Lincoln Electric F355I User Manual

Page 1

POWER WAVE F355i (CE)

RETURN TO MAIN MENU

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.

IM799-A

January, 2005

For use with machines Code 10997, 11252

POWER WAVE F355i

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you 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.

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

The Above For Gasoline Engines

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.

____________________________________________________

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 their removal is complete. Always use the greatest care when 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.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

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.

___________________________________________________

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.

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.

Mar ‘95

Page 3

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, 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.

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 with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

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 between the 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.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

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

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

Page 4

iii

SAFETY

iii

WELDING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

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 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

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

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

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Page 6

ELECTROMAGNETIC COMPATIBILITY (EMC)

Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industr ial and professional use.

Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

SAFETY

Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement; g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

3-1-96H L10093

Page 7

ELECTROMAGNETIC COMPATIBILITY (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations.

SAFETY

Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

Portions of the preceding text are contained in EN50199: "Electromagnetic Compatibility (EMC) product standard for

arc welding equipment."

3-1-96H

L10093

Page 8

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number____________________________________________________________________________ Date Purchased___________________________________________________________________________

viivii

Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

Page 9

viii

TABLE OF CONTENTS

Page

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

Technical Specifications - POWER WAVE 355 ....................................................A-1

Safety Precautions.................................................................................................A-2

Select Suitable Location........................................................................................A-2

Stacking ..........................................................................................................A-2

Tilting...............................................................................................................A-2

Input and Grounding Connections ..................................................................A-2

Power Cord Connection..................................................................................A-2

Undercarriage Mountings................................................................................A-2

Output Cables, Connections and Limitations.........................................................A-3

Negative Electrode Polarity ...................................................................................A-3

Voltage Sensing ............................................................................................A-3, A-4

Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-4

Control Cable Specifications..................................................................................A-4

System Description................................................................................................A-5

System Set-Up.........................................................................................A-6 thru A-8

Welding with Multiple Power Waves......................................................................A-9

I / O Receptacle Specifications............................................................................A-10

Dip Switch Settings and Locations...............................................................A-10

________________________________________________________________________

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

________________________________________________________________________

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

________________________________________________________________________

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

________________________________________________________________________

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

________________________________________________________________________

Wiring Diagram ....................................................................................Section F-1, F-2

Connection Diagram....................................................................................Section F-3

Dimension Print............................................................................................Section F-4

________________________________________________________________________

Parts Lists................................................................................................................P432

________________________________________________________________________

Control Board Dip Switch..............................................................................A-10

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

General Description...............................................................................................B-1

Recommended Processes and Equipment ...........................................................B-1

Recommended Processes..............................................................................B-1

Required Equipment .......................................................................................B-2

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

Duty Cycle and Time Period ...........................................................................B-2

Case Front Controls ................................................................................B-2, B-3

Nominal Procedures........................................................................................B-3

Fringe Procedures...........................................................................................B-3

Making a Weld ................................................................................................B-3

Welding Adjustment........................................................................................B-3

Constant Voltage Welding...............................................................................B-4

Pulse Welding, Pulse on Pulse (GMAW)........................................................B-4

Power Mode....................................................................................................B-5

Optional Equipment...............................................................................................C-1

Factory Installed..............................................................................................C-1

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

Compatible Lincoln Equipment

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

Capacitor Discharge Procedure ............................................................................D-1

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

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

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

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

Using the Status LED to Troubleshoot System Problems.....................................E-2

Troubleshooting Guide.............................................................................E-3 thru E-7

viii

Page 10

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

POWER WAVE F355i

INPUT AC VOLTAGE & DC OUTPUT

Product Ordering Input AC Rated DC Output Output Weight Dimensions

Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD

(continuous)

POWER K2260-1 380-415 350A / 34V / 60%

WAVE K2260-2 AMPS 110.0 lbs.

F355i 60/50 Hz 5-425 (50.0. kg.)

3 Phase 300A / 32V /100% * Includes Mounting

* Overall Length without Mounting Brackets, 21.06” (535mm)

14.6” x 17.2” x 27.6”*

(371 x 437 x 701*)mm

Brackets

POWER WAVE F355i INPUT CURRENT

Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs

Input 50/60 Hz Output Recommended

Voltage

380 400 415

Phases

3 3 3

300Amps @

32Volts(100%)

23 22 22

350Amps @

34Volts(60%)

28 27 26

Line Cord

10mm

Fuse size

40A 40A 40A

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Select The output cable size based upon the following chart.* Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:

DUTY CYCLE

100%

60%

CURRENT

300 350

LENGTH UP 200FT.(61m)

2/0 2/0

*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.

200-250 FT. (61-76m)

2/0 2/0

POWER WAVE F355i (CE)

Page 11

A-2

POWER WAVE F355i

GREEN/YELLOW BLUE

BLACK

BROWN

SAFETY PRECAUTIONS

INSTALLATION

A-2

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power off at the disconnect switch before attempting to connect or disconnect input power lines, output cables or con-

trol cables

• Only qualified personnel should perform this installation.

• Connect the green lead of the power cord to

ground per National Electrical Code.

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

SELECT SUITABLE LOCATION

The Invertec POWER WAVE F355i 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.

• Dirt and dust that can be drawn into the machine should be kept to a minimum. 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.

CAUTION

• Incorrect connection may result in equipment damage.

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

POWER CORD CONNECTION

A 7ft. (2m) power cord is provided and wired into the machine. Follow the power cord connection instructions.

Three Phase Input

Connect green lead to ground per National Electric Code. Connect black, red and white leads to power.

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

CAUTION

Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.

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

STACKING

POWER WAVE F355i can not

TILTING

Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.

INPUT AND GROUNDING CONNECTIONS

• Only a qualified electrician should connect the Invertec POWER WAVE F355i. Installation should be made in accordance with the appropriate National Electrical Code.

be stacked.

POWER WAVE F355i (CE)

Page 12

A-3

INSTALLATION

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Connect a work lead of sufficient size and length between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. Avoid excessive lengths and do not coil excess cable.

CAUTION

A-3

When operating with electrode polarity negative the "Electrode Sense Polarity" DIP switch must be set to the "Negative" position on the Wire Drive Feed Head PC Board. The default setting of the switch is positive electrode polarity. Set the Negative Polarity switch on Wire Feed Head PC board as follows:

WARNING

ELECTRIC SHOCK can kill

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

When using an inverter type power source like the Power Waves, use the largest welding (electrode and work) cables that are practical. At least 2/0 copper wire - even if the average output current would not normally require it. When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.

-----------------------------------------------------------------------Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire feeder and the positive (+) output Twist-Mate terminal on the power source. Connect the other end of the electrode cable to the wire feeder at it’s proper connection point. Be sure the connection makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the output cable connections section. Connect a work lead from the negative (-) power source output Twist-Mate terminal to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the Instruction Manuals.

CAUTION

Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance.

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

NEGATIVE ELECTRODE POLARITY

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 (-) Twist-Mate terminal, and work cable to the positive (+) Twist-Mate terminal.

• Do not touch electrically hot parts.

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

1. Turn off power to the power source at the disconnect switch.

2. Remove the front cover from the power source.

3. The feed head PC board is on the left side of the power source. Locate the 8-position DIP switch and look for switch 7 of the DIP switch.(See Figure A.1)

4. Using a pencil or other small object, slide the switch to the OFF position for positive electrode polarity. Conversely, slide the switch to the ON position for negative electrode polarity.

5. Replace the cover and screws. The PC board will“read” the switch at power up, and configure the work voltage sense lead appropriately.

VOLTAGE SENSING

The best arc performance occurs when the PowerWaves have accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramatic effect on performance. Sense Lead Kits (K940-10, -25 or -50) are available for this purpose.

CAUTION

If the voltage sensing is enabled but the sense leads are missing, improperly connected, or if the electrode polarity switch is improperly configured, extremely high welding outputs may occur.

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

The ELECTRODE sense lead (67) is built into the control cable, and is automatically enabled for all semi-automatic processes. The WORK sense lead (21) connects to the Power Wave at the four pin connector. By default the WORK voltage is monitored at the output stud in the POWER WAVE F355i (CE). For more information on the WORK sense lead (21), see"Work Voltage Sensing” in the following paragraph.

POWER WAVE F355i (CE)

Page 13

A-4

Enable the voltage sense leads as follows:

TABLE A.1

Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 lead

GMAW 67 lead required 21 lead optional GMAW-P FCAW 67 lead required 21 lead optional GTAW GMAW

SAW 67 lead required 21 lead optional

CAC-C

67 lead required 21 lead optional

Voltage sense at studs Voltage sense at studs Voltage sense at studs Voltage sense at studs

Voltage sense at studs Voltage sense at studs

INSTALLATION

A-4

5. Replace the wrap around and screws. The PC board will “read” the switch at power up, and configure the work voltage sense lead appropriately.

ELECTRODE VOLTAGE SENSING

Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder is present.

* The electrode voltage 67 sense lead is integral to the

control cable to the wire feeder.

Work Voltage Sensing

The standard POWER WAVE F355i (CE)’s default is to the work stud (work sense lead disabled).

For processes requiring work voltage sensing, connect the (21) work voltage sense lead (K940) from the Power Wave work sense lead receptacle to the work piece. Attach the sense lead to the work piece as close to the weld as practical, but not in the return current path. Enable the work voltage sensing in the Power Wave as follows:

WARNING

ELECTRIC SHOCK can kill

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

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

CAUTION

Important: The electrode polarity must be configured on the feed head PC board. Failure to do so may result in extremely high welding outputs.

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

POWER WAVE / POWER FEED WIRE FEEDER INTERCONNECTIONS

(See Section F-2 for Connection Diagram) Connect the control cable between the power source and wire feeder. The wire feeder connection on the POWER WAVE F355i (CE) is the 14-pin connector located on the left side of the machine. The control cable is keyed and polarized to prevent improper connection.

CONTROL CABLE SPECIFICATIONS

It is recommended that genuine Lincoln control cables be used at all times. Lincoln cables are specifically designed for the communication and power needs of the Power Wave / Power Feed system.

CAUTION

1. Turn off power to the power source at the dis-

connect switch.

2. Remove the wrap around cover from the power source.

3. The control board is on the center assembly facing the case front. Locate the 8-position DIP switch and look for switch 8 of the DIP switch

4. Using a pencil or other small object, slide the switch to the OFF position if the work sense lead is NOT connected. Conversely, slide the switch to the ON position if the work sense lead is present.

(See Figure A.1)

POWER WAVE F355i (CE)

The use of non-standard cables, especially in lengths greater than 25 ft.(7.6m), can lead to communi-cation problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).

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

HIGH SPEED GEAR BOX

Changing the ratio requires a gear change and a PC board switch change. The Power Feed Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder. To change Gear ratio see Power Feed 10/R Instruction Manual.

Page 14

A-5

INSTALLATION

A-5

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

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

1. Set the High/Low switch code on Feed Head PC board as follows:

2. Turn off power to the power source at the dis-

connect switch.

3. Remove the front cover from the power source.

4. The wire feed head board is on the left side of the power source. Locate the 8-position DIP switch and look for position 8 of the DIP switch.

