Lincoln POWER WAVE S350 Operator's Manual

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Page 2

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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.

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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

se corrective lenses if necessary

U to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

Safety 01 of 04 - 06/15/2016

Page 3

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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 purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet 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.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring

heir removal is complete. Always use the greatest care when

t working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Safety 02 of 04 - 06/15/2016

Page 4

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

f 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.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

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 filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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 hardfacing

(see instructions on container or SDS) 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 unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also 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 specific 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 products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Safety 03 of 04 - 06/15/2016

Page 5

SAFETY

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

rom starting a fire. Remember that welding sparks and hot

f materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

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,

tc. should be suitable for the application and

e maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. 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.

Safety 04 of 04 - 06/15/2016

Page 6

OWER WAVE

350 & S350 ALUMINUM

Page

Installation ................................................................................................................................................Section A

Technical Specifications ........................................................................................................................A-1, A-2

Safety Precautions ........................................................................................................................................A-3

Location, Lifting....................................................................................................................................A-3

Stacking ...............................................................................................................................................A-3

Tilting ...................................................................................................................................................A-3

Input and Ground Connections ..............................................................................................................A-3

Machine Grounding...............................................................................................................................A-3

High Frequency Protection....................................................................................................................A-3

Input Connection...........................................................................................................................................A-4

Input Fuse and Supply Wire ..................................................................................................................A-4

Input Voltage Selection .........................................................................................................................A-4

Power Cord Replacement......................................................................................................................A-4

Connection Diagram......................................................................................................................A-5, A-6

Recommended Work Cable Sizes..........................................................................................................A-7

Cable Inductance and its Effects on Welding.........................................................................................A-8

Remote Sense Lead Specifications................................................................................................A-8, A-9

Voltage Sensing Considerations for Multiple Arc Systems..........................................................A-10, A-11

Control Cable Connections ..........................................................................................................................A-12

________________________________________________________________________________

Operation ..................................................................................................................................................Section B

Safety Precautions ........................................................................................................................................B-1

Power-Up Sequence .............................................................................................................................B-1

Duty Cycle ............................................................................................................................................B-1

Graphic Symbols ..................................................................................................................................B-1

Product Description.......................................................................................................................................B-2

Recommended Processes and Equipment.....................................................................................................B-2

Equipment Limitations ..................................................................................................................................B-2

Common Equipment Packages......................................................................................................................B-2

Design Features............................................................................................................................................B-3

Case Front Controls.......................................................................................................................................B-3

Case Back Controls.......................................................................................................................................B-4

Common Welding Procedures .........................................................................................................B-5 thru B-7

________________________________________________________________________________

ABLE OF CONTENTS

Accessories .............................................................................................................................Section C

Kits, Options / Accessories...........................................................................................................C-1

Field Installed Options..................................................................................................................C-1

Stick Operations ..........................................................................................................................C-2

________________________________________________________________________

Maintenance............................................................................................................................Section D

Safety Precautions........................................................................................................................................D-1

Routine Maintenance ....................................................................................................................................D-1

Periodic Maintenance ...................................................................................................................................D-1

Calibration Specification ...............................................................................................................................D-1

________________________________________________________________________________

Troubleshooting.......................................................................................................................Section E

Safety Precautions .......................................................................................................................E-1

How to Use Troubleshooting Guide...............................................................................................E-1

Using Status LED, Error Fault Codes and Input Control Board .................................................................E-2, E-4

Troubleshooting Guide....................................................................................................E-5 thru E-8

________________________________________________________________________________

Wiring Diagram and Dimension Print .....................................................................................Section F

________________________________________________________________________

Parts List ........................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

_______________________________________________________________________________

Page 7

OWER WAVE

350 & S350 ALUMINUM

TECHNICAL SPECIFICATIONS - POWER WAVE®S350

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

Duty Cycle

nput Voltage ± 10%

nput Amperes

(1 Phase in parenthesis)

Idle Power

NSTALLATION

ower Factor @

Rated Output

39/35/19/17/14

*/NA/NA/NA)

(60/67

31/28/15/14/11

300 Watts Max.

(fan on)

.95

K2823-3/

K4188-1

40% rating

100% rating

08/230/400*460/575

50/60 Hz

(*includes 380V to 413V)

(60/53/NA/NA/NA)

RATED OUTPUT

INPUT

VOLTAGE/PHASE/

FREQUENCY

40%*

200-208/1/50/60

230/1/50/60

200-208/3/50/60

230/3/50/60

380-415/3/50/60

460/3/50/60 575/3/50/60

350

Amps

31.5 Volts

* On 230 Volt / 1 phase inputs the max. rating is at a duty cycle of 30%, except for GTAW processes. ** For all ra ted singl e ph ase input s, t he o ption al 1 15 V AC dup lex is r ated for 5 A mps when weld ing above

275 Amps at 100% Duty Cycle.

RECOMMENDED INPUT WIRE AND FUSE SIZES

GMAW

60% 60%100%**

300 Amps / 29 Volts

320

Amps

300

Amps

29 Volts

Volts

SMAW

40%* 100%

250 Amps / 30 Volts

325

Amps

33 Volts

275

Amps

250

Amps

30 Volts

Volts

GTAW-DC

40% 60% 100%**

350 Amps

24 Volts

23Volts

325

Amps

300 Amps

22 Volts

INPUT

VOLTAGE / PHASE/

INPUT AMPERE RATING AND

FREQUENCY

200-208/1/50/60 200-208/3/50/60

230/1/50/60 230/3/50/60

380-415/3/50/60

460/3/50/60 575/3/50/60

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.

MAXIMUM

DUTY CYCLE

60A, 100% 39A, 40% 67A, 30% 35A, 40% 19A, 40% 17A, 40% 14A, 40%

CORD SIZE

AWG SIZES (mm2)

6 (13) 8 (10) 4 (16) 8 (10) 12 (4) 12 (4)

14 (2.5)

TIME DELAY FUSE

OR BREAKER

AMPERAGE

80 50 80 45 30 25 20

A-1

Page 8

OWER WAVE

MODEL

350 & S350 ALUMINUM

ROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

SMAW

HEIGHT

WELDING PROCESS

OUTPUT RANGE (AMPERES)

40-350A

5-350A

55-325A

PHYSICAL DIMENSIONS

WIDTH

DEPTH

OCV (Uo)

Mean Peak

40-70V

24V

60V

INSTALLATION

00V

WEIGHT

K2823-3/

K4188-1

20.40 in ( 518 mm)

OPERATING TEMPERATURE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.

