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Lincoln Electric S350 User's Manual

1. ue GAS HOSE 77 CABLE K1543 XX NEGATIVE STUD zm H pul WORK CLAMP TO POSITIVE STUD PIECE Ne PF10 M WIRE FEEDER POWER WAVE S350 LINCOLN 8 m INSTALLATION 280 RECOMMENDED WORK CABLE SIZES FOR ARC WELDING Connect the electrode and work cables between the appropriate 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 electrode 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 out put connections at the power source electrode cable to the negative stud and work cable to the posi tive stud CAUTION Negative electrode polarity operation WITHOUT use of a remote work sense lead 21 requires the Negative 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 this Instruction Manual General Guidelines Select the appropriate size cables per the
2. 13008 40 3LIHM HUM SNOT SN31 93130 3903 LVH 1S3HV3N Nid WN N33H9 9 l1310IA A NMO S N Movia 8 SNIGOO O d 40 301 IN3NOdWOO 6913 H3d STOSWAS 1V2IH103 13 5 NIHJAWNN ALIAVO NOLLVIWHOHNI TVH3N39 S1300N NO 1N3S3Hd HO LIOVAVO pom ecl OSES 3AVM H3MOd rud eum Lk Sa yl jor OVA SHE 18 de amp TE Eer p saNo l ge VE vee mod ENG I3NH3H13 ac MHOLO3NNOO wan Time 1405 OL f T t1 n 8L POWER WAVE S350 LINCOLN E DIMENSION PRINT 27 43 22 25 i 18 81 18 36 POWER WAVE POWER WAVE S350 LINCOLN E Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO EE BIR Chinese Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s e
3. EEN D 1 Calibration ric oi teet eddie dead eege Eet D 1 Troubleshooting corem cereum n eoim euren cm eiue derniers Section E Safety Precautions ins E 1 How to Use Troubleshooting Guide E 1 Using Status LED Error Fault Codes and Input Control E 2 E 4 Troubleshooting Guide E 5 thru E 8 Wiring Diagram and Dimension Print ss Section F Parts PAQBS TN P 654 Series B INSTALLATION B TECHNICAL SPECIFICATIONS POWER WAVE 350 POWER SOURCE INPUT VOLTAGE AND CURRENT Duty Cycle Input Voltage 10 Input Amperes Idle Power Power Factor 1 Phase in parenthesis Rated Output 40 rating 39 35 19 17 14 60 67 208 230 400 460 575 K2823 3 50 60 Hz 100 rating includes 380V to 413V 300 Watts Max 31 28 15 14 11 fanon 60 53 NA NA NA RATED OUTPUT INPUT 6 SMAW VOLTAGE PHASE 200 208 1 50 60 300 Amps 29 Volts 250 Amps 30 Volts 460 3 50 60 575 3 50 60 On 230 Volt 1 phase inputs the max rating is at a duty cycle of 3096 except for GTAW processes RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT MAXIMUM CORD SIZE 3 TIME DELAY FUSE VOLTAGE PHASE INPUT AMPERE RAT AWG SIZES OR BREAKER 2 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 3 50 60 19A 40 460 3 50 60 17A 40
4. 575 3 50 60 14A 40 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 trip ping 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 8 ne INSTALLATION mee WELDING PROCESS PROCESS OUTPUT RANGE AMPERES OCV Uo GMAW GMAW Pulse 40 350A 40 70V FCAW GTAW DC 5 350A 24V SMAW 55 325A 60V PHYSICAL DIMENSIONS MODEL WEIGHT K2823 3 20 40 in 518 mm 14 00in 356 mm 24 80 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 Thermal tests have been performed at ambient tem perature The duty cycle duty factor at 40 C has been determined by simulation POWER WAVE S350 LINCOLN Fen INSTALLATION ma SAFETY PRECAUTIONS Read this entire installation section before you start installa tion WARNING ELECTRIC SHOCK can kill 0 Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before
5. Side the work cable should also be on your right side ev 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while 2 d 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 LINCOLN 8 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 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electro
6. C POWER WAVE S350 LINCOLN 8 INSTALLATION Ap CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade There are several factors that contribute to the overall inductance of the cabling system including cable size and loop area The loop area is defined by the separation distance between the electrode 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 always use the appropriate size cables and whenever possible run the electrode and work cables in close proximity to one another to minimize the loop area Since the most significant fac tor in cable inductance is the welding loop length avoid excessive lengths and do not coil excess cable For long work piece lengths a sliding ground should be considered 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 condi tions Depending upon the process inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder and have a dra matic effect on performance Remote voltage sense leads are used to improve the accuracy of the arc volt age informatio
7. ET DE EE A SE Mr de RIM 0 388 AQXAME Sigi RIRES BHE oe ENEE Aal alal d illai d AAL oig SOA Ai caulas Ca L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
8. MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria Feu 9 fsPBHEICTAESUCFEU e RED BEBE SH7IAE S XACOER E MASH 918 7127471 587E Assis oe lue chal TU Gal bacs ga
