Lincoln Electric IM10007 User Manual

Operator’s Manual
®
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POWER WAVE
®
S350
For use with machines having Code Numbers:
11589
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THANK YOU FOR SELECTING
AT ALL
TIMES.
SPECIA L SI TUATIONS
Additional precautionary measures
A QUALITY PRODUCT BY LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to stay a reasonable distance away from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate (See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly toxic fumes or gases.
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SECTION A:
Diesel Engines
Gasoline Engines
WARNINGS
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 engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE­MAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
SAFETY
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring 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.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is
hot.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
FOR ENGINE POWERED EQUIPMENT.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.
2.d.5. Do not work next to welding power source.
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.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage
two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
between the
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the 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.f. Also see item 1.b.
4
cause
SAFETY
WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER MAY EXPLODE IF DAMAGED.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, 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.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety Interactive Web Guide for mobile devices
5
SAFETY
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 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
INTRODUCTION
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled 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.
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 construction of an electro­magnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons
according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equip­ment.
ASSESSMENT OF AREA
Before installing welding equipment the user shall make an assessment of potential electromagnetic 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.
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 instructio ns. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. 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 work piece 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 work piece, 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.
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
Compatibility (EMC) product standard for arc welding equipment.”
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications ...............................................................................................A-1, A-2
Safety Precautions ...............................................................................................................A-3
Location, Lifting .............................................................................................................A-3
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Input and Ground Connections .....................................................................................A-3
Machine Grounding.......................................................................................................A-3
High Frequency Protection............................................................................................A-3
Input Connection ..................................................................................................................A-4
Input Fuse and Supply Wire..........................................................................................A-4
Input Voltage Selection .................................................................................................A-4
Power Cord Replacement .............................................................................................A-4
Connection Diagram .....................................................................................................A-5
Recommended Work Cable Sizes ................................................................................A-6
Cable Inductance and its Effects on Welding................................................................A-7
Remote Sense Lead Specifications.......................................................................A-7, A-8
Voltage Sensing Considerations for Multiple Arc Systems..................................A-9, A-10
Control Cable Connections ................................................................................................A-11
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols...........................................................................................................B-1
Power-Up Sequence .....................................................................................................B-1
Duty Cycle.....................................................................................................................B-1
Product Description ..............................................................................................................B-2
Recommended Processes and Equipment ..........................................................................B-2
Equipment Limitations ..........................................................................................................B-2
Common Equipment Packages............................................................................................B-2
Design Features ...................................................................................................................B-3
Case Front Controls .............................................................................................................B-4
Case Back Controls..............................................................................................................B-4
Common Welding Procedures................................................................................B-5 thru B-7
________________________________________________________________________________
viivii
Accessories .....................................................................................................Section C
Kits, Options / Accessories....................................................................................C-1
Field Installed Options...........................................................................................C-1
Stick Operations ............................................................................................C-2, C-3
________________________________________________________________________
Maintenance........................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification.......................................................................................................D-1
________________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Using Status LED, Error Fault Codes and Input Control Board....................................E-2, E-4
Troubleshooting Guide.............................................................................E-5 thru E-8
________________________________________________________________________________
Wiring Diagram and Dimension Print ............................................................Section F
________________________________________________________________________
Parts Pages ................................................................................................................P-609 Series
_______________________________________________________________________
________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE®S350
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model
Duty Cycle
Input Voltage ± 10%
Input Amperes
(1 Phase in parenthesis)
Idle Power
A-1
Power Factor @
Rated Output
39/35/20/17/14
(NA/65***/37/32/25)
30/28/16/14/11
(56/51/29/25/20)
300 Watts Max.
(fan on)