14.00in ( 356 mm)

TEMPERATURE RANGES

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

24.80in ( 630mm)

85 lbs (39 kg)*

STORAGE TEMPERATURE RANGE

Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been determined by simulation.

A-2

Page 9

OWER WAVE

350 & S350 ALUMINUM

INSTALLATION

SAFETY PRECAUTIONS Read this entire installation

ection before you start installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• 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 working on the equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE

a proper safety (Earth) ground.

-------------------------------------------------------------

S350 grounding lug to

SELECT SUITABLE LOCATION

The POWER WAVE®S350 will operate in harsh environments. Even so, it is important that simple preventative 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.

STACKING

The POWER WAVE®S350 cannot be stacked.

TILTING

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not operate machine while suspended when lifting.

FALLING

EQUIPMENT can

cause injury.

-------------------------------------------------------------

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.

• 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 normal 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 combustible 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®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®S350 with accessories attached to it.

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 PROTECTION

Locate the POWER WAVE®S350 away from radio controlled machinery. The normal operation of the POWER WAVE®S350 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

A-3

Page 10

OWER WAVE

INPUT POWER CORD

CONNECTION BLOCK

GROUND LUG

350 & S350 ALUMINUM

INPUT CONNECTION

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.

--------------------------------------------------------------------

A 15 ft. (4.6m) power cord may be 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.

INSTALLATION

WARNING

The POWER WAVE®S350 ON/OFF switch is

ot intended as a service disconnect for

n this equipment. Only a qualified electrician should connect the input leads to the

POWER WAVE

e made in accordance with all local and

S350. Connections should

national electrical codes and the connection 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

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.

------------------------------------------------

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 circuit 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.

*An input cord is provided with the POWER WAVE

S350.

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 GROUNDING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH) GROUND.

FIGURE A.1

A-4

Page 11

OWER WAVE

K3001-2

TIG WITH S-SERIES USER INTERFACE

FOOT AMPTROL

ORK PIECE

WORK CLAMP

TIG TORCH K

1782-1,-3,12

TO POSITIVE (+) STUD

TO REMOTE CONTROL

RECEPTACLE

SER INTERFACE

CONTROL PANEL

AS SOLENOID KIT

(INSIDE MACHINE)

2825-1

TO NEGATIVE (-) STUD

EGULATOR

FLOWMETER

GAS HOSE

KK878 70, K870-2 AND0, K870-2 AND K2909-1K2909-1

960-3

STICK WITH S-SERIES USER INTERFACE

K3001-2

REMOTE CONTROL BOX

K857-2

USER INTERFACE CONTROL PANEL

O POSITIVE

(+) STUD

LECTRODE HOLDER KIT K875 OR K704 (INCLUDES GROUND CLAMP)

TO NEGATIVE (-) STUD

WORK PIECE

WORK CLAMP

350 & S350 ALUMINUM

INSTALLATION

CONNECTION DIAGRAMS

GTAW (TIG) WELDING

A user interface is required for adjusting the TIG welding settings. S-series user interface (K3001-2) can be installed into the power source (Figure A.2). Refer to the connection diagrams based on the user interface that is being used. Alternate configurations are possible depending on the wire feeder that is being used. Refer to the wire feeder’s manual for alternative configurations.

FIGURE A.2

SMAW (STICK) WELDING

Similar to TIG welding a user interface is required for adjusting

he Stick welding settings. A Power Feed wire feeder can be

t used as the user interface, or a K3001-2 (user interface control panel) can be installed into the power source (Figure A.3). The connection diagram shown is based on the S-Series user

nterface (K3001-2). In this diagram the remote control box is

i optional.

GMAW (MIG) WELDING

An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.4 for the connection details.

FIGURE A.3

A-5

Page 12

OWER WAVE

MIG PROCESS

REGULATOR FLOWMETER

GAS HOSE

WORK PIECE

WORK CLAMP

TO POSITIVE (+) STUD

TO NEGATIVE (-) STUD

PF10-M

WIRE FEEDER

ARCLINK CABLE K

1543-[XX]

350 & S350 ALUMINUM

INSTALLATION

FIGURE A.4

A-6

Page 13

OWER WAVE

350 & S350 ALUMINUM

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 output connections 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 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 electrode and work cable set-up, See the standard “SAFETY INFORMATION” located in the front of this Instruction Manual.

General Guidelines

INSTALLATION

Select the appropriate size cables per the “Output Cable

• Guidelines” below. Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding 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

Amperes

200

250

300

350

** 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°C).

Cycle

100

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**

0 to 50 Ft.

2/0

1/0

50 to 100 Ft.

2/0

1/0

100 to 150 Ft.

2/0

150 to 200 Ft.

1/0

2/0

200 to 250 Ft.

1/0

2/0

3/0

A-7

Page 14

WORK

POWER WAVE S350

OWER WAVE

350 & S350 ALUMINUM

INSTALLATION

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

verall inductance of the cabling system including cable size,

o 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.5).

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 factor 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

Remote voltage sense leads are used to improve the accuracy of

he arc voltage information supplied to the control pc board.

t 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

re no requirements for setting-up the machine to use remote

a 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).

If the auto sense lead feature is disabled and remote voltage sensing is enabled but the sense leads are missing, improperly connected extremely high welding outputs may occur.

--------------------------------------------------------------------

CAUTION

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 Sensing Overview

Voltage sense leads requirements are based on the weld process (See Table A.2)

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 apparent at the studs of the welder, and have a dramatic effect on performance.

TABLE A.2

Process

Electrode Voltage Sensing

67 lead

GMAW

GMAW-P

FCAW GTAW

SMAW

(1)

The electrode voltage sense lead (67) is automatically enabled by the weld process, and 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.