9. Output Cable Guidelines below Excessive volt age drops caused by undersized welding cables and poor connections often result in unsatisfactory weld ing performance 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 undersized 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 the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop OUTPUT CABLE GUIDELINES Table A 1 Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK Amperes Cycle CABLES RUBBER COVERED COPPER RATED 167 F 75 0 to 50 Ft 50 to 100 Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft Tabled values are 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
10. The Power Wave S350 has the ability to automatically sense the polarity of the sense leads With this fea ture there are no set up requirements for welding with negative electrode polarity This feature can be dis abled 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 extremely high welding outputs may occur While most applications perform adequately by sens ing the work voltage directly at the output stud the use of a remote work voltage sense lead is recom mended 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 Voltage Sensing Considerations for Multiple Arc Systems POWER WAVE S350 LINCOLN A 10 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 applications do not necessarily dictate the use of remote work voltage sense leads but they are strong ly re
11. 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 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 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 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 adjusted 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 oper ator must adjust 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 decreasing the Pinch Control t
12. you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page INStallatlOM MEE Section A Technical Specifications ss 1 2 Safety Precautions AE A 3 Location Liting me EET 3 SLACKING PERS EE LEER 3 nmt A 3 Input and Ground Connections A 3 Machine Grounding RR A 3 High Fr
13. 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 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 UltimArc Control increases the pulse frequency and background current while decreasing the peak cur rent This results in a tight stiff arc used for high speed sheet metal welding Decreasing the UltimArc Control decreases the pulse frequency and background current while increasing the peak cur rent This results in a soft arc good for out of position welding See Figure B 4 FIGURE B 4 LIT UltimArc Control 10 0 UltimArc Control OFF Low Frequency Wide Medium Frequency and Width UltimArc Control 10 0 High Frequency Focused POWER WAVE S350 LINCOLN ACCESSORIES KITS OPTIONS AND ACCESSORIES All Kits Options and Accessories are 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 350 Allows stick and Tig operation without having a wire feeder Order K3001 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 K
14. 2823 1 power source Order K2829 1 DeviceNet Kit Mounts inside the back of the Power Wave S350 Allows 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 XX Series Order K1811 XX Series 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 Cam Lock 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 2 Cam Lock cable plug for 2 0 b0mm cable Order K2946 1 Coaxial Welding Cable Optimum weld cables for minimizing cable inductance and optimizing welding performance AWG 1 0 Coaxial Cables Order K1796 25 for 25 feet 7 6 m cable length Order K1796 50 for 50 feet 15 2 m cable length Order K1796 75 for 75 feet 22 9 m cable length Order K1796 100 for 100 feet 30 5 m cable length AWG 1 Coaxial Cables Order K2593 25 for 25 feet 7 6 m cable length Order K2593 50 for 50 feet 15 2 m cable length Order K2593 100 for 100 feet 30 5 m cable length K2909 1 12 pin to 6 pin adapter K2910 1 12 pin to 7 pin adapter Welding Fume Extractors Lincoln offers a wide range of fume extraction environ mental system s
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16. GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shieldin
17. Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone e WELDING SPARKS can cause fire or explosion Keep flammable material away 3 A m EI ARC RAYS can burn Wear eye ear and body protec 2 tion SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL POWER UP SEQUENCE When the POWER WAVE S350 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 inter face will not be active DUTY CYCLE i O O The duty cycle is based on a ten minute period A 40 duty cycle represents 4 minutes of welding and 6 minutes of idling in a ten minute period Refer to the technical specification section for the Power Wave S350 s duty cycle ratings POWER WAVE 350 LINCOLN B 1 WARNING OR CAUTION DANGEROUS VOLTAGE POSITIVE OUTPUT NEGATIVE OUTPUT HIGH TEMPERATURE STATUS PROTECTIVE GROUND COOLER OUTPUT OPERATORS MANUAL WORK CIRCUIT BREAKER adn OPERATION 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 welding It is ideal for a wide variety of materials including aluminum stainless and nickel where arc performance is critical The Power Wave S350 is designed to be a
18. MON WELDING PROCEDURES A WARNING MAKING A WELD The serviceability of a product or structure utiliz ing the welding programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selec tion Choose the electrode material electrode size shield ing gas and process GMAW GMAW P etc appro priate for the 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 Ifa special 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 system may not have all of the following adjustments See Accessories Section for Kits and Options avali able 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 se
