Connect green lead to ground per National Electrical Code Connect black and white leads to power Wrap red lead with tape to provide 600V insulation For Three Phase Input Connect green lead to ground per National Electric Code Connect black red and white leads to power INPUT FUSE AND SUPPLY
143. TION WELDING PROBLEMS General degradation of the Check for proper wire feeding Perform the welding performance Make certain that the actual Voltage Calibration speed is the same as the preset Verify that the correct wire drive and gear ratio have been selected Return to Section TOC Return to Master TOC Check the welding cables for loose or faulty connections Check for adequate gas shielding Make sure the welding process is correct for the wire feed and voltage settings Return to Section TOC Return to Master TOC The wire burns back to the tip at Reduce the burnback time the end of the weld Reduce the workpoint During a weld the machine shuts The secondary current limit has A non recoverable internal fault down been exceeded and the machine will interrupt the welding shuts down to protect itself output This condition will also Adjust the procedure to reduce result in a status light blinking the load and lower the output Check for error codes See current draw Status LED Troubleshooting in this section The arc is excessively long and In the wire feeder make certain Perform the erratic the correct wire drive and gear Voltage Calibration ratio have been selected for the 2 welding process being used o 5 o 2 8 sure the shielding gas is correct for the welding process being used Also make sure the flow rate
144. TOC 5 o E 2 r G 7 SCHEMATIC DIGITAL CONTROL PC BOARD G4799 PG 3 ELECTRICAL DIAGRAMS G 7 PRILCUR AZ PRI CUR A1 PRILCUR B1 MAIN CLUSTER 1 POS_LEM CURRENT DG2O1ADY LOW CHOPPER PWM BIAS DG201ADY X2L 15074 0 FEEDBAC de PRIMARY OVER CURRENT TRIP ADJUST tout 8 Q_OUT FPGA_ANALOG 25 2 TL30161D tour 0 0UT OVR CUR PRI CUR BZ HIGH INVERTER SEL I ON SLOPE COMPENSAT 2ND_LEM INPUT F 2ND LE LIMITER I FLOW STT FPGA_ANALOG 2 511 CURRENT FLOW
145. VDC LEM SUPPLY 15V TRIGGER OPTIONAL ASSEMBLY G5663 a USER 5 B Return to Master TOC i fr Return to Section USED FOR PRODUCTION MONITORING DOWNLOADING SOFTWARE OR UPLOADING MACHINE INFORMATION ETHERNET CONNECTOR 4J111 4J111 5111 6J111 gt 3J111 INTERFACE REMOTE CONTROL PCI PCB ASSEMBLY G6572 gt 1J31 1530 gt 2181 gt 3 31 gt 4J31 gt 52D a 4 112 RJ45 TYPE i a GAS SOLENOID LOCATED TOP OPTIONAL LEFT REAR PANEL FREQUENCY 7 ETHERNET CABLE 359 COM RC ESTABLISHED TRIGGER 15V 363 TE 6J112 OUTPUT ON 361 21 67 214 211 213 I Paid 1J9 gt 206 360 2J11 53 sa 4J9 6J8 3J8 gt 202 6J9 CONTROL P C BOARD 546 11J6 34 gt 934 DNET J13 1 24 GND J13 2 L 413 4 891 1 24 VDC LOCATED ON VERTICAL CAPACITOR NOT TYPICAL FEEDBACK j BL s Top Front DIVIDER PANEL PRESENT ON 4 500 i center EARLIER MODELS Nag Vp ai SCHEMATIC G4799 893 3 24 GND lt 892 lt 4 4CAN H 11412 KILL L 12J12 10212 lt 891 1 5 5 L 9 OVDCFAN 8 2 DEMCENET LOWSPEED 9 CON
146. a D DATA W2 pe ings CF_ADDR LES nc gt CF FPGA 5 DATA 826 CFLADDRA mo MTMDII CF_CAN_TX0 DATA ADDR3 224 s 2 6 MTMODO pesca P DATAZ 2 Apr 526 38 ce m RES 13 FPGA_PROG RST DATA 4 patie CF ADDRI P H BRECHA FPGA CONF DONE DATAO 33 401 CF_ADDRO 2 23 FPGA INIT DONE PPSCHT CF _PPSCL2 CF_MEM Return to Section TOC Return to Master TOC CF COMM CF ADDR 6 31 DATAL CF_COMM 2 SYSTEM MCF5484 CF_FPGA O CF_ CS_HPI 1 CF_ CS_FLAS CF TS CF R W PCIIDSEL PUIRDY PCIPAR TBCS5 5052 1 557 Return to Section TOC Return to Master TOC 3 KAZE ABS p lt 2 PCITRDY CF SOFTRST 24 pocigga tr TOUT3 CF KILL STOP PPCIBG PPCIBRt A PPCIBGO PPCIBRO MCF5484 C
147. actical and instead the arc length is set by adjusting trim Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length See figure B 3 FIGURE B 3 111 Trim 1 00 Arc Length Medium Trim 50 Arc Length Short Trim 1 50 Arc Length Long POWER WAVE S350 LINCOLN B OPERATION Most pulse welding programs are synergic As the wire feed speed is adjusted the Power Wave S350 will au tomatically recalculate the waveform parameters to maintain similar arc properties The Power Wave S350 utilizes adaptive control to compensate for changes in the electrical stick out while welding Electrical stick out is the distance from the contact tip to the work piece The Power Wave S350 waveforms are optimized for a 0 75 stick out The adaptive behavior supports a range of stick outs from 0 50 to 1 25 At very low or high wire feed speeds the adaptive range may be less due to reaching physical limitations of the welding process Return to Section TOC Return to Master TOC UltimArc Control adjusts the focus or shape of the arc UltimArc Control is adjustable from 10 0 to 10 0 with a nominal setting of 0 0 Increasing the UI timArc Control increases the pulse frequency and background current while decreasing the peak current This results in a tight stiff arc u
148. allation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH limits 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 products 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 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 Also see item 1 b POWER WAVE S350 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 8 c tc Return to Master TOC SAFETY B gt Z WELDING and CUTTING SPARKS 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 Where compressed gases are to be used
149. amp ERAL INFORMATION ELECTRICAL SYM u SEE PAGE 1 CAPACIT RESISTORS 0 1 PPLY VOLTAGE X46 3 10 10 JURCE POINT 48LCAMt 57 COMMON CONNECTION Vss 155 EI pe PT FRAME CONNECTION COLDFIRE SHEET 2 OF 2 LL EARTH GROUND CONNECTION PROPRIETARY amp CONFIDENTIAL 1 PROPRIETARY IN ORMA NED BY Ue SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION EQUIPMENT TYPE POWER WAVE WITHOUT AFFECTING THE INTERCHANGE DRAWN BY EF ABILITY OF COMPLETE BOARD THIS gt p Tra N DIAGRAM MAY NOT SHOW THE EXAC ENGINEER EF REFERENCE SUBJECT SCHEMATIC DIGITAL CONTROL PCB COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT _ 199 N HAVING COMMON CODE NUMBER APPROVED oisposition NA NuMBER 20119 G4799 4L1 CA Jobs G4800 4L1 COLDFIRE sbk 10 17 Aug 17 11 25 34 2009 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Master TOC LINCOLN ELECTRIC POWER WAVE S350 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio
150. c and automatically configured by the active weld mode Return to Section TOC Return to Master TOC Work Voltage Sensing The Power Wave S350 is configured at the factory to sense work voltage at the negative output stud positive output polarity with remote Work Voltage Sensing dis abled Negative Electrode Polarity The Power Wave S350 has the ability to automatically sense the polarity of the sense leads With this feature there are no set up requirements for welding with neg ative electrode polarity This feature can be disabled through the Weld Manager Utility available at www powerwavesoftware com or through the set up menu if a user interface is installed into the power source CAUTION If the auto sense lead feature is disabled and the weld polarity attribute is improperly configured ex tremely high welding outputs may occur Return to Section TOC Return to Master TOC While most applications perform adequately by sensing the work voltage directly at the output stud the use of a remote work voltage sense lead is recommended for optimal performance The remote WORK sense lead 21 can be accessed through the four pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit It must be attached to the work as close to the weld as practical but out of the weld current path For more information regarding the placement of remote work voltage sense leads see the section entitled V