67 lead required 67 lead required

67 lead required Voltage sense at studs Voltage sense at studs

(1)

Work Voltage Sensing

21 lead

21 lead optional 21 lead optional

21 lead optional

Voltage sense at studs Voltage sense at studs

(2)

(3)

FIGURE A.5

A-8

Page 15

OWER WAVE

350 & S350 ALUMINUM

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the 5-pin

rclink control cable and is always connected to the wire drive

a feed plate when a wire feeder is present. Enabling or disabling

lectrode voltage sensing is application specific, and

e automatically configured by the active weld mode.

Work Voltage Sensing

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 in this section entitled "Voltage Sensing Considerations for Multiple Arc Systems."

INSTALLATION

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 negative 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).

If the auto sense lead feature is disabled and the weld polarity attribute is improperly configured extremely high welding outputs may occur.

--------------------------------------------------------------------

CAUTION

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 "Voltage Sensing Considerations for Multiple Arc Systems."

A-9

Page 16

Direction of Travel

Connect all Work Leads at the Beginning of the Weld

Connect all Sense Leads at the End of the Weld

OWER WAVE

350 & S350 ALUMINUM

INSTALLATION

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,

ut they are strongly recommended.

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.

If Sense Leads ARE Used:

(See Figure A.6)

FIGURE A.6

• 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

thers current paths that can be misinterpreted by the power

o sources, and result in arc interference.

• For longitudinal applications, connect all work leads at one end of the weldment, and all of the work voltage sense leads at the opposite end of the weldment. Perform welding in the direction away from the work leads and toward the sense leads.

A-10

Page 17

OWER WAVE

SOURCE

POWER SOURCE #1

POWER

WER

SOURCE

SOURCE #1

WER

SOURCE

POWER

SOURCE

350 & S350 ALUMINUM

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.7)

IGURE A.7

A-11

Page 18

OWER WAVE

350 & S350 ALUMINUM

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-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (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®and Ethernet connections.

INSTALLATION

Product specific Installation Instructions

Connection Between Power Source and ArcLink®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 communication, 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 network should not exceed 200ft. (61.0m).

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 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 recommendations can result in an Ethernet connection failure during welding.

A-12

Page 19

NOTES

A-13

Page 20

OWER WAVE

350 & S350 ALUMINUM

PERATION

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.

• Do not touch electrically live part or lectrode with skin or wet clothing.

• Insul ate your self from wor k a nd

ground.

• Always wear dry insulating gloves.

• Do not operate with covers, panels or guards removed or open.

------------------------------------------------------------------

• FUMES AND GASSES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

----------------------------------------------

• WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

GRA PHIC SYM BOLS THAT APP EAR ON TH IS MACHINE OR IN THIS MANUAL

WARNING OR CAUTION

DANGEROUS VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

HIGH TEMPERATURE

STATUS

----------------------------------------------

ARC RAYS can burn.

• Wear eye, ear and body protection.

------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MANUAL.

------------------------------------------------------------------

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 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 minutes of idling in a ten-minute period. Refer to the technical specification section

for the Power Wave S350’s duty cycle ratings.

PROTECTIVE GROUND

COOLER

OUTPUT

OPERATORS MANUAL

WORK

CIRCUIT BREAKER

B-1

Page 21

OWER WAVE

350 & S350 ALUMINUM

OPERATION

PRODUCT DESCRIPTION

PRODUCT SUMMARY

he Power Wave

T source with high-end functionality capable of Stick, DC TIG, MIG,

ulsed MIG and Flux-Cored welding. It is ideal for a wide variety

P of materials including aluminum, stainless, and nickel — where arc performance is critical.

The Power Wave system. Like existing Power Wave’s®, the software based architecture allows for future upgradeability. One significant change from the current range of Power Wave®units is that the Ethernet communication 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®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 compatible with future advanced welding modules like STT

350 is a portable multi-process power

S350 is designed to be a very flexible welding

RECOMMENDED PROCESSES AND EQUIPMENT

EQUIPMENT LIMITATIONS

Only ArcLink compatible semiautomatic wire feeders and users

nterfaces may be used. If other Lincoln wire feeders or

i non-Lincoln wire feeders are used there will be limited process capability and performance and features will be limited.

The Power Wave®S350 is recommended for semiautomatic welding, and may also be suitable for basic hard automation applications. The Power Wave®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 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, 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 various materials especially steel, aluminum and stainless.

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 - 1/16 Aluminum wire.

B-2

Page 22

OWER WAVE

350 & S350 ALUMINUM

OPERATION

DESIGN FEATURES

oaded 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

• State of the art power electronics technology yields superior

• Electronic over current protection

• Input over voltage protection.

• F.A.N. (fan as needed). Cooling fan only runs when needed.

• Thermostatically protected for safety and reliability.

ArcLink

platform.

welding capability.

CASE FRONT CONTROLS

(See Figure B.1)

1. USER INTERFACE (optional)

2. STATUS LED - (See Troubleshooting Section for operational

functions)

3. THERMAL LED - Indicates when machine has thermal fault.

4. POWER SWITCH - Controls power to the Power Wave®S350.

5. NEGATIVE WELD OUTPUT

6. POSITIVE WELD OUTPUT

7. WORK SENSE LEAD CONNECTOR

8. 12-PIN CONNECTOR (Optional)

• Ethernet connectivity.

FIGURE B.1

• Panel mounted Status and Thermal LED indicators facilitate quick and easy troubleshooting.

• Potted PC boards for enhanced ruggedness/reliability.

• 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

B-3

Page 23

OWER WAVE

350 & S350 ALUMINUM

OPERATION

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)

CASE BACK CONTROLS

(See Figure B.2a for Code 11782/12371)

1. 115 VAC KIT (OPTIONAL) (STANDARD ON K4188-1)

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

FIGURE B.2a

B-4

Page 24

OWER WAVE

350 & S350 ALUMINUM

OPERATION

COMMON WELDING PROCEDURES

WARNING

MAKING A WELD

he serviceability of a product or structure utilizing the

T 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 selection.

Choose the electrode material, electrode size, shielding gas, and process (GMAW, GMAW-P etc.) appropriate 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. If a 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 avaliable to use with the Power Wave®S350.

Basic Welding Controls

Weld Mode

Selecting a weld mode determines the output characteristics of the Power Wave®power source. Weld modes are developed with a specific electrode material, electrode size, and shielding gas. For a more complete description of the weld modes

rogrammed into the Power Wave

350 at the factory, refer to

S 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.