19. POWER WAVE 5350 um For use with machines having Code Numbers 11694 11782 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 ISO 9001 CN Se mm A B V wm Nx Desigi a Qi nc ABS Quality Eval to ISO 9001 Re s CERTIFICATE NUMBER 30273 LINCOLN 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 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer 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 INJU
20. RY 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 purchase a copy of Safety in Welding A Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 5 d 5 1 h To avoid scalding do not remove the ex 22 radiator pressure when the engine is powered equipment ANM in 1 Turn the engine off before troubleshooting and maintenance x 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 3 outdoors 9 ELECTRIC AND N MAGNETIC FIELDS 1 c Do not add the fuel near an open flame s may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact with hot engine parts and current creates EMF fiel
21. T department for assistance 1a Verify the cables are fully insert ed into the bulk head connector 1b The LED under the PC board ethernet connector will be lit when the machine is connected to another network device 2 IP address information 2 Use the appropriate PC utility to verify the correct IP address infor mation has been entered 2a Verify no duplicate the IP addresses exist on the network Verify that the network device connected to the Power Wave is either a 10 baseT device or a 10 100 baseT device Connection Drops while welding 1 Cable Location Verify Network cable is not locat ed next to current carrying con ductors This would include input power cables and welding output cables CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN DIAGRAMS En F 1 5 95599 HOLO3NNOO ANN OHV STOHLdNV aN weng snivis man zzs99 804 1OHLNO9 310W3H kze ae ae bs GER 3909 91419373 TVNOLLVN Had OL anon eet qwasve Lov
22. acturer 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 i SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de 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 Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou 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 defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte l
23. cedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility WARNING Sc 0 ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before installation or changing drive rolls and or guides Do not touch electrically live parts e When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform maintenance work Observe all additional Safety Guidelines detailed throughout this manual A CAUTION If for any reason you do not understand th
24. chines may not yield satisfactory weld performance To ensure optimal performance the cal ibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the fac tory Generally the machine calibration will not need adjustment However if the weld performance changes or the yearly calibration check reveals a problem use the calibration section of the Diagnostics Utility to make the appropriate adjust ments The calibration procedure itself requires the use of a grid and certified actual meters for voltage and cur rent The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use The Diagnostics Utility includes detailed instructions and is available on the Service Navigator CD or at www powerwavesoftware com POWER WAVE S350 LINCOLN D 1 E TROUBLESHOOTING ES HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel 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 pro
25. commended If Sense Leads ARE NOT Used Avoid common current paths Current from adja cent arcs can induce voltage into each others cur rent paths that can be misinterpreted by the power sources and result in arc interference If Sense Leads ARE Used INSTALLATION A 10 Position the sense leads out of the path of the weld current Especially any current paths common to adjacent 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 weld ment Perform welding in the direction away from the work leads and toward the sense leads See Figure A 7 FIGURE A 7 LINCOLN o ELECTRIC DIRECTION OF e ae 27 CONNECT ALL SENSE LEADS AT THE END OF THE WELD 2 j LINCOLNL 3 ELECTRIC CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD POWER WAVE S350 LINCOLN 8 INSTALLATION an 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
26. 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 voltage 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 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN ES TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual INPUT CONTROL BOARD eg 331 Peak input current limit Input current limit has been exceeded Typically indicates short term power overload If problem persists contact Service Department 333 Under voltage lockout 15 VDC supply on Input control board too low Verify input voltage is within the acceptable range If problem persists contact service department 336 Thermal Fault Thermostat on primary modu