K2823-1
40% rating
100% rating
200-208/230/380-415/
460/575 50/60 Hz
RATED OUTPUT
INPUT
VOLTAGE / PHASE /
FREQUENCY
200-208/1/50/60
230/1/50/60 460/1/50/60 575/1/50/60
200-208/3/50/60
230/3/50/60
380-415/3/50/60
460/3/50/60 575/3/50/60
*** On 230 Volt / 1 phase inputs the max. rating is at a duty cycle of 30%, except for GTAW processes.
40%***
350
Amps
31.5
Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT
VOLTAGE / PHASE/
FREQUENCY
INPUT AMPERE RAT-
ING AND DUTY CYCLE
GMAW
60%
300 Amps / 29 Volts
320
Amps
30
Volts
MAXIMUM
100%
300
Amps
29
Volts
SMAW
(mm
60%
275
Amps
31
Volts
2
)
100%
Amps
3
40%***
250 Amps / 30 Volts
325
Amps
33
Volts
CORD SIZE
AWG SIZES
GTAW-DC
40%
250
30
Volts
TIME DELAY FUSE
350
Amps
24 Volts
1
OR BREAKER
AMPERAGE
60%
325
Amps
23Volts
2
.95
100%
300
Amps
22 Volts
NOTES
200-208/1/50/60 200-208/3/50/60
230/1/50/60
230/3/50/60 380-415/1/50/60 380-415/3/50/60
460/1/50/60
460/3/50/60
575/1/50/60
575/3/50/60
1. Based on U.S. National electrical Code
2. Also called " inverse time" or "thermal / magnetic" circuit breakers; circuit breakers that have a delay in trip-
ping action that decreases as the magnitude of the current increases
3. Type SO cord or similar in 30° C ambient
4. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
60A, 100% 39A, 40% 67A, 30% 35A, 40% 38A, 40% 19A, 40% 34A, 40% 17A, 40% 27A, 40% 14A, 40%
POWER WAVE®S350
6 (13) 8 (10) 4 (16) 8 (10) 8 (10) 12 (4) 8 (10) 12 (4) 10 (6)
14 (2.5)
80 50 80 45 50 30 45 25 35 20
NOTE 4
NOTE 4
A-2
PROCESS
GMAW
GMAW-Pulse
FCAW
GTAW-DC
SMAW
PHYSICAL DIMENSIONS
MODEL
HEIGHT
INSTALLATION
WELDING PROCESS
OUTPUT RANGE (AMPERES)
5-350
WIDTH
OCV (Uo)
Mean Peak
40-70 40-70 40-70 100V
24 60
DEPTH
A-2
WEIGHT
K2823-1
20.40 in ( 518 mm)
14.00in ( 356 mm)
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20C to 40C)
IP23 155º(F) Insulation Class
* Weight does not include input cord.
IEC 60974-1
24.80in ( 630mm)
STORAGE TEMPERATURE RANGE
Environmentally Hardened: -40°F to 185°F (-40C to 85C)
85 lbs (39 kg)*
POWER WAVE®S350
A-3
INSTALLATION
A-3
SAFETY PRECAUTIONS Read this
entire installation section before you start installa-
tion.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before work­ing on the equipment.
• Do not touch electrically hot parts.
• Always connect the POWER WAVE grounding lug to a proper safety (Earth) ground.
-------------------------------------------------------------
®
S350
SELECT SUITABLE LOCATION
The POWER WAVE®S350 will operate in harsh envi­ronments. Even so, it is important that simple preven­tative measures are followed in order to assure long life and reliable operation.
LIFTING
Both handles should be used when lifting POWER WAVE S350. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the POWER WAVE
®
S350 with accessories attached to it.
®
WARNING
• Lift only with equipment of ade­quate lifting capacity.
• Be sure machine is stable when lifting.
• Do not operate machine while suspended when lifting.
FALLING
EQUIPMENT can
cause injury.
-------------------------------------------------------------
STACKING
The POWER WAVE®S350 cannot be stacked.
TILTING
Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.
• The machine must be located where there is free circulation of clean air such that air movement in the back, out the sides and bottom will not be restricted.
• Dirt and dust that can be drawn into the machine should be kept to a minimum. The use of air filters on the air intake is not recommended because nor­mal air flow may be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.
• Do not mount the POWER WAVE bustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060” (1.6mm) thick, which shall extend not less than 5.90” (150mm) beyond the equipment on all sides.