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

• A Synergic welding mode offers the simplicity of single knob control. The machine will select the correct voltage and amperage based on the Wire Feed Speed (WFS) set by the operator.

Trim

In pulse 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 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 +10.0 with a nominal setting of 0.0.

B-5

Page 25

OWER WAVE

MAW (STICK) WELDING

350 & S350 ALUMINUM

The welding current and Arc Force settings can be set through a

ower Feed

™

0M or Power Feed

™

5M wire feeder.

2 Alternatively an optional Stick / TIG UI can be installed into the power source to control these settings locally.

n a SMAW (STICK mode), Arc Force can be adjusted. It can be

I set to the lower range for a soft and less penetrating 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 workpiece 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 electrodes. In either case the arc control is available to increase or decrease the energy level delivered 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 can be installed into the power source to control these settings locally.

OPERATION

CONSTANT VOLTAGE WELDING

ynergic CV

For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory.

The nominal preprogrammed voltage is the best average voltage

or a given wire feed speed, but may be adjusted to preference.

f 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 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 to less than 0.0 provides a softer arc (less spatter).

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.

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 impractical 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

B-6

Page 26

OWER WAVE

350 & S350 ALUMINUM

OPERATION

Most pulse welding programs are synergic. As the wire feed

peed is adjusted, the Power Wave

350 will automatically

S 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

ork piece.) The Power Wave

350 waveforms are optimized

S 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.

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 current. 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 current. This results in a soft arc good for out of position welding. (See Figure B.4)

FIGURE B.4

B-7

Page 27

OWER WAVE

350 & S350 ALUMINUM

CCESSORIES

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®S350. Allows stick and Tig operation without having a wire feeder.

Order K3001-2

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 (compatible with the K2823-1 and K2823-3 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

Coaxial Welding Cable

Optimum weld cables for minimizing cable inductance and

ptimizing welding performance.

AWG 1/0 Coaxial Cables: Order K1796-25 for 25 feet (7.6 m) cable length.

rder K1796-50 for 50 feet (15.2 m) cable length.

O 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 environmental system solutions, ranging from portable systems easily wheeled around a shop to shop-wide central systems servicing many dedicated welding stations.

Request Lincoln publication E13.40 (See www.lincolnelectric.com)

Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO2, Argon, or Argon-blend gas cylinders. 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 (50mm

) cable. Order K2946-1

C-1

Page 28

OWER WAVE

350 & S350 ALUMINUM

ACCESSORIES

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

ample pack of mild steel electrode. For

s use with K2946-1.

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-Mate™ 17V Air-Cooled TIG Torch Starter Pack

Get everything you need for TIG welding in one complete easy-to-order kit packaged in its own portable carrying 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

MIG OPTIONS

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 feeding equipment (See www.lincolnelectric.com)

TIG OPTIONS

Pro-Torch™ TIG Torches

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 current control for TIG welding.

Order K963-4 for Hand Amptrol with 12 pin connector

Foot Amptrol

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

C-2

Page 29

OWER WAVE

350 & S350 ALUMINUM

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not operate with covers removed.

•Turn off power source before installing or ervicing.

•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.

AINTENANCE

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 machines may not yield satisfactory weld performance. 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 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 adjustments.

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, and is available on the Service Navigator CD or at www.powerwavesoftware.com.

D-1

Page 30

OWER WAVE

350 & S350 ALUMINUM

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.

__________________________________________________________________________

ROUBLESHOOTING

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 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

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.

• 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.

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.

CAUTION

E-1

Page 31

OWER WAVE

350 & S350 ALUMINUM

TROUBLESHOOTING

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

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

he power source status light for error sequences as noted below.

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 the input control board and can be seen by looking through the left case side louvers.

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

TABLE E.1

Light

Condition

Steady Green

Blinking Green

Main control board status light

System OK. Power source is operational, and is communicating normally with all healthy periph-

eral equipment connected to its ArcLink network.

Occurs during power up or a system reset, and indicates the POWER WAVE

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.

Meaning

through either the status light or the status beeper.

Included in this section is information about the Status Lights and some

asic 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).

Error conditions are indicated in the following chart Table E.1.

Input control board

Not applicable.

S350 is

Not applicable.

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

Status LED off

Indicates Auto-mapping has failed

Non-recoverable system fault. If the Status lights are flashing any combination 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 (included on the

Service Navigator CD or available at www.powerwavesoftware.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.

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.

System OK

CAUTION

E-2

Page 32

OWER WAVE

350 & S350 ALUMINUM

bserve all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

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)

rror Code #

36 Thermal error

54 Secondary (Output) over current error

56 Chopper communication error

58 Primary Fault error

Other

Indication

Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine

The long term average secondary (weld) current limit has been exceeded. NOTE: The long term average secondary current limit is 325 amps.

Indicates communication link between main control board and chopper has errors. If cycling the input power on the machine does not clear the error, contact the Service Department.

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

E-3

Page 33

OWER WAVE

350 & S350 ALUMINUM

bserve all Safety Guidelines detailed throughout this manual

INPUT CONTROL BOARD

TROUBLESHOOTING

Error Code #

331 Peak input current limit

333 Under-voltage lockout

336 Thermal Fault

337 Pre-charge timeout

346 Transformer primary over current

Other

Indication

nput current limit has been exceeded. Typically indicates short term power

I overload. If problem persists contact Service Department.

+15 VDC supply on Input control board too low. Verify input voltage is within the acceptable range. If problem persists contact service department.

Thermostat on primary module tripped. Typically caused by bottom fan not working.

Problem with start-up sequence. If problem persists contact Service Department.

Transformer current too high. Typically indicates short term power overload. If problem persists contact service department.

Contact the Service Department.

CAUTION

E-4

Page 34

OWER WAVE

350 & S350 ALUMINUM

PROBLEMS

(SYMPTOMS)

bserve all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Basic Machine Problems

TROUBLESHOOTING

RECOMMENDED

COURSE OF ACTION

Input fuses keep blowing

Machine will not power up (no lights)

1. Improperly sized input fuses.

2. Improper Weld Procedure requiring output levels in excess of machine rating.

3. Major physical or electrical damage is evident when the covers are removed.

1. No Input Power

2. Input voltage is too low or too high.

1. Make sure fuses are properly sized. See nstallation section of this manual for

i recommended sizes.