27. d iti Mall oe e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e X7TTLA UACRUD PRE ETBRALY FE DF gt TKR e HE BIS ER Aie Ajo pha NM 90 juil ail e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e ID RAL EEE CH B EHTEUZSVCREU 9 SER HGTBI BUSUR RE ERE Ro e 800 Yel Me z calls UN Jada y e Aale veel Al dl Ayal Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO ZS BR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR f amp osdoemBox 2 o0dBcmEtEC MA ETISRUCESU CL TRHORERME HS an
28. d GTAW P on various materials especially steel aluminum and stainless PROCESS LIMITATIONS The software based weld tables of the Power Wave 350 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 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 perfor mance and features will be limited POWER WAVE S350 LINCOLN B 3 DESIGN FEATURES Loaded with Standard Features Multiple process DC output range 5 350 Amps 200 600 VAC 1 3 phase 50 60Hz input power New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations 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 F A N fan as needed when needed Cooling fan only runs Thermostatically protected for safety and reliability Ethernet connectivity Panel mounted Status and Thermal LED indicators facilitate quick and easy troubleshooting Pott
29. d integral to the 5 pin arclink control cable K1543 XX 2 When a 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 3 Negative polarity semi automatic process operation WITHOUT use of a remote work sense lead 21 requires the Negative Electrode Polarity attribute to be set FIGURE A 6 POWER WAVE S350 LINCOLN SE INSTALLATION Electrode Voltage Sensing The remote ELECTRODE sense lead 67 is built into the 5 pin arclink control cable and is always connect ed to the wire drive feed plate when a wire feeder is present Enabling or disabling electrode voltage sens ing is application specific and automatically config ured by the active weld mode Work Voltage Sensing While most applications perform adequately by sens ing the work voltage directly at the output stud the use of a remote work voltage sense lead is recom mended 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 in this section entitled Voltage Sensing Considerations for Multiple Arc Systems Negative Electrode Polarity
30. de 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 2 ARC RAYS burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND
31. ds around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated 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 before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Ix Exposure to EMF fields in welding may have other health parts when 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 Wii iu minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running
32. e ON posi tion Input voltage is too low or too 2 Make certain that input voltage is correct according to the Rating Plate located on the rear of the machine Machine won t weld can t get 1 Input voltage is too low or too high 1 Make certain that input voltage is correct according to the Rating Plate located on the rear of the machine See Thermal LED is ON sec tion Possible short in output circuit If condition persists contact an 3a Input control board fault see authorized Lincoln Electric Field input control board error status Service facility CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN Em TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Basic Machine Problems Continued 1 Improper fan operation 1 Check for proper fan operation Fan should run in a low speed setting when the machine is idle and in a high speed when the output is triggered Check for material blocking intake or exhaust louvers or for excessive dirt clogging cooling channels in machine 2 Open thermostat circuit 2 Check for broken wires open connections or faulty thermostats i
33. e test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN ES TROUBLESHOOTING E 2 USING THE STATUS LED TO There is an audible beeper associated with this input control TROUBLESHOOT SYSTEM PROBLEMS board s status light So the error codes on the input board can be detected through either the status light or the status e beeper Not all of the Power Wave S350 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 important 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 the status light on the input control board is one color Normal operation is for the status light to be off and the buzzer to be off There is one externally mounted status lights located on the case front of the machine This status light corresponds to the main control board s status A second status light is Internal and is located on t
34. ectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier 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 chauffement 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 lev age 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 soudage Ceci est particuli re