®
S350 over com-
INPUT AND GROUND CONNECTIONS
Only a qualified electrician should connect the POWER WAVE S350. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information in this manual.
®
MACHINE GROUNDING
The frame of the welder must be grounded. A ground terminal marked with a ground symbol is located next to the input power connection block.
See your local and national electrical codes for proper ground­ing methods.
HIGH FREQUENCY PROTECTION
The EMC classification of the POWER WAVE Industrial, Scientific and Medical (ISM) group 2, class A. The
®
POWER WAVE L10093 for further details).
Locate the POWER WAVE machinery. The normal operation of the POWER WAVE may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
S350 is for industrial use only. (See print
®
S350 away from radio controlled
®
S350 is
®
S350
POWER WAVE®S350
A-4
INSTALLATION
A-4
INPUT CONNECTION
WARNING
Only a qualified electrician should connect the input leads to the POWER WAVE should be made in accordance with
all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death.
-------------------------------------------------------------
A 10 ft. (3.0m) power cord is provided and wired into the machine.
For Single Phase Input
Connect green lead to ground per National Electrical Code.
Connect black and white leads to power.
Wrap red lead with tape to provide 600V insulation.
For Three Phase Input
Connect green lead to ground per National Electric Code.
®
S350. Connections
WARNING
The POWER WAVE®S350 ON/OFF switch is not intended as a service disconnect for this equipment. Only a qualified electrician should con-
®
nect the input leads to the POWER WAVE
S350. Connections should be made in accordance with all local and national electrical codes and the con­nection diagram located on the inside of the reconnect access door of the machine. Failure to do so may result in bodily injury or death.
------------------------------------------------------------------------
POWER CORD REPLACEMENT
WARNING
Only a qualified electrician should connect the input leads to the POWER WAVE should be made in accordance with all local and national electrical
codes and the connection dia­grams. Failure to do so may result in bodily injury or death.
®
S350. Connections
Connect black, red and white leads to power.
INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS
Refer to Specification Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers). Choose input and grounding wire size according to local or national electrical codes. Using input wire sizes, fuses or cir­cuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents.
INPUT VOLTAGE SELECTION
The POWER WAVE®S350 automatically adjusts to work with different input voltages. No reconnect switches settings are required.
------------------------------------------------------------------------
If the input power cord is damaged or needs to be replaced an input power connection block is located in the back of the machine with the access panel removed as shown Figure A.1.
ALWAYS CONNECT THE POWER WAVE GROUND- ING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH) GROUND.
FIGURE A.1
CONNECTION BLOCK
GROUND LUG
INPUT POWER CORD
POWER WAVE®S350
A-5
K87870
CONNECTION DIAGRAMS
INSTALLATION
SMAW (STICK) WELDING
A-5
GTAW (TIG) WELDING
A user interface is required for adjusting the TIG weld­ing settings. A Power Feed wire feeder can be used as the user interface (Figure A.2), or a S-series user inter­face (K2828-1) can be installed into the power source (Figure A.3). Refer to the connection diagrams based on the user interface that is being used. For either set­up the K2825-1 solenoid kit is recommended for con­trolling the gas. Alternate configurations are possible depending on the wire feeder that is being used. Refer to the wire feederʼs manual for alternative configura­tions.
FIGURE A.2
REGULATOR FLOWMETER
GAS HOSE
GAS SOLENOID KIT (INSIDE MACHINE) K2825-1
TIG WITH POWER FEED USER INTERFACE
Similar to TIG welding a user interface is required for adjusting the Stick welding settings. A Power Feed wire feeder can be used as the user interface, or a K2828-1 (user interface control panel) can be installed into the power source (Figure A.4). The connection diagram shown is based on the S-Series user inter­face (K2828-1). In this diagram the remote control box is optional.
GMAW (MIG) WELDING
An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.5 for the connection details.