2. Reduce output current, duty cycle, or

both.

3. Contact your local authorized Lincoln

Electric Field Service facility for technical assistance.

1. Make sure input supply disconnect has

been turned ON. Check input fuses. Make certain that the Power Switch (SW1) on the power source is in the “ON” position.

2. Make certain that input voltage is cor-

rect, according to the Rating Plate located on the rear of the machine.

Machine won’t weld, can’t get any output.

This problem will normally be accompanied by an error code. See “Status Light” section of this document for additional information.

Input voltage is too low or too high.

2. Thermal Error.

3. Secondary current limit has been exceeded. (see error 54)

3a. Input control board fault (see input con-

trol board error status).

1. Make certain that input voltage is correct, according to the Rating Plate located on the rear of the machine.

2. See “Thermal LED is ON” section.

3. Possible short in output circuit. If condition persists, contact an authorized Lincoln Electric Field Service facility.

CAUTION

E-5

Page 35

OWER WAVE

350 & S350 ALUMINUM

PROBLEMS

(SYMPTOMS)

bserve all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

TROUBLESHOOTING

RECOMMENDED

COURSE OF ACTION

Thermal LED is ON

“Real Time Clock” no longer functioning

General degradation of weld performance

Improper fan operation

Basic Machine Problems (Continued)

1. Improper fan operation.

2. Open thermostat circuit.

1. Control PC Board Battery.

Weld and Arc Quality Problems

1. Wire feed problem.

2. Cabling problems.

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. Check for broken wires, open connections or faulty thermostats in the thermostat circuit.

1. Replace the battery (Type: BS2032)

1. Check for feeding problems.

2. Check for bad connections, excessive loops in cable, etc.

3. Loss of, or improper Shielding Gas.

4. Verify weld mode is correct for process.

5. Machine calibration.

NOTE: The presence of heat in the external welding circuit indicates poor connections or undersized cables.

3. Verify gas flow and type are correct.

4.Select the correct weld mode for the

application.

5. The power source may require calibration. (current, voltage, WFS).

CAUTION

E-6

Page 36

OWER WAVE

350 & S350 ALUMINUM

PROBLEMS

(SYMPTOMS)

ire burns back to tip at the end of the

W weld.

bserve all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Weld and Arc Quality Problems (Continued)

. Burnback Time

. Reduce burnback time and/or work point.

TROUBLESHOOTING

RECOMMENDED

COURSE OF ACTION

Machine output shuts down during a weld.

Machine won’t produce full output.

Excessively long and erratic arc.

1. Secondary current limit has been exceeded, and the machine shuts down to protect itself.

2. System Fault

1. Input voltage may be too low, limiting output capability of the power source.

2. On 460 or 575 the input may be single phase.

3. Machine calibration.

1. Wire feed problem.

1. Adjust procedure or reduce load to lower current draw from the machine.

2. A non-recoverable fault will interrupt welding. This condition will also result in a status light blinking. See the Status Light section for more information.

1. Make certain that the input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. Verify all 3 phases are present.

3. Calibrate secondary current and voltage.

1. Check for feeding problems. Make sure proper gear ratio has been selected.

2. Loss of, or improper Shielding Gas

3. Machine calibration.

2. Verify gas flow and type are correct

3. Calibrate secondary current and voltage.

CAUTION

E-7

Page 37

OWER WAVE

350 & S350 ALUMINUM

PROBLEMS

(SYMPTOMS)

bserve all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Ethernet

TROUBLESHOOTING

RECOMMENDED

COURSE OF ACTION

Cannot Connect

1. Physical connection.

2. IP address information.

3. Ethernet Speed

1. Verify that the correct patch cable or cross over cable is being used (refer to local IT department for assistance).

1a. Verify the cables are fully inserted 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. Use the appropriate PC utility to verify the correct IP address information has been entered.

2a. Verify no duplicate the IP addresses

exist on the network.

3. 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

1. Verify Network cable is not located next to current carrying conductors. This would include input power cables and welding output cables.

CAUTION

E-8

Page 38

OWER WAVE

CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

461

J10A1,

J10B1,

J811

J3, J4,

J45, J61

J2, J5, J11,

J31, J46,

J51, J111

J9, J13, J16,

J26, J27, J62,

J112

J8, J24, J28,

J29, J43, J47,

J63

J12, J23,

J25, J42

J6, J7,

J41





3A1A2A



250 OHM 25 W

M20305-1

WORK

121110

876

J42

3 STAGE INVERTER

G4770-1

INPUT

CHOKE

B32

BL1

BL2

BL3

BL4

BL5

BL6

OUTPUT

CHOKE

HEAT

SINK

1234567

J28







654

342

343

344

345

346

347

348

341

316

3211

1 2 3 4 5

6 7 8 9 1

311

309

306

305

8765432

350

355

B28

B29

B41B37

B39

B38

B40

B31

B30

313

308

307

351

65A

353

322

326

J41

303

INPUT CONTROL

BOARD

G6758

1 2 3 4 5 6 7 8 9

326

331

334

324

301

J45

314 315 316

328

J43

338

337

333

332

335

336

334

331

J25

1 2 3 4 5 6 7 8

403 404

408

J24

543

J23

543

J26 J27

311

301

303

309

315

337

333

332

336

307

308

306

305

313

314

321

322

324

328

406

402

401

AA2A3A4A5

409

B53

543

216

211

213

212

CURRENT

TRANSDUCER

335

338





















6 7

2 1

4 3

123456789

3 4 5 6 7

9 1

3 4 5 6 7

2 1

4 3

J12

5 4 3 2 1

J13

CONTROL BOARD

G6682

345

346

341

344

348

408

401

402

355

418

409

410

404

403

370 371

CLEVELAND, OHIO U.S.A.

R - RED

B - BLACK

N- BROWN

LEAD COLOR CODING

ELECTRICAL SYMBOLS PER E1537.

V - VIOLET

GENERAL INFORMATION

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS ( ANODE)

ALIGNS WITH WHITE LEAD OF LED SOCKET.