35. ed PC boards for enhanced ruggedness relia bility Enclosure reinforced with heavy duty aluminum extrusions for mechanical toughness Waveform Control Technology for good weld appearance and low spatter even when welding nickel alloys Sync Tandem installed Cam Lock type connectors OPERATION CASE FRONT CONTROLS See Figure B 1 1 2 USER INTERFACE optional STATUS LED See Troubleshooting Section for operational functions THERMAL LED Indicates when machine has thermal fault POWER SWITCH Controls power to the Power Wave S350 NEGATIVE WELD OUTPUT POSITIVE WELD OUTPUT WORK SENSE LEAD CONNECTOR 12 PIN CONNECTOR Optional FIGURE B 1 OG POWER WAVE S350 LINCOLN pis OPERATION E CASE BACK CONTROLS See Figure B 2 for Code 11694 1 115 VAC KIT OPTIONAL 2 ARCLINK CONNECTOR 3 CIRCUIT BREAKER 4 SYNC TANDEM STT CONNECTOR 5 DEVICENET KIT OPTIONAL 6 ETHERNET 7 RESERVED FOR FUTURE DEVELOPMENT 8 GAS SOLENOID KIT OPTIONAL FIGURE B 2 CASE BACK CONTROLS See Figure B 2a for Code 11782 1 115 VAC KIT OPTIONAL 2 ARCLINK CONNECTOR 3 CIRCUIT BREAKER 4 SYNC TANDEM STT CONNECTOR 5 DEVICENET KIT OPTIONAL 6 ETHERNET 7 GAS SOLENOID KIT OPTIONAL FIGURE B 2a POWER WAVE S350 LINCOLN ES OPERATION BS COM
36. ength not exceed 100ft 30 5m The use of non standard cables especially in lengths greater than 25 feet can lead to communication prob lems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems Always use the shortest length of control cable possible and DO NOT coil excess cable Regarding cable placement best results will be obtained when control cables are routed separate from the weld cables This minimizes the possibility of interference between the high currents flowing through the weld cables and the low level signals in the control cables These recommendations apply to all communication cables including ArcLink amp and Ethernet connections Product specific Installation Instructions Connection Between Power Source and ArcLink amp Compatible Wirefeeders K1543 K2683 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 com munication and one lead for voltage sensing The 5 pin ArcLink 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 connection Best results will be obtained when control cables are routed separate from the weld cables especially in long distance applications The recommended combined length of the ArcLink control cable
37. equency Gs ee A 3 INPUT CONNECTION RP A 4 Input Fuse and Supply Wire A 4 Input Voltage SelectiOlni RE A 4 Power ancien A 4 Connection Diagrami sise A 5 A 6 Recommended Work Cable Sizes A 7 Cable Inductance and its Effects on Welding sse A 8 Remote Sense Lead Specifications A 8 A 9 Voltage Sensing Considerations for Multiple Arc Systems A 10 A 11 Control Cable Connections eene A 12 N EnA Nea A nT hOn A naa ESS SENSAS Section Safety Precautions siennes 1 Power Up Sequence EE 1 DEG C m B 1 Eer lee B 1 le Le EE B 2 Recommended Processes and Equipment B 2 Equipment EN B 2 Common Equipment Packages sn B 2 Design RE B 3 Case Front Controls d nieto RU B 3 2 epee eae 4 Common Welding B 5 thru B 7 fere rrnrc Section C Kits Options Accessories iecit cde hate ra ar I Enn da C 1 Field Installed Options C 1 SLICK Os ie C 2 ET EE Section D ele cp D 1 m nnn D 1 Periodic Maintenance xa epe xx
38. f 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 Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame 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 follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 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 manuf
39. g gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 4 LINCOLN 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 SAFETY 7 WELDING and CUTTING gt SPARKS 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 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
40. he input control board and can be Error conditions are indicated in the following chart Table seen by looking through the left case side louvers E1 TABLE E 1 Light earning Condition Main control board status light Input control board Steady Green System OK Power source is operational and is communicating normally with all Not applicable healthy peripheral equipment connected to its ArcLink network Blinking Green Occurs during power up or a system reset and indicates the POWER Not applicable 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 Fast Blinking Green Indicates Auto mapping has failed Not applicable Alternating Green and Red Non recoverable system fault If the Status lights are flashing any com Not applicable bination of red and green errors are present Read the error code s before the machine is turned off 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 green light Only active error conditions will be accessible through the Status Light Error codes can also be retrieved with the Diagnostics Utility includ ed on the Service Navigator CD or available at www power wavesoftware com This i
41. he wire feeder that is being used Refer to the wire feeder s manual for alternative config urations INSTALLATION SMAW STICK WELDING Similar to TIG welding a user interface is required for adjusting the Stick welding settings A Power Feed wire feeder can be used as the user interface or a K3001 1 user interface control panel can be installed into the power source Figure A 4 The connection diagram shown is based on the S Series user inter face K3001 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 A 5 for the connection details FIGURE A 3 TIG WITH S SERIES USER INTERFACE REGULATOR gt FLOWMETER JL GAS SOLENOID KIT INSIDE MACHINE K2825 1 GAS HOSE USER INTERFACE CONTROL PANEL K3001 1 TO REMOTE CONTROL RECEPTACLE FOOT AMPTROL 4 K870 K870 2 AND K2909 1 TO POSITIVE STUD TO NEGATIVE STUD WORK CLAMP WORK PIECE P TIG TORCH K1782 1 3 12 FIGURE A 4 TO NEGATIVE STUD WORK CLAMP WORK REMOTE CONTROL BOX 5 57 2 K3001 1 _ TO POSITIVE STUD SE ELECTRODE HOLDER KIT K875 OR K704 INCLUDES GROUND CLAMP POWER WAVE S350 LINCOLN 6 INSTALLATION 4 FIGURE A 5 REGULATOR _ 1e FLOWMETER y MIG PROCESS