151. case side See the 3 8 inch nutdriver remove the three nuts secur Cover Removal and DC Link Capacitor Dis ing the PFC Control Board See Figure F28 charge Procedure 4 Carefully slide the PFC Control Board from the mounting studs o c iz 12 FE E o s ele 815 2 POWER WAVE 5350 Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 71 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER LEM REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid in the removal and replacement of the Current Transducer LEM Module MATERIALS NEEDED 11 32 Inch Wrench 7 16 Inch Wrench Flat Head Screwdri
152. d 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 How ever 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 in sulated 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 in creasing 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 acc
153. d wire feeder can be used as the user interface or a K2828 1 user interface control panel can be installed into the power source The connection diagram shown is based on the S Series user interface K2828 1 In this diagram the remote control box is optional GMAW MIG WELDING An arclink compatible wire feeder is recommended for Mig welding Refer to Figure 5 the connection de tails FIGURE A 2 REGULATOR we g GAS SOLENOID INSIDE MACHINE K2825 1 GASHOSE 7 TO NEGATIVE TIG WITH POWER FEED USER INTERFACE TO REMOTE CONTROL S lt gt gt FOOT AMPTROL lt K870 lt s k 1 27 22 POSITIVE d STUD STUD WORK CLAMP SS SS 07 20 WORK PIECE gt TIG TORCH lt PF10 M 15 2266 1 SQ pd WIRE FEEDER INCLUDES WORK CLAMP ADAPTER AND REGULATOR FIGURE A 3 REGULATOR FLOWMETER GAS SOLENOID KIT INSIDE MACHINE K2825 1 GAS HOSE TO NEGATIVE STUD TIG TORCH K2266 1 KIT INCLUDES WORK CLAMP TIG WITH S SERIES USER INTERFACE USER INTERFACE CONTROL PANEL K2828 1 STUD FOOT AMPTROL K870 WORK CLAMP ADAPTER AND REGULATOR POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO gt OTe 05
154. danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Planar Transformer windings are good and not shorted to each other or to ground MATERIALS NEEDED Voltmeter Ohmmeter Multimeter POWER WAVE S350 LINCOLN B F 53 TROUBLESHOOTING AND REPAIR diu PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE continued eye 515 FIGURE F 21 TEST POINTS o B51 A os 3E INVERTER O CHOKE B9 B7 T 1 v Return to Section Return to Master TOC B41 PROCEDURE 1 Disconnect the input power to the Power Wave 5350 machine 2 To gain access to the Planar Transformer test points first perform the Case Cover and DC Link Capacitor Discharge Procedure See Figure F 21 for
155. des Fault codes can also be seen by using the Di agnostic Software OVER CURRENT PROTECTION If the average weld current exceeds 400 amps the machine s output will be disabled POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO w OTe gt 9 5 2 clo Return to Section TOC Return to Master TOC E 8 THEORY OF OPERATION E 8 FIGURE E 7 IGBT OPERATION MINIMUM OUTPUT 7 3 I 1 usec 1usec gt lt gt 1 16 6 sec MAXIMUM OUTPUT 7 3 usec lt 7 3 usec lt 1 psec 1usec gt lt gt lt gt 16 6 sec PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION PWM is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle Chang ing the pulse width is known as MODULATION Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output signal pos sible over a 16 6 microsecond time period The shaded portion of the signal represents one IGBT group1 con ducting for 1 microsecond The negative portion is the
156. des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage a l aide d crans appropri s et non inflammables Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons 4 sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place POWER WAVE S350 LINCOLN Return to Master TOC Return to Master TOC o 5 o 2 E tc Return to Master TOC SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of
157. diodes are in the from the Switch J41 Pin 6 circuit path to the Board Receptacle on Switch relay coil Board Buck Converter B12 High Resistance Machine off no IGBTs To Greater than 100 000 input power applied B28 ohms The Input Choke Typical failure is a disconnected from the short Switch Board B28 Buck Converter B28 High Resistance Machine no Diode To Greater than 100 000 input power applied 49 ohms The Input Choke Typical failure is a disconnected from the short Switch Board B28 Boost Converter B29 4 High Resistance Machine off no IGBTs To Greater than 10 000 input power applied 49 ohms The Input Choke Typical failure is a disconnected from the short Switch Board B28 Boost Converter B48 High Resistance Machine off no Diode To Greater than 10 000 input power applied B29 ohms The Input Choke Typical failure is a disconnected from the short Switch Board B28 Full Bridge High Side B48 To High Resistance Machine off no IGBTs B37 Greater than 10 000 input power applied Also ohms The Planar B48 To Typical failure is a Transformer B41 short electrically isolated from the Swithc Board at test points B37 and B41 POWER WAVE S350 LINCOLN B F 28 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 91 lz 9 5 D
158. e This status light corresponds tothe operation is for the status light to be off and the buzzer to be main control board s status A second status light is internal off and is located on the input control board and can be seen by looking through the left case side louvers Error conditions are indicated in the following chart Table F 1 TABLE F 1 ____________________ Main control board status light Input control board System OK Power source is operational and is communicating normally with all healthy peripheral equipment connected to its ArcLink network Light Condition Steady Green Not applicable Blinking Green Occurs during power up or a system reset and indicates the POWER WAVE S350 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 Indicates Auto mapping has failed Not applicable Non recoverable system fault If the Status lights are flashing any com bination of red and green errors are present Read the error code s before the machine is turned off Not applicable Fast Blinking Green Alternating Green and Red Not applicable Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a gre
159. e the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER WAVE S350 LINCOLN F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO w OTe gt 9 5 Dio clo Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR F3 PC BOARD TROUBLESHOOTING PROCEDURES K ELECTRIC SHOCK can kill Have electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid problems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock
160. e welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop TABLE A 1 OUTPUT CABLE GUIDELINES Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CA Amperes Cycle BLES RUBBER COVERED COPPER RATED 167 F 75 C to 50 Ft 50 to 100 Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft Tabled values for operation at ambient temperatures of 104 F 40 C and below Applications above 104 F 40 C may require cables larger than recommended or cables rated higher than 167 F 75 C POWER WAVE S350 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lt 2 jos tc Return to Section TOC o 5 o 2 8 Return to Master INSTALLATION ii CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding per formance to degrade There are several factors that contribute to the overall inductance of the cabling sys tem including cable size and loop area The loop area is defined by the separation distance between the elec trode and work cables and the overall welding loop length The welding loop length is defined as the total of length of the electrode cable A work cable B work path C See Figure A 6 To minimize inductance a
161. ed connection panel for protection against ac cidental impact Ethernet connectivity via IP 67 rated ODVA compliant RJ 45 connector Panel mounted Status and Thermal LED indicators facilitate quick and easy troubleshooting Potted PC boards for enhanced ruggedness reliabil ity Enclosure reinforced with heavy duty aluminum ex trusions for mechanical toughness OJO OTe gt 13 a Dio amp c Remote control Foot amptrol ready Waveform Control Technology for good weld ap pearance and low spatter even when welding nickel alloys Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt OTe 9 5 Dio amp c Return to Section TOC Return to Master TOC CASE FRONT CONTROLS See Figure B 1 1 USER INTERFACE optional 2 STATUS LED See Troubleshooting Section for op erational functions 3 THERMAL LED Indicates when machine has ther mal fault 4 POWER SWITCH Controls power to the Power Wave S350 5 WORK STUD 6 ELECTRODE STUD 7 WORK SENSE LEAD 8 6 PIN REMOTE FIGURE B 1 P OPERATION P CASE BACK CONTROLS See Figure B 2 1 115 VAC RECEPTACLE AND CIRCUIT BEAKER OPTIONAL 2 ARCLINK BREAKER RECEPTACLE C
162. en light Only active error conditions will be ac cessible through the Status Light Error codes can also be retrieved with the Diagnostics Utility refered to on the Service Navigator DVD or available at www power wavesoftware com This is the preferred method since it can access historical information contained in the error logs To clear the active error s turn power source off and back on to reset Not applicable Steady Red Blinking Red Not applicable Error Code interpretation Indi vidual code digits are flashed in red with a long pause between digits These error codes are three digit codes that all start with a number three CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Not applicable POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO gt OTe 05 9 5 Dio amp c Return to Section TOC Return to Master TOC r1 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual ERROR CODES FOR THE POWER WAVE S350 The following is a list of possible error codes for the POWER WAVE S350 MAIN CONTROL BOARD STATUS L
163. ent may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Digital Volt Ohmmeter DVM Misc Hand Tools Wiring Diagram POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C QJ 9 5 amp c Return to Section TOC Return to Master TOC ro TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST PROCEDURE continued FIGURE F 17 INPUT RECTIFIER LOCATION CHOPPER CONTROL BOARD PLANAR TRANSFORMER INPUT RECTIFIER TEST POINTS CURRENT TRANSDUCER ON OFF SWITCH INPUT CHOKE PROCEDURE 1 Remove the input power to the machine 2 Perform the Cover Removal and DC Link Capacitor Discharge Procedure 3 Locate the Input Rectifier and associated leads See Figure F 17 and Figure F 18 4 Use the digital voltmeter DVM
164. er TOC lt 2 io tc Return to Section TOC Return to Master TOC o 5 o 2 8 F 86 TROUBLESHOOTING AND REPAIR REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE continued REMOTE PC BOARD PROCEDURE 1 Disconnect the input power to the Power Wave 5 Using the phillips head screwdriver remove the 5350 machine three screws securing the Remote PC Board to 2 To gain access to the Remote PC Board see the ihe vertical divider panel Case Cover Removal and DC Link Capacitor 6 Carefully remove the Remote PC Board Dischatae Procedure Remove the right cage 7 Install the new DC Board onto the mounting cover studs 3 Locate the Remote PC Board See Figure F 36 8 Using the three screws previously removed 4 Label and remove the two molex plugs from the mount the Remote PC Board to the vertical di Remote PC Board See Figure F 37 vider panel 9 Install the two molex plugs POWER WAVE S350 LINCOLN 5 F 86 TROUBLESHOOTING AND REPAIR dud REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 37 REMOTE PC BOARD LOCATIONS J111 J112 J113 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 0 lz 2 a Dio EIX Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B NOTES pu
165. er lens should conform to ANSI Z87 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 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 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 ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precau tions are also required when welding on galvanized steel 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 specific welding procedure and application involved Worker expo sure level should be checked upon inst
166. et equipment cables switches etc as defined by the connection diagrams must be supplied by the customer It is critical that all Ethernet cables external to either a conduit or an enclosure are solid conductor shielded cat 5e cable with a drain The drain should be grounded at the Source of transmission For best results route Ethernet cables away from weld cables wire drive control cables or any other current carrying device that can create a fluctuating magnetic field For additional guidelines refer to ISO IEC 11801 Failure to follow these recommenda tions can result in an Ethernet connection failure during welding POWER WAVE S350 LINCOLN B A 14 NOTES POWER WAVE 5350 LINCOLN D A 14 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC B 1 TABLE OF CONTENTS OPERATION SECTION B Operation rm B 1 Safety Precautions u uyu us gw eme B 2 Graphic Symbol ove vd PY ss yasaq ET B 2 Power Up Sequence De RETARE GG Sa Saa Q b E a bound pr ARR B 2 Duty B 2 Product Description soss ss neu ever hen eae pos ERU p Ed RE Rog eR V E
167. f the input power cord is damaged or needs to be re placed an input power connection block is located in the back of the machine with the access panel removed as shown Figure A 1 ALWAYS CONNECT THE POWER WAVE GROUND ING LUG LOCATED AS SHOWN IN FIGURE A 1 TO A PROPER SAFETY EARTH GROUND FIGURE A 1 POWER WAVE S350 LINCOLN Return to Section TOC Return to Section TOC OJO gt OTe 05 o a Dio amp c Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC INSTALLATION CONNECTION DIAGRAMS GTAW TIG WELDING Auser interface is required for adjusting the TIG welding settings A Power Feed wire feeder can be used as the user interface Figure A 2 or a S series user interface K2828 1 can be installed into the power source Fig ure A 3 Refer to the connection diagrams based on the user interface that is being used For either set up the K2825 1 solenoid kit is recommended for controlling the gas Alternate configurations are possible depending on the wire feeder that is being used Refer to the wire feeder s manual for alternative configurations SMAW STICK WELDING Similar to TIG welding a user interface is required for adjusting the Stick welding settings A Power Fee
168. fects and other reproductive harm birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment Ny 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 49 ELECTRIC AND 5 MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld dangerous ing arc or when the engine is running Stop the engine and allow
169. from the work leads and toward the sense leads See Figure A 7 ojo 5 E FIGURE A 7 E 8 CONNECT ALL SENSE LEADS AT THE END 212 DIRECTION OF THE WELD cc RA OWER WAVE INCOLNL ELECTRIC H 5 CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD o 515 os 5 2 POWER WAVE 5350 LINCOLN B Return to Section TOC Return to Master TOC o 2 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION For circumferential applications connect all work leads on one side of the weld joint and all of the work voltage sense leads on the opposite side such that they are out of the current path See Figure A 8 FIGURE A 8 BAD CURRENT FLOW FROMARC 1 AFFECTS SENSE LEAD 2 Work 1 Sense 1 CURRENT FLOW FROM ARC 2 AFFECTS SENSE LEAD 1 NEITHER SENSE LEAD PICKS UP THE CORRECT WORK VOLTAGE CAUSING STARTING AND WELDING ARC INSTABILITY 2 B L el ZI LER SENSE LEAD 1 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 1 O SENSE LEAD
170. have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the war ranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid de nial of legitimate PC board warranty claims POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO w OTe 0 91 lz ol 5 Dio a Return to Section TOC Return to Master TOC Return to Master TOC in TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S Major physical or case is removed The
171. he possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention Dur ing Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing sal CYLINDER 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follo
172. he supply voltages are correct proceed to Step 7 For Steps 7 through 13 refer to the information in the Diagnostic Utility found on the Lincoln Service Navigator or at Powerwavemanager com 7 Using the Ethernet Cross Connect cable con nect a laptop computer to the Power Wave S350 via the Ethernet port located at the top rear of the machine See Figure F 25 8 Connect a load bank or 50 Ft weld cable to the Positive and Negative output terminals on the Power Wave S350 9 Using the Diagnostic Utility Software a Establish Communication with the PW S350 Select the Calibrate tab Select the 50 amp current set point Select Turn Output On Use an external calibrated ammeter that is not affected by inverter noise to read the actual current 10 Check the current transducer s feedback volt age at the Control Board plug J8 per Pin 1 lead 211 to pin 6 lead 214 See Figure 23 23 for pin locations 11 Repeat the test at several other current levels If the transducer feedback voltage is correct for the actual current the current transducer is functioning properly If there is no feedback voltage check the wiring from the control board to the current transducer See the wiring dia gram CAUTION If using a weld cable across the output terminals instead of a load bank do not exceed the cur rent rating of the cable 12 If the supply voltages are correct but the
173. heck the voltages per Table F 5 9 test point locations Check the switch board resistances per See Figure F 9 for test point locations If any of the above tests are not correct the Switch should be replaced Replace all plugs and leads that were previ ously disconnected 10 Replace the case covers POWER WAVE S350 LINCOLN B r TROUBLESHOOTING AND REPAIR Ess SWITCH BOARD TEST PROCEDURE continued olo 8 8 5 5 FIGURE F 7 SWITCH BOARD LOCATION ele cre 212 CHOPPER 2 CONTROL PCB 2 PLANAR TRANSFORMER INPUT CHOKE o s lt 2 Be E Return to Master TOC DC LINK CAPACITOR PRE CHARGE RELAY SWITCHBOARD PCB Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO gt mi 91 gt 9 5 Dio amp c Return to Section TOC Return to Master TOC Return to Master TOC ree TROUBLESHOOT
174. ine Refer to the Maintenance Section of this manual The air intake and exhaust louvers may be blocked due to inadequate clearance around the machine Make sure the fans functioning correctly The fans should run in a low speed setting when the machine is at idle and in a high speed when welding output is activated The fans should also run if a thermostat has tripped TROUBLESHOOTING AND REPAIR F 5 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Perform the Input Rectifier Perform the Switch Board Test Perform the Transformer Resistance Test Perform the Control Board Perform the Optional User Interface Board Test Perform the Output Rectifier Perform the DC Bus Board Test Check the thermostats and associated wiring for loose or faulty connections See the wiring diagram Check the DC voltages being applied to the fans at lead 351 to lead 353 At the low speed setting the voltage should be 24VDC At the high Speed setting the voltage should be 48VDC See the wiring diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master
175. input power applied to machine and pre charge completed If not correct the Perform the Power Factor See wiring diagam Correct input power applied to machine and pre charge completed If not correct Perform the Input Rectifier Test Correct input power applied to machine and pre charge completed If not correct Perform the 100VAC from Planar Transformer Winding B38 To B40 100V AC Correct input power applied to machine and pre charge completed If not correct Perform the 100VDC from Output Rectifier B52 To B51 100VDC POWER WAVE S350 LINCOLN B Correct input power applied to machine and pre charge completed If not correct Perform the Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C 0 Of dc ol a amp c Return to Section TOC Return to Master TOC F 28 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE continued TABLE F 6 SWITCH BOARD RESISTANCE MEASUREMENTS Meter Test Points Description Expected Readings Conditions and Polarity 100 Ohm Pre Charge B10 100 Ohm Machine off no Resistor To input power applied B12 Pre Charge Relay J41 Pin 5 15 000 to 30 000 Machine off no Coil Resistance Receptacle on Switch ohms dependant on input power applied Board meter being used Plug J41 removed To Two
176. io amp Return to Section TOC Return to Master TOC pes TROUBLESHOOTING AND REPAIR cee SWITCH BOARD TEST PROCEDURE continued TABLE F 7 SWITCH BOARD RESISTANCE MEASUREMENTS continued Full Bridge Low Side B37 To High Resistance Machine off no IGBTs B49 Greater than input power applied Also 10 000 ohms The Planar B41 To Typical failure is a Transformer 49 short electrically isolated from the Switch Board at test points B37 and B41 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC e lt 09 is E tc Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC F0 TROUBLESHOOTING AND REPAIR FD SWITCH BOARD TEST PROCEDURE continued FIGURE F 9 SWITCH BOARD TEST POINTS A INVERTER I CHOKE 066 9 11111 11101111 8 1 POWER WAVE 5350 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC C gt 9 5 Dio amp Return to Section TOC Retur
177. ious materials especially steel aluminum and stainless OPERATION E PROCESS LIMITATIONS The software based weld tables of the Power Wave S350 limit the process capability within the output range and the safe limits of the machine In general the processes will be limited to 030 052 solid steel wire 030 045 stainless wire 035 1 16 cored wire and 035 and 1 16 Aluminum wire EQUIPMENT LIMITATIONS Only ArcLink compatible semiautomatic wire feeders and users interfaces may be used If other Lincoln wire feeders or non Lincoln wire feeders are used there will be limited process capability and performance and fea tures will be limited POWER WAVE S350 LINCOLN OPERATION DESIGN FEATURES Loaded with Standard Features Multiple process DC output range 5 350 Amps 200 600 VAC 1 3 phase 50 60Hz input power Return to Section TOC Return to Master TOC New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctua tions Utilizes next generation microprocessor control based on the ArcLink platform State of the art power electronics technology yields superior welding capability Electronic over current protection Input over voltage protection fan as needed Cooling fan only runs when needed Return to Section TOC Return to Master TOC Thermostatically protected for safety and reliability Recess
178. ir should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Switch Board It is very important to make sure the Power Factor Control Board is not damaged before replacing the Switch Board Perform the Power Factor Control Board Test MATERIALS NEEDED 5 16 Nutdriver 7 16 Wrench 3 8 Nutdriver POWER WAVE S350 LINCOLN B F 77 EB TROUBLESHOOTING AND REPAIR FR SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 32 SWITCH BOARD LOCATION amp MOUNTING SCREWS MOUNTING SCREWS 4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC INPUT CHOKE SWITCH BOARD ASSEMBLY PROCEDURE 1 Disconnect the input power to the Power Wave 7 Using the 7 16 wrench remove the two input 5350 machine choke leads from terminals B28 and B29 See Figure
179. it to cool before refueling 2 a Electric current flowing through any conductor causes to prevent spilled fuel from vaporizing on con localized Electric and Magnetic Fields EMF Welding tact with hot engine parts and igniting Do not current creates EMF fields around welding cables and spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated b EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when c Exposure to EMF fields in welding may have other health starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the 2 d 1 Route the electrode and work cables together Secure maintenance requiring their removal is complete them with tape when possible Always use the greatest care when working near moving parts 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and
180. lways use the appropriate size cables and whenever possible run the electrode and work cables in close proximity to one another to mini mize the loop area Since the most significant factor in cable inductance is the welding loop length avoid ex cessive lengths and do not coil excess cable For long work piece lengths a sliding ground should be consid ered to keep the total welding loop length as short as possible REMOTE SENSE LEAD SPECIFICATIONS Voltage Sensing Overview The best arc performance occurs when the Power Wave S350 has accurate data about the arc conditions Depending upon the process inductance within the electrode and work cables can influence the voltage ap parent at the studs of the welder and have a dramatic effect on performance Remote voltage sense leads are used to improve the accuracy of the arc voltage infor mation supplied to the control pc board Sense Lead Kits K940 xx are available for this purpose The Power Wave S350 has the ability to automatically sense when remote sense leads are connected With this feature there are no requirements for setting up the machine to use remote sense leads This feature can be disabled through the Weld Manager Utility available at www powerwavesoftware com or through the set up menu if a user interface is installed into the power source CAUTION If the auto sense lead feature is disabled and remote voltage sensing is enabled but the sense leads are
181. missing or improperly connected extremely high welding outputs may occur General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical and out of the weld current path when possi ble In extremely sensitive applications it may be nec essary to route cables that contain the sense leads away from the electrode and work welding cables Voltage sense leads requirements are based on the weld process See Table A 2 TABLE A 2 Electrode Voltage Sensing 67 lead Work Voltage 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 SMAW Voltage sense at studs Voltage sense at studs The electrode voltage sense lead 67 is automatically enabled by the weld process and integral to the 5 pin arclink control cable K1543 When work voltage sense lead 21 is connected the power source will automatically switch over to using this feedback if the auto sense feature is enable FIGURE A 6 POWER WAVE S350 LINCOLN B Am INSTALLATION Electrode Voltage Sensing The remote ELECTRODE sense lead 67 is built into the 5 pin arclink control cable K1543 xx and is always connected to the wire drive feed plate when a wire feeder is present Enabling or disabling electrode volt age sensing is application specifi
182. most of the time The Buck Boost circuit operates at 25kHz The Buck Boost circuit s output is a 400 volt regulated bus The output of the Buck Boost circuit is filtered and ap plied to an IGBT controlled full wave bridge inverter that is located on the switch board The resultant 400 volt output is coupled to the primary winding of a Planar Transformer that is also located on the switch board The full wave bridge operates at G0kHz switching fre quency with a 99 on time The PFC board controls the firing of the Buck Boost circuit and the IGBT full wave bridge circuit This per mits the PFC board to monitor and control the wave shape of the applied input current to provide a optimal power factor correction for the Power Wave S350 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE S350 LINCOLN B E 4 E 4 THEORY OF OPERATION FIGURE E 4 PLANAR TRANSFORMER OUTPUT RECTIFICATION AND FILTERING SWITCH BOARD Return to Section TOC OJO OTe Of c lz 9 5 Do amp Return to Section TOC Return to Master TOC Return to Master TOC INPUT CHOKE 60KHZ INPUT IGBT 400V RELAY FULL WAVE MAIN DCLINK FIRST STAGE SWITCH INPUT RECTIFIER 100 CAPACITOR BUCK BOOST SECOND STAGE HIGH FRQUENCY INVERTER TPUT WITH PLANER TRANSFORMER RECTIFIER POSITIVE TERMINAL 100V OUTPUT CAPACITO
183. n to Master TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Power Factor Correction Control Board is functioning correctly There are very high voltages present on the PFC Control Board This test will be limited to LED and audio error codes and also resistance checks with the input power re moved from the machine MATERIALS NEEDED Voltmeter Ohmmeter Multimeter POWER WAVE S350 LINCOLN B F 31 32 TROUBLESHOOTING AND REPAIR dic POWER FACTOR CONTROL BOARD TEST PROCEDURE continued PROCEDURE 1 Disconnect the input power to the Power Wave S350 machine 2 Perform the Case Cover and DC Link Capac itor Discharge Procedure 3 Locate the PFC Control Board 4 Apply the correct input powe
184. n to Section TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR F 19 CONTROL BOARD TEST PROCEDURE continued TABLE F 3 CONTROL BOARD ASSOCIATED RESISTANCE Description Test Points Leads Expected Conditions Numbers Reading Connection to J9 pin 3 Output To Terminals Negative Output Terminal J9 pin 1 To Positive Output Terminal Connections to J5 pin 2 Normally To Closed J5 pin 3 Thermostats Lead 202 Zero Ohms No Input power To applied to machine Negative Output Terminal Lead 206 To Positive Output Terminal Lead 410 Zero Ohms No Input power To applied to machine Lead 409 Zero Ohms POWER WAVE S350 LINCOLN B TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE continued FIGURE F 4 LED LOCATIONS Return to Section TOC Return to Master TOC 10 O 4 ele 8 S s olee HE os cle e 9 eio ale 215 G4800 CONTROL BOARD p 2 LED COLOR FUNCTION 2 1 STATUS 5 DI o c a 2 RED STATUS ERROR CHECK CODE FOR SPECIFIC ERROR 3 GREEN OUTPUTENABLE 4 GREEN SINGLE PHASE DETECT 5 GREEN 67 SENSE 6 GREEN 21SENSE olo 9 7 GREEN ETHERNET STATUS c iz 5 2 8 ETHERNET STATUS 9 GREEN INPUT SUPPLY 30 VDC TO 55 VDC ele 315 1
185. nd the Chopper Control Board It also receives output current and voltage information from the Current Transducer and via leads 202 and 206 from the output terminals The Current Transducer monitors the output current and converts that information into a low voltage signal that is sent to the Control Board 500 Amps 4 0VDC The Control Board uses this current feedback information along with the output voltage feedback to monitor and control the output of the machine The control board also houses the software welding tables In addition the Control Board monitors the thermostat circuitry the shutdown circuitry and controls the two speed fans NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC o lt 2 Be E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC E 6 THEORY OF OPERATION FIGURE E 6 DC BUS BOARD AND OPTIONAL USER INTERFACE BOARD SWITCH BOARD SECOND STAGE HIGH FRQUENCY INVERTER WITH PLANER TRANSFORMER RECTIFIER Pre OUTPUT POSITIVE CAPACITORS INPUT iaer 400V THIRD STAGE RELAY MULTI PHASE BUCK MAIN INPUT DCLINK FIRST STAGE CONVERTER SWITCH RECTIFIER 1000hm CAPACIT
186. not putyour hands near theengine tan Do work cables If the electrode cable is on your right not attempt to override the governor or idler by the work le should al n your right pushing on the throttle control rods while the SIG Mewar Should also be on yourright ngine is running ano 9 Connect the work cable to the workpiece close as possible to the area being welded To prevent accidentally starting gasoline engines while 4 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate POWER WAVE S350 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 8 c tc Return to Master TOC SAFETY ELECTRIC 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 grating
187. o Section TOC Return to Master TOC lt 2 Be E Return to Master TOC Description Meter Test Points and Polarity Expected Readings Conditions Auxiliary Power Input Circuit Receptacle J27 Pin 3 Very High resistance Greater Input power removed Remove To than 50 000 ohms Plug J27 from the Receptacle J27 Pin PFC Board Typical 4 failure is a short Auxiliary Power B48 Very High Input power Dlode Circuit on To resistance Greater removed Typical Switch Board Plug J27 Pin 4 than 50 000 ohms failure is a short If shorted replace the Switch Board Auxiliary Power B12 Very High Input power Dlode Circuit on To resistance Greater Typical Switch Board Plug J27 Pin 4 than 50 000 ohms failure is a short If shorted replace the Switch Board Pre Charge Relay Drive Circuit Plug J23 Pin 3 To Plug J23 Pin 4 High resistance Greater than 30 000 ohms Input power removed Remove Plug J41 from the Switch Board Typical failure is a short Full Bridge Gate Drive Circuit Plug J23 Pin 6 To High resistance Greater than 30 000 Input power removed Remove Plug J41 from the Drive Circuit To be greater than 500 removed Remove Plug J41 from the e Plug J23 Pin 5 ohms 21 E Ede Typical failure is a 519 short Main Buck Gate Plug
188. oln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Control Board is receiving the correct supply voltages and creating the correct output voltages to various circuits Also the LED s status chart will provide information as to the Control Board s functionality Return to Section TOC Return to Master TOC MATERIALS NEEDED Voltmeter Ohmmeter Multimeter C gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO C ol ol 5 Dio amp Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR pe CONTROL BOARD TEST PROCEDURE continued TABLE F 2 CONTROL BOARD VOLTAGE TESTS Description Test Points Leads Expected Conditions Numbers Reading Input Supply to J4 pin 2 Lead 356 Input power applied to Board To To machine J4 pin 1 Lead 358 Power from J12 pin 12 Lead 342 Input power applied to control board to To To machine chopper board J12 pin 3 Lead 341 Secondary J6 pin 10 Lead 404 Input power applied to voltage from To To machine PFC board J7 pin 14 Lead 406 Fan control J7 pin 16 Lead 350 0 V
189. oltage Sensing Considerations for Multiple Arc Systems OJO 9 a Dio amp c Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC OJO 91 gt o s 5 Dio amp c A 11 VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS Special care must be taken when more than one arc is welding simultaneously on a single part Multiple arc ap plications do not necessarily dictate the use of remote work voltage sense leads but they are strongly recom mended If Sense Leads ARE NOT Used Avoid common current paths Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources and result in arc interference OF INSTALLATION A 11 If Sense Leads ARE Used Position the sense leads out of the path of the weld current Especially any current paths common to ad jacent arcs Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources and result in arc interference For longitudinal applications connect all work leads at one end of the weldment and all of the work volt age sense leads at the opposite end of the weldment Perform welding in the direction away
190. ording 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 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment POWER WAVE S350 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories setaa ak waa akaqa qasa masasun am sss si SEQ S s ms Section C MERERETUR Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams s s s sss asas w eee wis siw W Cs a s w ws W W W a w OR Uw Section G Parts Manual ois u ls ala kic eae eed C RO RC cu ee P 609 POWER WAVE S350 LINCOLN TABLE OF CONTENTS INSTALLATION SECTION o D hlc E EE b EE O E EEEE EEE A 1 15 oO 2 Technical Specifications u usu EG a ILES see hip A 2 E Safety Precautions
191. ortest length of control cable possible and DO NOT coil excess cable Regarding cable placement best results will be ob tained when control cables are routed separate from the weld cables This minimizes the possibility of interfer ence between the high currents flowing through the weld cables and the low level signals in the control ca bles These recommendations apply to all communica tion cables including ArcLink and Ethernet connections Product specific Installation Instructions Connection Between Power Source and ArcLink amp Com patible Wirefeeders K1543 ArcLink Control Cable The 5 pin ArcLink control cable connects the power source to the wire feeder The control cable consists of two power leads one twisted pair for digital communi cation and one lead for voltage sensing The 5 pin Ar cLink connection on the Power Wave S350 is located on the rear panel above the power cord The control cable is keyed and polarized to prevent improper con nection Best results will be obtained when control ca bles are routed separate from the weld cables especially in long distance applications The recom mended combined length of the ArcLink control cable network should not exceed 200ft 61 0m INSTALLATION A 13 Connection Between Power Source and Ethernet Networks The Power Wave S350 is equipped with an IP67 rated ODVA compliant RJ 45 Ethernet connector which is lo cated on the rear panel All external Ethern
192. other IGBT group The dwell time off time is 14 6 mi croseconds both IGBT groups off Since only 2 mi croseconds of the 16 6 microsecond time period are devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 7 3 microseconds each and allowing only 2 microseconds of dwell or off time one microsecond during each half cycle during the 16 6 microsecond cycle the output is maximized The darkened area under the minimum output curve can be compared to the area under the maximum output curve The more darkened area the more power is present POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ol 5 Dio EIX Return to Section TOC Return to Master TOC THEORY OF OPERATION ET FIGURE E 8 IGBT OPERATION O GATE SOURCE BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semiconduc tors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply bu
193. oudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui pro duit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants parce que la tension entre les deux pinces peut tre le total 11 Pour obtenir de plus amples renseignements sur la s ret voir de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES SOUDER enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET 2 Dans le cas de travail au dessus du niveau du sol se prot ger corps REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi 1 qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter
194. r to the Power Wave S350 machine 5 Locate LED 2 on the PFC Control Board Figure F 11 Return to Section TOC Return to Master TOC 6 LED 2 should be on and green during proper operation of the PFC Control Board 7 Locate LED 1 and the audio buzzer on the PFC Control Board See Figure F 11 8 Ifthere is a problem with the PFC Control Board LED 1 and the buzzer will provide an error code See Figure 11 error codes LED 2 will also be OFF or blinking Return to Section TOC Return to Master TOC 9 If further testing is required remove the input power to the machine and perform the resist ance checks in Table F 8 and Table 9 See Figure F 11 and Figure F 12 for test point loca tions To access some of the test points the PFC Control Board may have to be removed from its mounting studs See the Power Factor Correction Control Board Removal and Re 10 When testing is complete replace all plugs pre viously remove the PFC Board and the case covers OJO gt 9 5 Dio amp c Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o lt 2 jos tc Return to Section TOC Return to Master TOC o 5 o 2 8 ESS TROUBLESHOOTING AND REPAIR did POWER FACTO
195. re is on the Utilities Disc that was shipped with the machine It can also be accessed from the Lincoln Service Navigator or down loaded from the web at Powerwavemanager com POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC C 9 5 Dio amp Return to Section TOC Return to Master TOC F 60 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE continued PROCEDURE 1 Disconnect the input power to the Power Wave S350 machine 2 To gain access to the Current Transducer first perform the Case Cover and DC Link Capac itor Discharge Procedure 3 Locate plug J8 on the Control Board See Fig ure 23 gain access to the remove the right case side 4 Locate the Current Transducer 5 Carefully apply the correct input power to the Power Wave S350 6 Check for the correct DC supply voltage to the current transducer See Figure F 23 for Plug J8 A Pin2 lead 212 to Pin 6 lead 214 or 216 should read 15VDC B Pin 3 lead 213 to pin 6 lead 214 or 216 should read 15VDC Note Do not attempt to check the voltages at the current transducer connector The terminals are small and delicate and may be damaged if probed with meter leads If the DC supply voltages are not present the Control Board may be faulty If t
196. roubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Section TOC Return to Master TOC OJO OTe gt 9 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC F 10 USING THE STATUS LED TO TROU BLESHOOT SYSTEM PROBLEMS TROUBLESHOOTING AND REPAIR F 10 There is an audible beeper associated with this input control board s status light So the error codes on the input board can be detected through either the status light or the status beeper Not all of the Power Wave S350CE errors will be displayed on the user interface if it is installed There are two status lights that display error codes If a problem occurs it is impor tant to note the condition of the status lights Therefore prior to cycling power to the system check the power source status light for error sequences as noted below Included in this section is information about the Status Lights and some basic troubleshooting charts for both machine and weld performance The status lights for the main control board is a dual color LED s Normal operation for each is steady green Where as There is one externally mounted status lights located on th status light on the input control board is one color Normal case front of the machin
197. s lock washers and nuts mounting olo the Current Transducer Module to the output 11 Attach the negative output flex cable to the out choke bracket put choke aluminum strap 51 6 Using the 7 16 inch wrench remove the 12 Replace the four pin molex type plug into the 5 8 tive output flex cable from the output choke alu new Current Transducer Module 2 minum strap 13 Replace the left case side See the ele Cover Removal and DC Link Capacitor Dis Bls charge Procedure POWER WAVE S350 EG TROUBLESHOOTING AND REPAIR Ee CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid in the removal and replacement of the Control Board MATERIALS NEEDED 3 8 Inch Nutdriver Return to Section TOC Return to Master T
198. s Board and the output voltages are not correct or missing the DC Bus Board may be faulty POWER WAVE S350 LINCOLN B TROUBLESHOOTING AND REPAIR sd DC BUS BOARD TEST continued eio 5 5 FIGURE F 27 DC BUS BOARD LOCATIONS ele HE LEAD J47 mp 475 LEAD Sw 5 eio o o LEAD 5 5 474 518 gt LEAD 52 5 2 2 INDICATES OUTPUT TP CI 1 ojo S 5 IE FEE F 8 al JE LEAD 21 66 c k oje 5 0 o 215 elc POWER WAVE G9 S350 LINCOLN guy NOTES eae POWER WAVE 5350 LINCOLN D F 68 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Ee TROUBLESHOOTING AND REPAIR ree POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the
199. s 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 Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS 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 filt
200. sed for high speed sheet metal welding Decreasing the UltimArc Control de creases the pulse frequency and background current while increasing the peak current This results in a soft arc good for out of position welding See Figure B 4 lt 09 B Return to Master TOC J c i 5 5 FIGURE 4 0 8 5 oO UltimArc Control 10 0 UltimArc Control OFF UltimArc Control 10 0 Low Frequency Wide Medium Frequency and Width High Frequency Focused Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC TABLE OF CONTENTS ACCESSORIES SECTION 7 5 U asa a 1 Kits Options ACCESSONES osse x tte CAGE ER DEE eS C 2 Field Installed asas eee eee goa C 2 C 3 Stick OPUONS C 3 C 4 POWER WAVE S350 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC OJO OTe lz ol 5 Dio amp Return to Section TOC Return to Master TOC Return to Master TOC e ACCESSORIES KITS OPTIONS AND ACCESSORIES All Kits Options and Accessories are
201. sult in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The procedure will aid the technician in determining if the DC Bus Board is functional MATERIALS NEEDED Volt Ohmmeter Return to Section TOC Return to Master TOC C gt 9 5 Dio amp Return to Section TOC Return to Master TOC POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO gt OTe 05 gt s 5 2 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 66 TROUBLESHOOTING AND REPAIR F 66 DC BUS BOARD TEST continued FIGURE F 26 DC BUS BOARD LOCATIONS D MJ PROCEDURE 1 Disconnect the input power to the Power Wave 5350 machine To gain access to the DC Bus Board see the Case Cover Removal
202. t since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position POSITIVE VOLTAGE a ain GATE A BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER INJECTING LAYER B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to down stream components as long as the positive gate signal is present This is similar to turning ON a light switch POWER WAVE S350 LINCOLN E 10 NOTES POWER WAVE 5350 LINCOLN D E 10 DOL Je1Se N 0 uunjeH DOL Je1Se N 01 uunjeH DOL 0 DOL 0 ODOL Uonoes uunjeg DOL DOL uonoes OOL uonoes uunjeg Return to Master TOC Return to Master TOC o 5 o 8 5 tc Return to Master TOC F TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F Troubleshooting and Repair F 1 How to Use Troubleshooting Guide
203. the dominant control parameter The user justs WFS according to factors such as wire size pen etration requirements heat input etc The Power Wave S350 then uses the WFS setting to adjust the voltage and current according to settings contained in the Power Wave In non synergic modes the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments Therefore to maintain proper arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS Amps In constant current modes this control adjusts the weld ing amperage Volts In constant voltage modes this control adjusts the weld ing voltage Trim In pulse synergic welding modes the Trim setting ad justs the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting and is a good starting point for most conditions UltimArc Control UltimArc Control allows the operator to vary the arc characteristics UltimArc Control is adjustable from 10 0 to 410 0 with a nominal setting of 0 0 POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO 0 13 3 3 Do amp Return to Section TOC Return to Master TOC 87 OPERATION 87 SMAW STICK WELDING The welding current and Arc Force settings can be set through a Power Feed 10M
204. urn to Section TOC Return to Master TOC EG TROUBLESHOOTING AND REPAIR rae SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 33 SWITCH BOARD LEADS HEAT SINK THERMOSTAT CHOPPER POSITIVE OUTPUT BOARD CABLE CONNECTION CONNECTOR PLUG J45 J28 OUTPUT CHOKE CONNECTIONS LEAD A2 LEAD A3 LEAD A4 LEAD A5 LEAD A6 INPUT PHASE CONNECTIONS INPUT CHOKE CONNECTIONS LEAD LEAD LEAD 1A PLUG J42 PLUG 41 12 Carefully place the new Switch Board Assembly 17 Reconnect all of the leads previously removed into position in the chassis See Figure F 33 13 Secure the Switch Board Assembly to the chas 18 Replace the five molex plugs previously re sis with the four screws and washers previously moved See Figure F 33 removed 19 Clear and position all leads 15 Dane 20 Replace the case cover See the Case Cover 15 Connect leads 410 and 409 to the heat sink Removal and DC Link Capacitor Discharge thermostat 16 Reconnect the positive output cable 21 Perform the Retest After Repair Procedure POWER WAVE S350 LINCOL
205. ver POWER WAVE S350 LINCOLN B F 71 CURRENT TRANSDUCER LINCOLN B TROUBLESHOOTING REPAIR ale CURRENT TRANSDUCER LEM e fe REMOVAL AND REPLACEMENT PROCEDURE continued 5 5 FIGURE F 29 CURRENT TRANSDUCER LOCATION OUTPUT CHOKE ON OFF SWITCH INPUT CHOKE olo PROCEDURE 1 Disconnect the input power to the Power Wave 7 Take note of the arrow direction on Current 515 S350 machine Transducer Module The new Module must be 5 installed with the arrow pointing in the same di 53 E 2 To gain access to the Current Transducer see rection the Cover Removal and DC Link c pacitor Discharge Procedure 8 Carefully remove the Current Transducer Mod 3123 ule from the aluminum strap This may require D E 3 Locate the Current Transducer Module on the some gentle twisting E left side of the machine See Figure F 29 9 Carefully place the new Current Transducer 4 Locate and carefully unplug the four pin molex Module into the proper position taking note of type plug from the Current Transducer It is lo the arrow direction discussed in Step 7 cated on the underneath side of the module 10 Mount the new Current Transducer Module to 5 Using the flat head screwdriver and the 11 32 the output choke bracket using the machine inch wrench remove the two machine screws screws washers and nuts previously remove flat washer
206. w the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information POWER WAVE S350 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 8 E tc Return to Master TOC Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains
207. welding or other activities are to be carried out POWER WAVE S350 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 E tc Return to Master TOC 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 ac tivities 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 be tween 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 modifie
208. will determine if the User Interface Board is functional MATERIALS NEEDED Voltmeter Ohmmeter Multimeter POWER WAVE S350 LINCOLN B F 43 TROUBLESHOOTING REPAIR OPTIONAL USER INTERFACE BOARD TEST PROCEDURE continued PROCEDURE 1 Disconnect the input power to the Power Wave 5350 machine 2 To gain access to the User Interface Board test points remove the four screws from the front display panel Carefully remove the optional user interface board leaving the four pin con nector in place Return to Section TOC Return to Master TOC 3 Carefully apply the correct input power to the Power Wave S350 machine 4 Ifthe displays light on the front of the machine the User Interface is receiving the correct input voltage 40VDC 5 Table 2 10 and Figure F 15 for the de scription of the LED functions on the User Inter face Board 6 If the displays do not light carefully check to make sure the User Interface Board is receiving the correct input supply voltage F 16 and the wiring diagram If the supply volt age 40VDO is present and the user interface board does not light up the board may be faulty If the correct supply voltage is not present pro ceed to the next step Return to Section TOC Return to Master TOC 7 Remove the input power to the Power Wave S350 machine and discharge the DC Link Ca pacitor Check the continuity of the supply leads 51D and 52D between Plug
209. your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in checking and if necessary adjusting the calibration of the POWER WAVE S350 Calibration should be checked as part of the Test After Repair MATERIALS NEEDED Diagnostic Utilities Software www powerwavemanager com or Service Navigator Laptop or other Suitable Computer Ethernet Cross Connect Cable LECO M19969 7 Resistive Load Bank Two 2 Welding Cables 20ft 4 0 Calibrated Ammeter and Voltmeter Calibration inaccuracies due to external metering can and will effect weld perform ance Use good quality digital meters that are calibrated and traceable to Na tional Standards POWER WAVE S350 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC OJO w S 05 9 5 Dio Return to Section Return to Master TOC Return to Master TOC F 40 TROUBLESHOOTING AND REPAIR F 40 CURRENT AND VOLTAGE CALIBRATION PROCEDURE continued CALIBRATION SET UP Load the Diagnostic Utility Software into the

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