G - GREEN

RJ 45

TYPE

ETHERNET

CONNECTOR





L15732

358

356









USER

INTERFACE

PCB ASSY

G6554

OPTIONAL

KIT

K3001

DEVICENET

CONNECTOR

(OPTIONAL)

SYNC/TANDEM

CONNECTOR

BLK/GRN

GRN

GND3 CASEFRONT

GND2 CASEBACK

GND1 VERTICAL PANEL

BASE

GROUND BOND CIRCUIT

373 372

J51

STATUS

RED/GREEN LED

THERMAL LED

372

373

370

371

206

901B

903B

J46

349

352

354

357

347

342

343

J15

410

G6536-2PRINT

LEM

J47

236

200 OHM

100 W

B52

206A

207

TO EARTH GROUND PER THE

NATIONAL ELECTRIC CODE

FAN

1J56

3J56

353A

351A

1J55

3J55

353C

351C

1J54

3J54

353D

351D

353B

351B

351

353

DIFF_1 HIGHADIFF_1 LOW

DIFF_2 HIGH

DIFF_2 LOW

DEF

+24 VDC INPUT 2

+24 VDC COMMON 3

DNET CAN_H

DNET CAN_L

J55

2345678

J50

234

GRN

RED

BLK/RED

BLK/GRN

891

892

893

894

53C

54C

52C

51C

5354675251

53A

54A

67A

52A

51A

357

354

352

349

CB2

10A

65A

407

894 891

893 892

OPTIONAL

DEVICENET

BLK/RED

RED

415

CB1

10A

(Neutral Bonded)

115V

RECEPTACLE

GND5

33A

32A

(OPTIONAL)

xxxxxxx xxxxxxx

412

411

413

414

32A

33A

GND

2 1

4 3

J61

J63

317

317A

318

318A

115 VAC

INVERTER PCB

OPTIONAL

(ASSEMBLY G6571)

317A

318

317

318A

CAPACITOR NOT

PRESENT ON

EARLIER MODELS

REMOTE

AMPTROLS

ARC LINK

CONNECTOR

DEF

53F

54F

51F

52F

REMOTE CONTROL PCB

(ASSEMBLY G6948)

J111

J112

ETHERNET

CABLE

























REMOTE

AMPTROLS

ARC LINK

CONNECTOR

360

359

53B

54B

52B

51B

554

351

353

GAS

SOLENOID

(OPTIONAL)

553A

553

554

202

67B

67C

200

J115

J114

2 1

54F

53F

52F

51F

200

J31

153

154

51D

52D

53C

54C

51C

67D

52C

361

359

363

360

362

364

67E

67C

67D

LEADS 317A AND

318A PRESENT ON

EARLIER MODELS

LEADS 317A AND

318A PRESENT ON

EARLIER MODELS

ARCLINK - A

ARCLINK + B

0 VDC

+40VDC

ELECTRODE

SENSE

S3 ARCLINK

RECEPTACLE

51B

51A

52B

52A

67A

54B

54A

53B

53A

67B

.0047 uF

TOROID





































































POWER WAVE S350 WIRING DIAGRAM

350 & S350 ALUMINUM

IAGRAMS

F-1

els. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure pan-

Page 39

OWER WAVE

27.43 22.25

13.91

18.81

18.36

6.00

350 & S350 ALUMINUM

DIAGRAMS

F-2

Page 40

Power Wave S350

Aluminum - 12371

Page 41

THIS PAGE INTENTIONALLY LEFT BLANK

Page 42

Index of Sub Assemblies - 12371

KEY PART NUMBER DESCRIPTION QTY

P-855-A INDEX OF SUB ASSEMBLIES AR

P-855-B.2 MISCELLANEOUS ITEMS AR

1 P-855-C CASE FRONT ASSEMBLY AR

2 P-855-D BASE & POWER CONVERSION ASSEMBLY AR

3 P-855-E VERTICAL DIVIDER PANEL ASBLY AR

4 P-855-F OUTPUT CHOKE ASSEMBLY AR

5 P-855-G CASE BACK ASSEMBLY AR

6 P-855-H ROOF ASSEMBLY AR

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Power Wave S350 Aluminum - 12371 1

Page 43

Index of Sub Assemblies - 12371

2 Power Wave S350 Aluminum - 12371

P-855-A.jpg

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Page 44

Miscellaneous Items

KEY PART NUMBER DESCRIPTION QTY

9SG6094 PRIMARY CONTROL HARNESS 1

9SM19969-2 ETHERNET PATCH CABLE 1

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Power Wave S350 Aluminum - 12371 3

Page 45

Miscellaneous Items

4 Power Wave S350 Aluminum - 12371

No Image

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Page 46

Case Front Assembly

KEY PART NUMBER DESCRIPTION QTY

9SG8388 CASE FRONT ASSEMBLY 1

1 9SG6513-3 CASE FRONT 1

9SM22487-1 LED HARNESS 1

9SS23740-2 LED PANEL MOUNT ASSEMBLY 2

9ST13657-4FA YELLOW LED 1

9ST13657-7H24 LED-T-1 3/4BI-COLORRED/GREEN 1

3 9SS23093-1 LED LENS CLEAR 2

3A 9SS23094-1 RETAINING O RING 2

4A 9SM20305-1 NOISE SUPPRESSOR PC BD ASBLY 1

4B 9SS28402 NOISE SUPPRESSOR BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

5A 9SL13263-1 PCB MOUNTING BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

6A 9SL13263-2 PCB MOUNTING BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

7A 9SS20030-1 LINE SWITCH 1

7B 9SS25384-1 SWITCH COVER - WEATHER RESISTANT 1

9ST9695-1 LOCKWASHER 2

9SCF000084 #10-32X.625HHCS 2

9SS18491-3 M.O.V. ASBLY 1

15A 9SM13896-9 OUTPUT TERMINAL MOLDING 2

15B 9SS9225-101 SELF TAPPING SCREW 4

16A 9SG6758-1 INPUT CONTROL & POWER SUPPLY PC BD ASBLY 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 3

18 9SG8226 NAMEPLATE 1

19 9ST10397-3 PLUG BUTTON 1

21 9ST10397-23 PLUG BUTTON 1

9SS9225-99 SELF TAPPING SCREW 4

26A 9SS9262-80 PLAIN WASHER 2

26B 9SE106A-15 LOCKWASHER 2

26C 9SCF000021 1/2-13X1.00HHCS 2

30A 9SS18657 SQUARE FLANGE FEMALE RECEPTACLE 1

9SS8025-118 SELF TAPPING SCREW 2

31A 9SL15069 COVER PLATE 1

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Power Wave S350 Aluminum - 12371 5