TO REMOTE CONTROL RECEPTACLE
REGULATOR FLOWMETER
GAS HOSE
PF10-M WIRE FEEDER
GAS SOLENOID KIT (INSIDE MACHINE)
K2825-1
ARCLINK CABLE K1543-[XX]
TO NEGATIVE (-) STUD
TIG TORCH
K2266-1 KIT (INCLUDES WORK CLAMP, ADAPTER, AND REGULATOR)
FIGURE A.3
TIG WITH S-SERIES USER INTERFACE
USER INTERFACE CONTROL PANEL K2828-1
TO NEGATIVE (-) STUD
TIG TORCH K2266-1 KIT
(INCLUDES WORK CLAMP,
ADAPTER, AND REGULATOR)
POWER WAVE®S350
TO POSITIVE (+) STUD
TO POSITIVE (+) STUD
WORK CLAMP
WORK PIECE
TO REMOTE CONTROL
RECEPTACLE
WORK CLAMP
WORK PIECE
FOOT AMPTROL
FOOT AMPTROL K870
A-6
INSTALLATION
FIGURE A.4
STICK WITH S-SERIES USER INTERFACE
A-6
TO NEGATIVE (-) STUD
WORK CLAMP
REGULATOR FLOWMETER
WORK PIECE
USER INTERFACE CONTROL PANEL
K2828-1
FIGURE A.5
MIG PROCESS
TO POSITIVE (+) STUD
REMOTE CONTROL BOX
K857
ELECTRODE HOLDER KIT K2394-1 KIT (INICLUDES GROUND CLAMP)
PF10-M
WIRE FEEDER
GAS HOSE
ARCLINK CABLE K1543-[XX]
TO POSITIVE (+) STUD
POWER WAVE®S350
TO NEGATIVE (-) STUD
WORK CLAMP
WORK PIECE
A-7
INSTALLATION
A-7
RECOMMENDED WORK CABLE SIZES FOR ARC WELDING
Connect the electrode and work cables between the appropriate output studs of the Power Wave per the following guidelines:
• Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source. Connect a work lead from the negative (-) power source output stud to the work piece
• When negative electrode polarity is required, such as in some Innershield applications, reverse the out­put connections at the power source (electrode cable to the negative (-) stud, and work cable to the posi­tive (+) stud).
®
S350
CAUTION
Negative electrode polarity operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode Polarity attribute to be set. See the Remote Sense Lead Specification section of this document for further details.
-----------------------------------------------------------------------
For additional Safety information regarding the elec­trode and work cable set-up, See the standard “SAFE­TY INFORMATION” located in the front of the Instruction Manuals.
OUTPUT CABLE GUIDELINES (Table A.1)
General Guidelines
• Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive voltage drops caused by undersized welding cables and poor con­nections often result in unsatisfactory welding perfor­mance. Always use the largest welding cables (elec­trode and work) that are practical, and be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicates undersized cables and/or bad connections.
• Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil excess cable. Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit.
• Always weld in a direction away from the work (ground) connection.
Table A.1 shows copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.
Percent Duty
Amperes
200
200
250
250
250
250
300
300
350
** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may
require cables larger than recommended, or cables rated higher than 167°F (75°C).
Cycle
60
100
30
40
60
100
60
100
40
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 0 to 50 Ft.
2
2
3
2
1
1
1
2/0
1/0
50 to 100 Ft.
2
2
3
2
1
1
1
2/0
1/0
POWER WAVE®S350
100 to 150 Ft.
2
2
2
1
1
1
1
2/0
2/0
167°F (75°C)]**
150 to 200 Ft.
1
1
1
1
1
1
1/0
2/0
2/0
200 to 250 Ft.
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
A-8
INSTALLATION
CABLE INDUCTANCE AND ITS EFFECTS ON WELDING
Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (See Figure A.6).
To minimize inductance always use the appropriate size cables, and whenever possible, run the electrode and work cables in close proximity to one another to minimize the loop area. Since the most significant fac­tor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long work piece lengths, a sliding ground should be considered to keep the total welding loop length as short as possible.
REMOTE SENSE LEAD SPECIFICATIONS
Voltage Sensing Overview
The best arc performance occurs when the Power
®
Wave tions.
S350 has accurate data about the arc condi-
TABLE A.2
Process
Electrode Voltage Sensing
67 lead
A-8
Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder, and have a dra­matic effect on performance. Remote voltage sense leads are used to improve the accuracy of the arc volt­age information supplied to the control pc board. Sense Lead Kits (K940-xx) are available for this pur­pose.
The Power Wave ly sense when remote sense leads are connected. With this feature there are no requirements for setting­up the machine to use remote sense leads. This fea­ture can be disabled through the Weld Manager Utility (available at www.powerwavesoftware.com) or through the set up menu (if a user interface is installed into the power source).
®
S350 has the ability to automatical-
CAUTION
If the auto sense lead feature is disabled and remote voltage sensing is enabled but the sense leads are missing, improperly connected extreme­ly high welding outputs may occur.
------------------------------------------------------------------------
General Guidelines for Voltage Sense Leads
Sense leads should be attached as close to the weld as practical, and out of the weld current path when possible. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.
Voltage sense leads requirements are based on the weld process (See Table A.2)
(1)
Work Voltage Sensing
21 lead
(2)
GMAW
GMAW-P
FCAW GTAW
SMAW
(1)
The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin arclink control cable (K1543­xx).
(2)
When a work voltage sense lead (21) is connected the power source will automatically switch over to using this feedback (if the auto sense feature is enable).
POWER WAVE S350
67 lead required 67 lead required
67 lead required Voltage sense at studs Voltage sense at studs
FIGURE A.6
A
B
POWER WAVE®S350
21 lead optional 21 lead optional
21 lead optional Voltage sense at studs Voltage sense at studs
C
WORK
A-9
Electrode Voltage Sensing
The remote ELECTRODE sense lead (67) is built into the 5-pin arclink control cable (K1543-xx) and is always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automati­cally configured by the active weld mode.
Work Voltage Sensing
®
The Power Wave sense work voltage at the negative output stud (posi­tive output polarity with remote Work Voltage Sensing disabled).
S350 is configured at the factory to
INSTALLATION
A-9
Negative Electrode Polarity
The Power Wave ly sense the polarity of the sense leads. With this fea­ture there are no set-up requirements for welding with negative electrode polarity. This feature can be dis­abled through the Weld Manager Utility (available at www.powerwavesoftware.com) or through the set up menu (if a user interface is installed into the power source).
®
S350 has the ability to automatical-
CAUTION
If the auto sense lead feature is disabled and the weld polarity attribute is improperly configured extremely high welding outputs may occur.
------------------------------------------------------------------------
While most applications perform adequately by sens­ing the work voltage directly at the output stud, the use of a remote work voltage sense lead is recom­mended for optimal performance. The remote WORK sense lead (21) can be accessed through the four-pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit. It must be attached to the work as close to the weld as practical, but out of the weld current path. For more information regarding the placement of remote work voltage sense leads, see the section entitled "Voltage Sensing Considerations for Multiple Arc Systems."
POWER WAVE®S350
A-10
INSTALLATION
A-10
VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS
Special care must be taken when more than one arc is welding simultaneously on a single part. Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads, but they are strong­ly recommended.
If Sense Leads ARE NOT Used:
• Avoid common current paths. Current from adja­cent arcs can induce voltage into each others cur­rent paths that can be misinterpreted by the power sources, and result in arc interference.
FIGURE A.7
DIRECTION OF TRAVEL
If Sense Leads ARE Used:
• Position the sense leads out of the path of the weld current. Especially any current paths common to adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources, and result in arc interference.
• For longitudinal applications, connect all work leads at one end of the weldment, and all of the work volt­age sense leads at the opposite end of the weld­ment. Perform welding in the direction away from the work leads and toward the sense leads.
(See Figure A.7)
CONNECT ALL SENSE LEADS AT THE END OF THE WELD.
CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD.
POWER WAVE®S350
A-11
INSTALLATION
• For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path.
(See Figure 8.A)
FIGURE A.8
POWER
SOURCE
#1
WER
PO SOURCE
#2
A-11
POWER SOURCE #1
WER
PO SOURCE
#1
POWER
SOURCE
#2
WER
PO
SOURCE
#2
POWER WAVE®S350
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