5. Using a pencil or other small object, slide the switch to the OFF position, when the low speed gear is installed. Conversely, slide the switch to the ON position when the high speed gear is installed.

6. Replace the cover and screws. The PC board will “read” the switch at power up, automatically adjusting all control parameters for the speed range selected.

(See Figure A.1)

switch 8 work sense lead

off work sense lead not connected* on work sense lead connected

Feed Head Board DIP Switch:

switch 1 = Object Instance LSB (see table 1) switch 2 = Object Instance MSB (see table 1) switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = negative polarity switch

switch 7 electrode polarity

off positive * on negative

switch 8 = high speed gear

switch 8 wire drive gear

off low speed gear * on high speed gear

TABLE 1 Object Instance switch 2 switch 1 Instance

off off 0 * off on 1 on off 2 on on 3

DIP Switch Settings and Locations

(See Figure A.1) DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches:

WARNING

• Turn off power at the disconnect switch.

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

• Remove the top four screws securing the front access panel.

• Adjust the DIP switches as necessary.

• Replace the panel and screws, and restore power.

Control Board DIP Switch:

switch 1 = Object Instance LSB 1 (see table 1) switch 2 = Object Instance MSB 2 (see table 1) switch 3 = Equipment Group 1 Select switch 4 = Equipment Group 2 Select switch 5 = Equipment Group 3 Select switch 6 = Equipment Group 4 Select switch 7 = reserved for future use switch 8 = work sense lead 1 LEAST SIGNIFICANT BIT 2 MOST SIGNIFICANT BIT

*Factory Setting

FEED HEAD BOARD DIP SWITCH

65478

O N

LOCATION OF DIP SWITCHES IN MACHINE

FIGURE A.1

O N

1 2

POWER WAVE F355i

5 6

O N

1 23

456

CONTROL BOARD DIP SWITCH

O N

12345678

POWER WAVE F355i (CE)

Page 15

A-6

Connect All Work Sense Leads at the

End of

the

Joint

Connect All Welding Work Leads at the Beginning of the Joint

Travel

Direction

POWER WAVE F355i

INSTALLATION

A-6

WELDING WITH MULTIPLE POWER WAVES

CAUTION

Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified.

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

Each power source requires a work lead from the work stud to the welding fixture. Do not combine all of the work leads into one lead. The welding travel directions should be in the direction moving away from the work lead as shown below. Connect all of the work sense leads from each power source to the work piece at the end of the weld. (See Figure A.2)

For the best results when pulse welding, set the wire size and wire feed speed the same for all the Power Waves. When these parameters are identical, the pulsing frequency will be the same, helping to stabilize the arcs.

Every welding gun requires a separate shielding gas regulator for proper flow rate and shielding gas coverage.

Do not attempt to supply shielding gas for two or more guns from only one regulator.

If an anti-spatter system is in use then each gun must have its own anti-spatter system.

FIGURE A.2

TWO POWER WAVES

I / O RECEPTACLE SPECIFICATIONS

14-Pin Robotic Wire Feeder Connector

Pin Lead Function

A 539 Motor + B 541 Motor C 521 Solenoid + D 522 Solenoid common E 845 Tach 2A Differential Signal F 847 Single Tach input G 841 +15V Tach Supply H 844 Tach common I Open Reserved for future use J GND Shielding drain K 842 Tach 1A Differential Signal L 843 Tach 1B Differential Signal M 846 Tach 2B Differential Signal N 67 Electrode Sense (67)

VOLTAGE SENSE RECEPTACLE

PIN LEAD# FUNCTION

3 21 Work Voltage Sense 1 67 Electrode Voltage Sense

RS232 RECEPTACLE

PIN LEAD# FUNCTION

2 253 RS232 Receive 3 254 RS232 Transmit 4 # Pin5 5 # Pin4 6 # # Pin20

20 # # Pin6

7 251 RS232 Common

WIRE FEEDER RECEPTACLE*

PIN LEAD# FUNCTION

A 153 Communiction Bus L B 154 Communiction Bus H C 67 Electrode Voltage Sense D 52 Ovdc E 51 +40vdc +

* Not on Codes 10997

or below.

POWER WAVE F355i (CE)

Page 16

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several sec-

onds after the welding ceases.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

GENERAL DESCRIPTION

The Power Wave Robotic power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, constant power, pulse on pulse and pulse welding modes.

The Power Wave power source is designed to be used with the Robotic family of Power Feed wire feeders, operating as a system. Each component in the system has special circuitry to "talk with" the other system components, so each component (power source, wire feeder Robotic Controller knows what the other is doing at all times. These components communicate with Arc Link.

The POWER WAVE F355i (CE) is a high performance, digitally controlled inverter welding power source capable of complex, high-speed waveform control. Properly equipped, it can support the GMAW, GMAW-P and FCAW processes. It carries an output rating of 350 Amps, 34 Volts at 60% duty cycle and 300 Amps, 32 volts at 100% duty cycle.

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

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

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

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

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning of this manual.

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The POWER WAVE F355i (CE) can be set up in a number of configurations, some requiring optional equipment or welding programs. Each machine is factory preprogrammed with multiple welding procedures, typically including GMAW, GMAW-P and FCAW for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.

• The POWER WAVE F355i (CE) is recommended for Robotic welding with the Fanuc R-J3i.

• This POWER WAVE F355i (CE) is not recommended for processes other than those listed.

REQUIRED EQUIPMENT

Any Arc Link compatible semi-automatic wire feeding equipment. Specifically, the Power Feed 10 Robotic Wire drive.

POWER WAVE F355i (CE)

Page 17

B-2

OPERATION

B-2

LIMITATIONS

• Only Arc Link compatible Power Feed automatic wire feeders and users interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders cannot be used.