Page 47

Case Front Assembly

KEY PART NUMBER DESCRIPTION QTY

31B 9SS9225-99 SELF TAPPING SCREW 4

31C 9SG6529 UI TRIM 1

31D 9SG6601 DECAL 1

6 Power Wave S350 Aluminum - 12371

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Page 48

Case Front Assembly

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Power Wave S350 Aluminum - 12371 7

P-855-C.jpg

Page 49

Base & Power Conversion Assembly

KEY PART NUMBER DESCRIPTION QTY

1A 9SL15067-1 BASE 1

9SS9225-99 SELF TAPPING SCREW 6

2 9SM21251-2 BASE EXTRUSION 2

3A 9SL15091 BRACKET 2

3B 9SS9225-99 SELF TAPPING SCREW 4

9ST9695-1 LOCKWASHER 2

4A 9SCF000013 1/4-20X.625HHCS 4

4B 9SS28070 QUICK LOCK FOOT 4

9SE106A-2 LOCKWASHER 4

5A 9SL16139-1 INPUT CHOKE ASBLY 1

5C 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

10A 9SL13138 CORNER CAP 4

10B 9SS9262-182 PLAIN WASHER 8

10C 9SS9225-100 SELF TAPPING SCREW 8

12A 9SM21469-3 POWERBOARD BOTTOM BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

13 9SG6037-1 POWER BOARD ASBLY 1

13A 9ST13359-29 THERMOSTAT 1

9SS9225-100 SELF TAPPING SCREW 4

9SE106A-1 LOCKWASHER 4

9SS9262-27 PLAIN WASHER 4

14 9SM15045-100 ACOUSTICAL FOAM 3

16A 9SCF000010 #10-24HN 2

16B 9SE106A-1 LOCKWASHER 1

8 Power Wave S350 Aluminum - 12371

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Base & Power Conversion Assembly

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Vertical Divider Panel Asbly

KEY PART NUMBER DESCRIPTION QTY

9SG8279 VERTICAL DIVIDER PANEL ASSEMBLY 1

1 9SG6511 CENTER PANEL 1

2A 9SL15732-1 40 V DC BUS BD ASBLY 1

2B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4

3B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4

3C 9SG6571-3 115V SUPPLY PC BD ASBLY 1

9SS19300-7 SUPPORTPCBSNAP-IN0.63 2

4A 9SS28105 MYLAR INSULATION 1

4B 9SS20763-3 TERMINAL BLOCK 1

9SCF000193 #8-32X1.25RHS 2

5A 9SS31170-3 CONTROL PC BD ASBLY 1

5B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4

7 9ST12380-1 BUSHING 1

9SS18858-11 SUPPRESSOR ASBLY 1

11 9SG8226 NAMEPLATE 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

9SS8025-99 SCREW #10 x 1.50 GIMLET POINT SLOTTED 2

9ST13260-4 DECAL-EARTH GROUND CONN 1

10 Power Wave S350 Aluminum - 12371

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Vertical Divider Panel Asbly

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Output Choke Assembly

KEY PART NUMBER DESCRIPTION QTY

9SL13270-3 OUTPUT CHOKE ASBLY 1

1 9SM21471-3 TOP CHOKE BRACKET 1

2 9ST11827-3 CARRIAGE BOLT 1

9SS28371 CHOKE INSULATOR 2

4 9SS25781-2 SPACER WASHER 6

5 9SS26801-2 OUTPUT CHOKE COIL 3

6A 9SM21472-3 BOTTOM CHOKE BRACKET 1

6B 9SS18504-10 CURRENT TRANSDUCER 1

9SCF000033 #8-32X.50RHS 1

9SS9262-3 PLAIN WASHER 1

9ST4291-A LOCKWASHER 1

7A 9ST14605 INSULATOR 1

7B 9SS9262-98 PLAIN WASHER 1

7C 9SE106A-2 LOCKWASHER 1

7D 9SCF000017 1/4-20HN 1

14A 9SS22168 HEAT SINK HOLDER 2

9SCF000015 1/4-20X1.00HHCS 2

14C 9SS9262-98 PLAIN WASHER 4

14D 9SE106A-2 LOCKWASHER 2

14E 9SCF000017 1/4-20HN 2

15A 9SM22372 BUS BAR 1

15B 9SCF000015 1/4-20X1.00HHCS 2

15C 9SS9262-98 PLAIN WASHER 4

15D 9SE106A-2 LOCKWASHER 2

15E 9SCF000017 1/4-20HN 2

16A 9SCF000015 1/4-20X1.00HHCS 3

16B 9SS9262-98 PLAIN WASHER 6

16C 9SE106A-2 LOCKWASHER 3

16D 9SCF000017 1/4-20HN 3

17A 9SS10404-137 RESISTOR-WW100W2005% 1

17B 9ST4479-A INSULATING WASHER 2

17C 9SS9262-27 PLAIN WASHER 1

9ST9695-1 LOCKWASHER 1

17E 9SCF000191 #10-24X7.50RHS 1

12 Power Wave S350 Aluminum - 12371

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Output Choke Assembly

KEY PART NUMBER DESCRIPTION QTY

9SS9225-99 SELF TAPPING SCREW 4

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Power Wave S350 Aluminum - 12371 13

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Output Choke Assembly

14 Power Wave S350 Aluminum - 12371

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Case Back Assembly

KEY PART NUMBER DESCRIPTION QTY

9SG8172 CASE BACK ASSEMBLY 1

1A 9SL15066-1 FAN BRACKET 1

1B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4

2A 9SM22149 FAN ASBLY 3

2B 9SCF000408 #8-32X2.00HHMS 12

9SS9262-3 PLAIN WASHER 12

9ST4291-A LOCKWASHER 12

5 9SG8173 REAR PANEL 1

6A 9SS19999 CORD GRIP CONNECTOR 1

6B 9ST14370-3 CONDUIT LOCKNUT 1

7A 9SM19969-14 ETHERNET RECEPTACLE 1

7B 9SS8025-118 SELF TAPPING SCREW 2

7C 9SS31117 ADAPTER PLATE 1

7D 9SM22444 ETHERNET COVER 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

9SL15109 FAN HARNESS 1

10A 9ST12287-20 CIRCUIT BREAKER-10A250VAC 1

10B 9SS22061-3 SEALING BOOT 1

11A 9SS31114 COVER PLATE 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

12A 9SS31116 COVER PLATE 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

13B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

13C 9SG6602 RECEPTACLE ASSEMBLY 1

14 9ST10397-4 PLUG BUTTON 1

9SM21927-1 PLUG AND LEAD ASBLY 1

15A 9SS12021-79 BOX RECEPTACLE SOLID SHELL 1

15B 9SS25438-2 CONNECTOR ADAPTER PLATE 1

9SS8025-96 SELF TAPPING SCREW 2

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

16A 9SL16762 LOUVER PLATE 1

16B 9SS9225-99 SELF TAPPING SCREW 6

9SS9225-99 SELF TAPPING SCREW 4

21 9SS28056-2 RATING PLATE 1

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Power Wave S350 Aluminum - 12371 15

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Case Back Assembly

KEY PART NUMBER DESCRIPTION QTY

22A 9SL15123 AIR BAFFLE 1

22B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

23 9SG8226 NAMEPLATE 1

9SS18573-17 INPUT LEAD ASBLY 1

9SM22519 CONNECTOR & LEAD ASBLY 1

25A 9SS12021-73 BOX RECEPTACLE SOLID SHELL 1

9SS8025-118 SELF TAPPING SCREW 2

25C 9SS17062-10 CABLE CONNECTOR CAP 1

26 9SS17062-9 CABLE CONNECTOR CAP 1

9SS31115 SOLENOID MTG PLATE 1

9SS9225-99 SELF TAPPING SCREW 2

16 Power Wave S350 Aluminum - 12371

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Case Back Assembly

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Power Wave S350 Aluminum - 12371 17

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Roof Assembly

KEY PART NUMBER DESCRIPTION QTY

9SM25337 ROOF ASBLY 1

1A 9SL16749 ROOF 1

1B 9SG8226 NAMEPLATE 1

1C 9SL8064-1 WARNING DECAL (INTERNATIONAL) 1

1D 9SG8216 WIRING DIAGRAM 1

9SS9225-99 SELF TAPPING SCREW 10

9SM22375-1 TOP EXTRUSION ASSEMBLY 1

2A 9SL15068-1 HORIZONTAL DIVIDER PANEL 1

2B 9SM21251-1 TOP EXTRUSION 2

2C 9SS9225-99 SELF TAPPING SCREW 6

2D 9SM21469-2 POWER BOARD UPPER BRACKET 1

9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2

3A 9SL15070 HANDLE MOUNTING BRACKET 2

3B 9SS9225-100 SELF TAPPING SCREW 8

5A 9SL13138 CORNER CAP 4

5B 9SS9262-182 PLAIN WASHER 12

5C 9SS9225-100 SELF TAPPING SCREW 12

6A 9SG6525-1 HANDLE SAND CAST 2

6B 9SCF000410 1/4-20x.75HHCS-FULL-GR2-4554 8

9SE106A-27 LOCK WASHER 8

9SM25327-1 LEFT CASE SIDE ASBLY 1

7A 9SL16747-1 LEFT CASE SIDE 1

7B 9SS27368-4 DECAL LE LOGO 1

7C 9SS27468-1 POWER WAVE LOGO 1

9SS31176 ALUMINUM SOLUTIONS LOGO 1

9SL16760 LOUVER INSERT 1

9ST12584-13 BLIND RIVET 6

9SM25325-1 RIGHT CASE SIDE ASBLY 1

8A 9SL16748-1 RIGHT CASE SIDE 1

8B 9SS27368-4 DECAL LE LOGO 1

8C 9SS27468-1 POWER WAVE LOGO 1

8D 9SS28039-2 DECAL GREEN INITIATIVE 1

9SL16760 LOUVER INSERT 1

9ST12584-13 BLIND RIVET 6

18 Power Wave S350 Aluminum - 12371

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Roof Assembly

KEY PART NUMBER DESCRIPTION QTY

9SS9262-182 PLAIN WASHER 4

9SS9225-100 SELF TAPPING SCREW 4

9C 9SS9225-99 SELF TAPPING SCREW 8

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Roof Assembly

20 Power Wave S350 Aluminum - 12371

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Page 62

WARNING

panish

AVISO DE

PRECAUCION

French

ATTENTION

erman

WARNUNG

ortuguese

ATENÇÃO

Japanese

Chinese

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

No toque las partes o los electrodos bajo carga con la piel o ropa mojada.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

Isole-se da peça e terra.

l Keep flammable materials away.

Mantenga el material combustible fuera del área de trabajo.

Gardez à l’écart de tout matériel inflammable.

l Entfernen Sie brennbarres Material!

Mantenha inflamáveis bem guardados.

l Wear eye, ear and body protection.

Protéjase los ojos, los oídos y el cuerpo.

Protégez vos yeux, vos oreilles et votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

Use proteção para a vista, ouvido e corpo.

Korean

Arabic

READ AND UNDERSTAND THE 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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 63

l Keep your head out of fumes. l Use ventilation or exhaust to

remove fumes from breathing zone.

l Turn power off before servicing.

l Do not operate with panel open or

guards off.

WARNING

l Los humos fuera de la zona de res-

piración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

Vermeiden Sie das Einatmen von Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça. l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-

tien.

Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

l Não opere com as tampas removidas. l Desligue a corrente antes de fazer

serviço.

Não toque as partes elétricas nuas.

l No operar con panel abierto o

guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen!

Mantenha-se afastado das partes moventes.

l Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

rench

ATTENTION

German

WARNUNG

ortuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 64

USTOMER ASSISTANCE POLICY

he business of The Lincoln Electric Company is manufacturing and

T selling high quality welding equipment, consumables, and cutting equipment. 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

roducts. We respond to our customers based on the best information

p in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

ABLE OF CONTENTS

T INSTALLATION OPERATION ACCESSORIES MAINTENANCE TROUBLESHOOTING

IAGRAMS

Lincoln POWER WAVE S350 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual