Lincoln POWER WAVE S350 Operator's Manual
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IM10061-D
© Lincoln Global, Inc. All Rights Reserved.
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| Issue D ate July-16
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After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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
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
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.
o
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
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
OWER WAVE
P
®
350 & S350 ALUMINUM
S
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
T
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.
_______________________________________________________________________________
2
OWER WAVE
P
®
350 & S350 ALUMINUM
S
TECHNICAL SPECIFICATIONS - POWER WAVE®S350
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model
Duty Cycle
nput Voltage ± 10%
I
nput Amperes
I
(1 Phase in parenthesis)
Idle Power
NSTALLATION
I
ower Factor @
P
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
2
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
30
300
Amps
29 Volts
Volts
SMAW
40%* 100%
250 Amps / 30 Volts
325
Amps
33 Volts
275
Amps
31
250
Amps
30 Volts
Volts
GTAW-DC
40% 60% 100%**
350 Amps
24 Volts
23Volts
1
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)
3
TIME DELAY FUSE
OR BREAKER
2
AMPERAGE
80
50
80
45
30
25
20
A-1
OWER WAVE
P
MODEL
®
350 & S350 ALUMINUM
S
ROCESS
P
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
1
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
OWER WAVE
P
®
350 & S350 ALUMINUM
S
INSTALLATION
SAFETY PRECAUTIONS Read this entire installation
ection before you start installation.
s
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
OWER WAVE
INPUT
POWER
CORD
CONNECTION
BLOCK
GROUND
LUG
P
®
350 & S350 ALUMINUM
S
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
b
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
OWER WAVE
K3001-2
TIG WITH S-SERIES USER INTERFACE
FOOT AMPTROL
W
ORK PIECE
WORK CLAMP
TIG TORCH
K
1782-1,-3,12
TO POSITIVE
(+) STUD
TO REMOTE CONTROL
RECEPTACLE
U
SER INTERFACE
CONTROL PANEL
G
AS SOLENOID KIT
(INSIDE MACHINE)
K
2825-1
TO NEGATIVE
(-) STUD
R
EGULATOR
FLOWMETER
GAS HOSE
KK878 70, K870-2 AND0, K870-2 AND
K2909-1K2909-1
K
960-3
STICK WITH S-SERIES USER INTERFACE
K3001-2
REMOTE CONTROL BOX
K857-2
USER INTERFACE
CONTROL PANEL
T
O POSITIVE
(+) STUD
E
LECTRODE HOLDER KIT
K875 OR K704
(INCLUDES GROUND CLAMP)
TO NEGATIVE
(-) STUD
WORK PIECE
WORK CLAMP
P
®
350 & S350 ALUMINUM
S
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
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]
P
®
350 & S350 ALUMINUM
S
INSTALLATION
FIGURE A.4
A-6
OWER WAVE
P
®
350 & S350 ALUMINUM
S
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
200
250
250
250
250
300
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
60
100
30
40
60
100
60
100
40
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED
COPPER - RATED 167°F (75°C)]**
0 to 50 Ft.
2
2
3
2
1
1
1
2/0
1/0
50 to 100 Ft.
2
2
3
2
1
1
1
2/0
1/0
100 to 150 Ft.
2
2
2
1
1
1
1
2/0
2/0
150 to 200 Ft.
1
1
1
1
1
1
1/0
2/0
2/0
200 to 250 Ft.
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
A-7
B
A
C
WORK
POWER
WAVE
S350
OWER WAVE
P
®
350 & S350 ALUMINUM
S
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)
(3)
(3)
FIGURE A.5
A-8
OWER WAVE
P
®
350 & S350 ALUMINUM
S
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
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
P
®
350 & S350 ALUMINUM
S
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.
b
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
OWER WAVE
P
O
W
ER
SOURCE
#2
POWER
SOURCE
#1
POWER
PO
WER
SOURCE
SOURCE
#1
PO
WER
SOURCE
#2
#2
POWER
SOURCE
#1
P
®
350 & S350 ALUMINUM
S
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
F
A-11
OWER WAVE
P
®
350 & S350 ALUMINUM
S
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
NOTES
A-13
OWER WAVE
P
®
350 & S350 ALUMINUM
S
PERATION
O
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.
e
• 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
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