• POWER WAVE F355i (CE) Output Limitations

The POWER WAVE F355i (CE) will support maximum average output current of 350 Amps @ 60% duty cycle.

DUTY CYCLE AND TIME PERIOD

The duty cycle is based upon a ten minute period. A 60% duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period.

CONNECTOR STATUS LIGHTS(Per Fig B.1)

1. STATUS LIGHT: A two color light that indicates

system errors. Normal operation is a steady green

light. Error conditions are indicated, per Table B.1. NOTE: The POWER WAVE F355i (CE) status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

2. HIGH TEMPERATURE LIGHT (thermal overload): A yellow light that comes on when an over temperature situation occurs. Output is disabled and the fan continues to run, until the machine cools down. When cool, the light goes out and output is enabled.

3. CB1 WIRE FEEDER CIRCUIT BREAKER:

Protects 40 volt DC wire feeder power supply.

Figure B.1

Light

Condition

Steady Green

Blinking Green

Alternating Green and Red

TABLE B.1

Meaning

System OK. Power source communicating normally with wire feeder and its components.

Occurs during a reset, and indicates the POWER WAVE F355i (CE) is mapping (identifying) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation

Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the POWER WAVE F355i (CE). Read the error

code 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.

To clear the error, turn power source off, and back on to reset. See Troubleshooting Section.

CASE FRONT LAYOUT

POWER WAVE F355i (CE)

4. LEAD CONNECTOR (SENSE LEAD)

5. DIAGNOSTIC CONNECTOR (RS-232)

6. WIRE FEEDER RECEPTACLE (14-PIN)

7. NEGATIVE TWIST- MATE TERMINAL

8. POSITIVE TWIST- MATE TERMINAL

9. WIRE FEEDER RECEPTACLE (5 PIN) NOT ON CODES 10997 OR BELOW.

Steady Red

Blinking Red

Non recoverable hardware fault. Generally indicates nothing is connected to the POWER WAVE F355i (CE) wire feeder receptacle. See Trouble Shooting Section.

Not applicable.

POWER WAVE F355i (CE)

Page 18

B-3

OPERATION

B-3

NOMINAL PROCEDURES

The Power Wave is designed to operate with 3/4" electrode stick-out for CV and Pulse processes.

FRINGE PROCEDURES

Excessively short or long electrode stick-outs may function only on a limited basis, if at all.

MAKING A WELD

WARNING

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

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

First, consider the desired welding process and the part to be welded. Choose an electrode material, diameter, shielding gas and process (GMAW, GMAWP, etc.)

Second, find the program in the welding software that best matches the desired welding process. The standard software shipped with the Power Waves encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales representative.

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.

• VOLTS / TRIM:

In constant voltage modes (pulse on pulse GMAW, standard CV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting to adjust the arc length. It is adjustable from 0.500 to 1.500. A Trim setting of 1.000 is a good starting point for most conditions.

• WELDING MODE

Selecting a welding mode determines the output characteristics of the Power Wave power source. For a more complete description of the welding modes available in the Power Wave and for a complete set of weld modes programmed into the Power Wave at the factory, refer to the weld mode print included with the Power Wave.

• ARC CONTROL

Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from "soft" to "harsh" in all weld modes. It is adjustable from -10.0 to +10.0, with a nominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels). See the Welding Mode descriptions, below, for detailed explanations of how the Arc Control affects each mode.

To make a weld, the Power Wave needs to know the desired welding parameters. The Power Feed (PF) family of feeders communicate settings to the Power Wave through control cable connection. Arc length, wire feed speed, arc control, etc. are all communicated digitally via the control cable.

• WFS / AMPS: In synergic welding modes (pulse on pulse GMAW, pulse GMAW) WFS (wire feed speed) is the dominant control parameter, controlling all other variables. The user adjusts WFS according to factors such as weld size, penetration requirements, heat input, etc. The Power Wave then uses the WFS setting to adjust its output characteristics (output voltage, output current) according to pre-programmed settings contained in the Power Wave.

POWER WAVE F355i (CE)

Page 19

B-4 CONSTANT VOLTAGE WELDING

Non Synergic CV:

This type of CV mode behaves more like a conventional CV power source. Voltage and WFS are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.

OPERATION

The Power Wave utilizes "adaptive control" to compensate for changes in electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The Power Wave waveforms are optimized for a

0.75" (19mm) stick-out. The adaptive behavior supports a range of stickouts from 0.50" (13mm) to 1.25" (32mm). At very low or high wire feed speeds, the adaptive range may be less due to reaching physical limitations of the welding

All CV Modes:

process.

Arc Control, often referred to as wave control, adjusts the inductance of the wave shape. The wave control adjustment is similar to the "pinch" function in that it is inversely proportional to inductance. Therefore, increasing wave control greater than 0.0 results in a harsher, colder arc while decreasing the wave control to less than 0.0 provides a softer, hotter arc. (See Figure B.2)

Arc Control, often referred to as wave control, in pulse programs usually adjusts the focus or shape of the arc. Wave control values greater than 0.0 increase the pulse frequency while decreasing the background current, resulting in a tight, stiff arc best for high speed sheet metal welding. Wave control values less than 0.0 decrease the pulse frequency while increasing the background current, for a soft arc good for out-of-position welding.See Figure B.3)

FIGURE B.2

CURRENT WAVE FORM (CV)

B-4

FIGURE B.3

CURRENT WAVE FORM (PULSE)

Current

Time

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.

Current

All pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave will automatically recalculate the waveform parameters to maintain similar arc properties.

Time

PULSE-ON-PULSE™ (GMAW-PP)

Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/4" thick) aluminum. It gives weld beads with very consistent uniform ripple.