42. hen using a crane or overhead device a lifting strap should be connected to both handles Do not attempt to lift the POWER WAVE S350 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 350 cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUND CONNECTIONS Only a qualified electrician should connect the POWER WAVE S350 Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information 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 ground ing methods HIGH FREQUENCY PROTECTION Locate the POWER WAVE S350 away from radio controlled machinery The normal operation of the POWER WAVE 350 may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE S350 LINCOLN Ber INSTALLATION n INPUT CONNECTION A WARNING e Only a qual
43. ified 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 A 15 ft 4 6m 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 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 electrical codes Using input wire sizes fuses or cir cuit breakers smaller than recommended may result in nuisance 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 0 The POWER WAVE S350 ON OFF switch is not intended as a service disconnect for this equ
44. ipment 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 con nection 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 dia grams Failure to do so may result in bodily injury or death 9 If the input power cord is damaged or needs to be replaced 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 8 A 5 CONNECTION DIAGRAMS GTAW TIG WELDING A user interface is required for adjusting the TIG weld ing settings S series user interface K3001 1 can be installed into the power source Figure A 3 Refer to the connection diagrams based on the user interface that is being used Alternate configurations are possi ble depending on t
45. 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 debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you hank OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical c
46. le tripped Typically caused by bottom fan not working 337 Pre charge timeout Problem with start up sequence If problem persists contact Service Department 346 Transformer primary over current Transformer current too high Typically indicates short term power overload If problem persists contact service department CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 350 LINCOLN E TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Basic Machine Problems Input fuses keep blowing 1 Improperly sized input fuses 1 Make sure fuses are properly sized See installation section of this manual for recommended sizes 2 Improper Weld Procedure requir 2 Reduce output current duty ing output levels in excess of cycle or both machine rating Major physical or electrical dam 3 Contact your local authorized age is evident when the covers Lincoln Electric Field Service are removed facility for technical assistance Machine will not power up no lights 1 No Input Power Make sure input supply discon nect has been turned ON Check input fuses Make certain that the Power Switch SW1 on the power source is in th
47. lse synergic welding modes the Trim setting adjusts the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting and is a good start ing point for most conditions UltimArc Control UltimArc Control allows the operator to vary the arc characteristics UltimArc Control is adjustable from 10 0 to 10 0 with a nominal setting of 0 0 POWER WAVE S350 LINCOLN aii OPERATION B 6 SMAW STICK WELDING The welding current and Arc Force settings can be set through a Power Feed 10M or Power Feed 25M wire feeder Alternatively an optional Stick TIG UI can be installed into the power source to control these set tings locally In a SMAW STICK mode Arc Force can be adjust ed It can be set to the lower range for a soft and less penetrating arc characteristic negative numeric val ues 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 electrodes E7018 E8018 E9018 etc a softer arc is usually desirable and the lower end of the Arc Control suits these types of elec trodes In either case the arc control is available to increase or decrease the energy level delivered to
48. m the down to protect itself machine 2 System Fault 2 A non recoverable fault will inter rupt welding This condition will also result in a status light blink ing See the Status Light section for more information Machine won t produce full output 1 Input voltage may be too low lim 1 Make certain that the input voltage iting output capability of the power is proper according to the Rating source Plate located on the rear of the machine 2 460 or 575 the input may Del Verify all 3 phases are present single phase 3 Machine calibration 3 Calibrate secondary current and voltage Excessively long and erratic arc 1 Wire feed problem 1 Check for feeding problems Make sure proper gear ratio has been selected 2 Loss of or improper Shielding 2 Verify gas flow and type are cor Gas rect 3 Machine calibration 3 Calibrate secondary current and voltage CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN EM TROUBLESHOOTING EB Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Ethernet 1 Physical connection 1 Verify that the correct patch cable or cross over cable is being used refer to local I