In Pulse on Pulse modes, two distinct pulse types are used, instead of the single pulse type normally used in GMAW-P. A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc. Such pulses are shown in Figure B.4. After a number "N" of such pulses, depending on the wire feed speed used, an identical number "N" of low energy pulses are performed. These low energy pulses, shown in Figure B.4, do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low.

FIGURE B.4

"N" PULSES "N" PULSES

PEAK AMPS

BACKGROUND AMPS

HIGH HEAT PULSES

TIME

LOW HEAT PULSES

POWER WAVE F355i (CE)

Page 20

B-5

OPERATION

The Peak Current, Background Current, and Frequency are identical for the high energy and low energy pulses. In addition to cooling the weld down, the major effect of the low energy pulses is that they form a weld ripple. Since they occur at very regular time intervals, the weld bead obtained is very uniform with a very consistent ripple pattern. In fact, the bead has its best appearance if no oscillation of the welding gun ("whipping") is used.(See Figure B.5)

B-5

Power Mode™ is a method of high speed regulation of the output power whenever an arc is established. It provides a fast response to changes in the arc. The higher the Power Mode Setting, the longer the arc. If a welding procedure is not established, the best way to determine the Power Mode Setting is by experimentation until the desired output result is established.

In the Power Mode two variables need to be set:

FIGURE B.5

When Arc Control is used in the Pulse on Pulse modes, it does the same things it does in the other pulsed modes: decreasing the Arc Control decreases the droplet transfer and weld deposition rate. Increasing the Arc Control increases the droplet transfer and weld deposition rate. Since Arc Control varies weld droplet transfer rate, the Arc Control can be used to vary the ripple spacing in the weld bead.

POWER MODE™

The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For aluminum welding, it provides excellent control and the ability to maintain constant arc length. This results in improved welding performance in two primary types of applications.

• Wire Feed Speed

• Power Mode Trim

Setting up a Power Mode procedure is similar to setting a CV MIG procedure. Select a shielding gas appropriate for a short arc process.

• For steel, use 75/25 Ar/CO2shield gas.

• For stainless, select a Helium blend Tri-Mix.

• For aluminum, use 100% Ar.

Start by setting the wire feed speed based upon material thickness and appropriate travel speed. Then adjust the Volts/Trim knob as follows:

• For steel, listen for the traditional “frying egg”

sound of a good short-arc MIG procedure to know you have the process set correctly.

• For aluminum, simply adjust the Volts/Trim knob

until the desired arc length is obtained.

Note the Volts/Trim display is simply a relative number and DOES NOT correspond to voltage.

• Short Arc MIG at low procedure settings.

• Aluminum MIG welding.

Some procedure recommendations appear in Table B.1.

Recommended Welding Procedures for Power Mode - Table B.1

MATERIAL

WIRE

WIRE SIZE

GAS

MATERIAL THICKNESS

COMMENTS

Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel

E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L

0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035

100% Ar. 100% Ar. 100% CO

22 ga.

20 ga. 120 / 1.0 120 / 1.0 100 / 0.7 100 /1.0 80 / 1.5 50 / 0.5

18 ga. 140 / 1.7 140 / 1.5 110 / 1.5 110 / 1.5 100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0

16 ga. 190 / 2.0 190 / 2.0 125 / 2.0 125 / 2.0 125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7

14 ga. 400 / 2.0 400 / 2.5 260 / 3.0 260 / 3.0 160 / 2.3 160 / 2.3 160 / 3.8 160 / 3.5 210 / 3.0 190 / 3.5

12 ga. 330 / 5.0 330 / 4.5 230 / 3.5 230 / 3.5 200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0

10 ga. 500 / 7.0 500 / 7.0 300 / 6.0 300 / 6.0 240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0

3/16 570 / 9.0 600 / 7.8 400 / 7.5 400 / 7.0

WFS / POWER MODE SETTING

1/4 700 / 9.1 700 / 8.5

Not

Recommended

below 400

WFS

Not

Recommended

below 400

WFS

Not Recommended

75/25 Ar/CO2100% CO275/25 Ar/CO2100% CO275/25 Ar/CO2Tri-mix Tri-mix

100 / 0.8

Not Recommended

90 / 1.0

POWER WAVE F355i (CE)

Page 21

C-1

ACCESSORIES

OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED

K940-[ ] Work Voltage Sense Lead Kit (Sense Lead Kits,10 Ft.,25 Ft.,50 Ft., or 75 Ft. lengths) K1796-Coaxial Welding CableK2176-1 Twist-mate to Lug Adapters

Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE

COMPATIBLE LINCOLN EQUIPMENT

Power Feed 10 Robotic Wire Drive K1785-[ ] 14 Pin to 14 Pin Fanuc

(Control Cable,12 Ft.,16 Ft. or 25 Ft. lengths)

(Requires Adapter K2176-1)

C-1

COMMUNICATION INTERFACE

K2436-1 (Not on Codes 10997 or below)

POWER WAVE F355i (CE)

Page 22

D-1

CAPACITOR TERMINALS

RESISTOR

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

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

EXPLODING PARTS can cause injury.

•

Failed parts can explode or cause other parts to explode when power is applied.

•

Always wear a face shield and long

sleeves when servicing.

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

See additional warning information throughout this Operator’s Manual

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

CAPACITOR DISCHARGE PROCEDURE

1. Obtain a power resistor (25 ohms, 25 watts).

2. Hold resistor body with electrically insulated glove. DO

NOT TOUCH TERMINALS. Connect the resistor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all four capacitors.

PERIODIC MAINTENANCE

Calibration of the POWER WAVE F355i (CE) 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 speaking the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility.

The calibration procedure itself requires the use of a resistance load, 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. Detailed instructions are available with the utility.

3. Use a DC voltmeter to check that voltage is not present across the terminals on all four capacitors.

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing out the machine, using a low pressure airstream, to remove accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in the

machine.

POWER WAVE F355i (CE)

Page 23

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

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.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE F355i (CE)

Page 24

E-2

TROUBLESHOOTING

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user interface, and feed head) has a status light, and when a problem occurs it is important to note the condition of each.

Included in this section is information about the power source Status LED, and some basic troubleshooting charts for both machine and weld performance.

The STATUS LIGHT is a two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the following chart.

NOTE: The POWER WAVE F355i (CE) status light will flash green, and sometimes red and green, for up to one minute when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

E-2

Light

Condition

Steady Green

Blinking Green

Alternating Green and Red

Meaning

System OK. Power source communicating normally with wire feeder and its components.

Non-recoverable system fault. If the PS Status light is flashing any combination of red and green, errors are present in the POWER WAVE F355i (CE). Read the error

code before the machine is turned off.

To clear the error, turn power source off, and back on to reset. See Troubleshooting Section.

Steady Red

Blinking Red

Non recoverable hardware fault. Generally indicates nothing is connected to the POWER WAVE F355i (CE) wire feeder receptacle. See Trouble Shooting Section.

Not applicable.

POWER WAVE F355i (CE)

Page 25

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWER WAVE

The following is a list of possible error codes that the POWER WAVE F355i (CE) can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.

Error Code #

11 CAN communication bus off. 12 User Interface time out error.

21 Unprogrammed Weld Mode. 22 Empty Weld Table. 23 Weld Table checksum error.

31 Primary overcurrent error. 32 Capacitor "A" under voltage

33 Capacitor "B" under voltage

34 Capacitor "A" over voltage

35 Capacitor "B" over voltage

Indication

Probably due to excessive number of communication errors. UI is no longer responding to the Power Source. The most likely cause is a fault/bad connection in the communication leads or control cable.

Contact the Service Department for instructions on reloading the Welding Software. Contact the Service Department for instructions on reloading the Welding Software. Contact the Service Department for instructions on reloading the Welding Software. Excessive Primary current present. May be related to a short in the main transformer or output rectifier. Low voltage on the main capacitors. May be caused by improper input configuration. When accompanied by an overvoltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine. Excess voltage on the main capacitors. May be caused by improper input configuration.

When accompanied by an under voltage error on the same side, it indicates no capacitor voltage present on that side, and is usually the result of an open or short in the primary side of the machine.

36 Thermal error

37 Soft start error 41 Secondary overcurrent error

43 Capacitor delta error

Other

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

Capacitor precharge failed. Usually accompanied by codes 32-35. The secondary (weld) current limit has been exceeded. When this occurs the machine output will phase back to 100 amps, typically resulting in a condition referred to as "noodle welding"

NOTE: The secondary limit is 570 amps for the standard stud, and 325 amps for all single phase operation.

The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors 32-35.

Error codes that contain three or four digits are defined as fatal errors. These codes generally indicate internal errors on the Control Board. If cycling the input power on the machine does not clear the error, try reloading the operating system. If this fails, replace the control board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE F355i (CE)

Page 26

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

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

Input fuses keep blowing, or input breaker keeps tripping.

Machine will not power up (no lights, no fan, etc.)

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.

1. Make certain that fuses or breakers are properly sized. See Installation section of this manual for recommended fuse and breaker sizes.

2. Welding procedure is drawing too much output current, or duty cycle is too high. Reduce output current, duty cycle, or both.

3. There is internal damage to the power source. Contact an authorized Lincoln Electric Service facility.

1. Make certain that the Power to the POWER WAVE F355i (CE) is on.

2. Circuit Breaker CB1 (on Case Front) may have opened. Reset. An over load on the 40V Wire Feeder supply may cause this to trip.

3. Circuit breaker CB3 (in reconnect area) may have opened. Reset.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized Lincoln Electric Field Service Facility for technical assistance.

POWER WAVE F355i (CE)

Page 27

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Thermal LED is lit.

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

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Fan thermostat has opened. Check for proper fan operation. (Fan should run whenever output power is on.) Check for material blocking intake or exhaust louvers, or for excessive dirt clogging cooling channels in machine. Blow air in rear louvers to remove dirt around the fan.

2. Secondary rectifier or Choke thermostat has opened. After machine has cooled, reduce load, duty cycle, or both. Check for material blocking intake or exhaust louvers.

3. DC Bus PC board thermostat has opened check for excessive load on 40VDC supply.

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

2. If the Thermal LED is also lit, see “Yellow Thermal LED is Lit” section.

3. Primary current limit has been exceeded. Possible short in output circuit. Turn machine off. Remove all loads from the output of the machine. Turn back on. If condition persists, turn power off, and contact an authorized Lincoln Electric Field Service facility.

. This problem will normally be

accompanied by an error code. Error codes are displayed as a series of red and green flashes by the status light. See "Troubleshooting the Power Wave / Power Feed System Using the Status LED" section of this text.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

CAUTION

POWER WAVE F355i (CE)

Page 28

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-6

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Machine often “noodle welds” (output is limited to approximately 100 amps) when running a particular procedure, especially a procedure with high WFS.

Machine won’t produce full output.

For no apparent reason, the welding characteristics have changed.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1.Secondary current limit has been

exceeded, and the machine has phased back to protect itself.

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

1. Input voltage may be too low, limiting output capability of the power source. Make certain that the input voltage is proper, according to the Rating Plate located on the rear of the machine.