49. ment important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit 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 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 gs PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 pan talons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis du poste conformement au code de
50. n supplied to the control pc board Sense Lead Kits K940 xx are available for this pur pose 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 missing improperly connected extreme ly 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 possible In extremely sensitive applications it may be necessary 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 1 Work Voltage Sensing 2 67 lead 21 lead GMAW 67 lead required 21 lead optional 3 P 67 lead required 21 lead optional 3 67 lead required 21 lead optional 3 Voltage sense at studs Voltage sense at studs Voltage sense at studs Voltage sense at studs 1 The electrode voltage sense lead 67 is automatically enabled by the weld process an
51. n the thermostat circuit Real Time Clock no longer func 1 Control PC Board Battery 1 Replace the battery Type oin BS2032 Weld and Arc Quality Problems General degradation of weld perfor 1 Wire feed problem 1 Check for feeding problems mance 2 Check for bad connections excessive loops in cable etc NOTE The presence of heat in the external welding circuit indicates poor connections or undersized cables 3 Loss of or improper ShieldinglS Verify gas flow and type are cor Gas rect 4 Verify weld mode is correct for 4 Select the correct weld mode for process the application 5 Machine calibration 5 The power source may require calibration current voltage WFS CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN EN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Weld and Arc Quality Problems Continued Wire burns back to tip at the end of 1 Burnback Time 1 Reduce burnback time and or the weld work point Machine output shuts down during al Secondary current limit has 1 Adjust procedure or reduce load exceeded and the machine shuts to lower current draw fro
52. network should not exceed 200ft 61 0m INSTALLATION A 12 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 located on the rear panel All external Ethernet equip ment cables switches etc as defined by the con nection 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 recommendations can result in an Ethernet connection failure during welding POWER WAVE S350 LINCOLN 8 E OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL A 1 4 20 OG SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE A WARNING ELECTRIC SHOCK 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 removed or open FUMES AND GASSES can be dangerous
53. ng equipment See www lincolnelectric com A full line of air cooled and water cooled torches available 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 Order K963 4 for Hand Amptrol with 12 pin connector Foot Amptrol amp Provides 25 ft 7 6 m of remote current control for TIG welding Order K870 2 for Foot Amptrol with 12 pin connector Cam Lock Torch Adapter For connecting K1782 1 K1782 3 K1782 12 torches to the S350 Order K960 3 POWER WAVE S350 LINCOLN MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill not operate with covers removed Turn off power source before installing 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 ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a low pressure air stream to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine PERIODIC MAINTENANCE Calibration of the Power Wave S350 is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated ma
54. ntrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR ELE het EE LATE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB GH e eA BOAIUBRT HER Xe uc a e sis HIE Weal AMI W o uil el jad Quali Y O grandi ai ay Ast gl o lala All usu DA dan ule Y Jio tne Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA IEEE IIS eis A d s Jo ALD al gll pis e Ac AI Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para vista ouvido e corpo HAUSHERMRELTTF HEBS SOSRSHR ez 119 59 s ESSAI due ule Al y lan Al n e 4 dang READ AND UNDERSTAND THE
55. o less than 0 0 provides a softer arc less spatter PULSE WELDING Pulse welding procedures are set by controlling an overall 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 predicted when all the pulsing waveform parameters are known Using a preset voltage becomes impracti cal 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 11 1 00 Arc Length Medium Trim 50 Arc Length Short Trim 1 50 Arc Length Long POWER WAVE S350 LINCOLN OPERATION Most pulse welding programs are synergic As the wire feed speed is adjusted the Power Wave S350 will automatically recalculate the waveform parame ters 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
56. olutions ranging from portable sys tems easily wheeled around a shop to shop wide cen tral systems servicing many dedicated welding sta tions Request Lincoln publication E13 40 See www lincolnelectric com POWER WAVE S350 LINCOLN C 2 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 ACCESSORIES 2 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 carrying case Includes PTA 17V torch parts kit Harris amp flowmeter regulator 10 ft 3 0 m gas hose and work clamp and cable Order K2265 1 pack of mild steel electrode For use with K2946 1 MIG OPTIONS 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 K2946 1 ORDER K704 REMOTE OUTPUT CONTROL Permits remote adjustment of output Order K857 2 for 25 ft 7 6m with 12 pin connector TIG OPTIONS Pro Torch TIG Torches Work and Feeder Welding Cables 350 amps 60 duty cycle with Cam Lock connectors and Ground Clamp Order K1803 2 COMPATIBLE LINCOLN EQUIPMENT Any Arclink compatible wire feedi
57. onsideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information
58. path See Figure 8 A FIGURE A 8 BAD CURRENT FLOW FROM ARC 1 AFFECTS SENSE LEAD 2 Work 1 ep VS S sous 7 a CURRENT FLOW FROM ARC 2 AFFECTS SENSE LEAD 1 NEITHER SENSE LEAD PICKS UP THE CORRECT WORK VOLTAGE CAUSING STARTING AND WELDING ARC INSTABILITY SENSE LEAD 1 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 1 SENSE LEAD 2 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 2 DUE TO VOLTAGE DROPS ACROSS THE WORKPIECE ARC VOLTAGE MAY BE LOW CAUSING NEED FOR DEVIATION FROM STANDARD PROCEDURES Sense 1 Sense 2 re gt 9 9 BOTH SENSE LEADS ARE OUT OF THE CURRENT PATHS BOTH SENSE LEADS DETECT ARC VOLTAGE ACCURATELY O NO VOLTAGE DROP BETWEEN ARC AND SENSE LEAD BEST STARTS BEST ARCS MOST RELIABLE RESULTS POWER WAVE S350 LINCOLN 8 A 12 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 sys tems Most are designed to be connected end to end for ease of extension Generally it is recommended that the total l
59. 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 the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode i
60. s 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 Steady Red Not applicable Not applicable Blinking Red Not applicable Error Code interpretation Individual 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE S350 LINCOLN ES TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE S350 The following is a partial list of possible error codes for the POWER WAVE S350 For a complete listing consult the Service Manual for this machine MAIN CONTROL BOARD STATUS LIGHT ee 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 exceeded NOTE The long term average secondary current limit is 325 amps 56 Chopper communication error Indicates communication link between main
61. t by the operator SYNERGIC WELDING MODES A Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the Wire Feed Speed WFS set by the operator Basic Welding Controls 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 materi al electrode size and shielding gas For a more com plete description of the weld modes programmed into the Power Wave S350 at the factory refer to the Weld Set Reference 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 the dominant control parameter The user adjusts WFS according to factors such as wire size penetration 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 welding amperage Volts In constant voltage modes this control adjusts the welding voltage Trim In pu
62. very flex ible welding system Like existing Power Wave s 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 amp S350 which allows for effortless software upgrades through Powerwavesoftware com The Ethernet communica tion also gives the Power Wave 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 S350 is being designed to be compati ble with future advanced welding modules like STT RECOMMENDED PROCESSES AND EQUIPMENT The Power Wave amp S350 is recommended for semiautomat ic welding and may also be suitable for basic hard automa tion applications The Power Wave S350 can be set up in a number of configurations some requiring optional equip ment or welding programs RECOMMENDED EQUIPMENT The Power Wave S350 is designed to be compatible with the current range of Power Feed systems including future versions of ArcLink feeders RECOMMENDED PROCESSES The Power Wave S350 is a high speed multi process power source capable of regulating the current volt age 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 an
63. working on this equipment Turn off the input power to any other equipment connected to the welding system atthe disconnect switch or fuse box before work ing on the equipment Do not touch electrically hot parts Always connect the POWER WAVEG S350 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 The machine must be located where there is free circulation of clean air such that air movement in the back out the sides and bottom will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum 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 Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles Do not mount the POWER WAVE S350 over com bustible surfaces Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 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 350 W

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