2. Secondary current or voltage not be properly calibrated. Check values displayed on the Power Feed 10/11 verses readings on an external meter.

1. Check for proper Wire Feed Speed setting. In CV MIG and FCAW modes, check for proper Voltage setting. In the MIG/MAG pulse modes, check the Trim setting. These controls are on the wire feeder.

2. Check for proper shielding gas mix and flow.

3. Check for loose or faulty weld cables and cable connections.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustments have been checked and the problem persists,

contact your local Lincoln Authorized Field Service Facility.

The Power Wave is triggered to weld, but there is no output.

1. Check for fault signals from the I/O connector. Possible faults are lack of water flow/ water flow turned off.

CAUTION

POWER WAVE F355i (CE)

Page 29

E-7

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-7

General degradation of the weld performance

Excessively long and erratic arc.

The feeder will not cold inch wire.

1.Check for feeding problems, bad

connections, excessive loops in cabling, etc.

2. Verify weld mode is correct for

processes.

3. The power source may require

calibration.

4. Check the actual current dis-

played on the Power Feed 10 vs. actual current measured via external meter.

5. Check the actual voltage dis-

played on the Power Feed 10 vs. actual voltage measured via external meter.

6. Check the actual WFS displayed

on the Power Feed 10 vs. actual WFS measured via external meter.

1. Check for proper configuration

and implementation of voltage sensing circuits.

1. Check for fault signals from the

I/O connector. Possible faults are lack of water flow/ water cooler turned off.

If all recommended possible areas of misadjustments have been checked and the problem persists, contact

your local Lincoln Authorized Field Service Facility.

Arc loss fault on robot.

1. Possibly caused by wire feeding

problem.

2. Problem - Conduit leading to the

wire feeder has bends or twists, which can reduce the wire feed speed. Solution - Remove bends and twists from conduit.

3. Problem – Conduit leading up to

the wire feeder from the wire reel is too long. Solution – Use a shorter length of conduit.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE F355i (CE)

Page 30

F-1

502

40VDC BUS

BOARD

xxxxxxx

504

J46

J47

231

65C

66C

477

475

1104

153A

154A

1103

1010

10201002

1001

903

RIGHT SIDE OF MACHINE

WIRING DIAGRAM POWER WAVE F355i FOR CODE 10997

610

616

608

605

1020

1001

1002

1010

208

J21

C1,C3

3200/300

206 203

205

209

J20

SWITCH

716

715

602

611

609

612

615

607

N.F.

N.D.

A1B1C1

(U) B

INPUT

(G/Y)

(N)W

(B) R

N.C.

DIAGRAMS

F-1

G4146

J8,

J20,J21,

J22, J41,

J2,J5,J11,

J1,J6,J7,

N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR

J10A,

J10B

J4, J43

J47, J84

J9, J42, J83

J82

J46, J81,

J52, J86

J85, J87

BASE

CASE

FAN

TOP CENTER

550-575V OPERATION. (PW F355i CE HAS 380-415 V CONNECTION)

N.C. LEADS A1, B1, C1 ARE PART OF THE INPUT POWER LINE FILTER & IT IS PRESENT ONLY ON PW F355i CE.

FRONT

SHROUD

PANEL

N.D. TERMINAL BLOCK PRESENT ONLY ON PW F355i CE.

PROTECTIVE BONDING CIRCUIT

N.E. ON PW F355i CE, MOV's ARE IN THE INPUT POWER LINE FILTER.

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

ELECTRI CAL SYMBOLS PER E1537

N.F. TOROID ON GROUND LEAD PRESENT ONLY ON PW F355i CE.

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

11 10

J87

13 12

RED

WHITE

BLACK

GREEN

131415

605

610

615

503

MAIN

TRANSFORMER

PW F355i CE

CB2

2.5A

32A

( 380-575VAC POSITION )

J86

11 10

J85

13 12

253

251

101112

503

502

611

612

609

602

N.E.

TP3

TP1

209

INPUT

BRIDGE

380-

415V

CB3

N.B.

847

GREEN

67B

RECEPTACLE

WIRE FEEDER

WHITE

BLACK

251

254

253

254

407

401A

408

402

389

403A

410

411

1112

405

412

406

OUTPUT

RECTIFIER

TP2

207

440-

460V

550-

575V

TO ROBOTIC CONTROLLER

FEED HEAD P.C. BOARD

J83

J82

J81

154A

153A

880

886

J84

521

541

539

BLACK

886

880

847

522

J11

J10BJ10A

CONTROL

BOARD

874

901

806

801

802

804

715

716

2 B

67A

504

xxxxxxx

201

204

J22

2 W

PRI-IN

201

PRI-

205

505

207

C2,C4

3200/300

202

FAN

P22 (TO SWITCHBOARD)

1 B

1 W

607

608

616

505

506

xxxxxxx

CHOKE

PRI-IN

PRI-

204

208

FAN

PW F355i

P22

J22A

632

FAN1

31B

31A

P22A (TO SWITCHBOARD)

FAN

RECEPTACLE

VOLTAGE SENSE

67B

67A

2 B

BLACK

LED

YELLOW

THERMAL

NUB

H6 H5 H4

H3 H2 H1

AUXILIARY

TRANSFORMER

R = RED

G = GREEN

B = BLACK

COLOR CODE:

522

RED

BLACK

GND-A

2 W

42V

115V

521

BER

SNB

COM 1

COM 2

541

539

STATUS

1 B

1104

1103

65C

66C

LED

RED/GREEN

1 W

403A

401

403

402

401

406

403

405

477

475

408

1 4

411

407

412

2400/80

65B

66B

CONTROL

RECTIFIER

15A

CB1

COM1A

J52

W = WHITE

B 1 0 9

903B

903

POWER

J43

J41

J42

LEGEND

ALL MACHINES

OPTION

N = BROWN

U = BLUE

Y = YELLOW

COMPONENT OUTLINE

FRONT VIEW OF MACHINE

901

LEFT SIDE OF MACHINE

J90

CURRENT

TRANSDUCER

NOTES:

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

POWER WAVE F355i (CE)

Page 31

F-2

DIAGRAMS

F-2

67C

67B

51A

52A

ARCLINK

RECEPTACLE

TO ROBOTIC CONTROLLER

154A

154B

153A

153B

FEED HEAD P.C. BOARD

502

40VDC BUS

BOARD

xxxxxxx

504

J46

J47

231

65C

66C

477

475

1104

153B

154B

1103

1010

10201002

1001

903

886

J11

J10BJ10A

CONTROL

BOARD

874

901

806

801

802

804

2 B

67A

PRI-IN

RIGHT SIDE OF MACHINE

1010

208

C1,C3

3200/300

206 203

J20

SWITCH

607

205

716

715

615

WIRING DIAGRAM POWER WAVE F355i FOR CODE 11252

N.F.

N.D.

A1B1C1

(G/Y)

(N)W

(U) B

(B) R

INPUT

201

PRI-OU

205

505

504

610

616

608

605

1020

1001

1002

xxxxxxx

201

207

J21

C2,C4

3200/300

202

204

209

J22

602

611

609

612

N.C.

A.02

G5375

J8,

J20,J21,

J22, J41,

J2,J5,J11,

J1,J6,J7,

N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR

J10A,

J10B

J4, J43

J47, J84

J9, J42, J83

J82

J46, J81,

J52, J86

J85, J87

BASE

CASE

FRONT

FAN

SHROUD

TOP CENTER

PANEL

550-575V OPERATION. (PW F355i CE HAS 380-415 V CONNECTION)

PROTECTIVE BONDING CIRCUIT

N.C. LEADS A1, B1, C1 ARE PART OF THE INPUT POWER LINE FILTER & IT IS PRESENT ONLY ON PW F355i CE.

CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF BOARD)

ELECTRIC AL SYMBOLS PER E1537

N.D. TERMINAL BLOCK PRESENT ONLY ON PW F355i CE.

N.E. ON PW F355i CE, MOV's ARE IN THE INPUT POWER LINE FILTER.

N.F. TOROID ON GROUND LEAD PRESENT ONLY ON PW F355i CE.

WHITE

389

OUTPUT

RECTIFIER

RECEPTACLE

VOLTAGE SENSE

67C

BLACK

YELLOW

THERMAL

2 B

H6 H5 H4

H2 H1

AUXILIARY

522

BLACK

539

GND-A

STATUS

LED

1 B

2 W

1104

1103

NUB

BER

SNB

COM 1

42V

COM 2

115V

TRANSFORMER

541

RED/GREEN

401

65C

66C

847

GREEN

BLACK

67A

407

401A

408

402

403A

410

411

405

412

406

J52

RED

LED

405

COM1A

B = BLACK

COLOR CODE:

521

1 W

403

402

401

406

403

477

475

408

1 4

411

407

412

2400/80

65B

66B

15A

CB1

403A

G = GREEN

10 9

CONTROL

R = RED

RECTIFIER

U = BLUE

W = WHITE

B 1 0 9

903B

903

POWER

J43

J41

J42

N = BROWN

Y = YELLOW

LEGEND

ALL MACHINES

FRONT VIEW OF MACHINE

901

J90

CURRENT

TRANSDUCER

OPTION

COMPONENT OUTLINE

LEFT SIDE OF MACHINE

NOTES:

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

11 10

J87

13 12

J86

67B

11 10

J85

BLACK

616

506

J84

RED

607

615

503

FAN

FAN1

CB2

32A

WHITE

BLACK

GREEN

131415

605

612

610

MAIN

TRANSFORMER

PW F355i CE

N.E.

2.5A

( 380-575VAC POSITION )

13 12

RECEPTACLE

WIRE FEEDER

251

254

253

254

251

1112

101112

503

502

611

609

602

TP3

TP2

TP1

207

209

INPUT

BRIDGE

380-

440-

415V

460V

CB3

550-

575V

N.B.

J83

J82

J81

154A

521

541

539

51A

52A

BLACK

153A

886

880

847

522

880

715

716

2 W

FAN

P22 (TO SWITCHBOARD)

1 B

1 W

608

505

xxxxxxx

CHOKE

PRI-IN

PRI-O

204

208

FAN

PW F355i

P22

J22A

632

FAN1

31B

31A

P22A (TO SWITCHBOARD)

FAN

POWER WAVE F355i (CE)

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

Page 32

F-3

Connection Diagram Semi-automatic "Simple System"

(Electrode Positive, CV / Pulse Configuration shown) SEE SECTION A-4, Power Wave / Power Feed Wire Feeder Interconnections

CONNECTION DIAGRAM

F-3

COMMUNICATION INTERFACE OPTIONAL (K2436-1) NOT ON CODES 10997 OR BELOW.

WORK

POWER WAVE F355i

VOLTAGE SENSE LEADS (OPTIONAL) K940

WIRE

FEEDER

CONTROL CABLE K1785

FANUC R-J3i

POWER WAVE F355i (CE)

Page 33

F-4

DIMENSION PRINT

F-4

.81

.51

M19982

25.15

27.60

3.37

.40

10.06

17.20

14.64

POWER WAVE F355i (CE)

Page 34

NOTES

POWER WAVE F355i (CE)

Page 35

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● 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.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 36

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

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

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● 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.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

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 37

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric F355I User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual