Lincoln Electric IM10007 User Manual

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Page 1

Operator’s Manual

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POWER WAVE

S350

For use with machines having Code Numbers:

11589

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Date Purchased

Code: (ex: 10859)

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IM10007 | Issue D ate Oct- 13

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Page 2

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.

Page 3

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.

Page 4

SAFETY

ELECTRIC SHOCK CAN KILL.

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

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

cause

Page 5

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks 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

Page 6

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.

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

Page 7

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

_______________________________________________________________________

________

Page 8

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

Volts

MAXIMUM

100%

300

Amps

Volts

SMAW

(mm

60%

275

Amps

Volts

)

100%

Amps

40%***

250 Amps / 30 Volts

325

Amps

Volts

CORD SIZE

AWG SIZES

GTAW-DC

40%

250

Volts

TIME DELAY FUSE

350

Amps

24 Volts

OR BREAKER

AMPERAGE

60%

325

Amps

23Volts

.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

Page 9

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

Page 10

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

Page 11

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

Page 12

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

WORK CLAMP

WORK PIECE

TO REMOTE CONTROL

RECEPTACLE

WORK CLAMP

WORK PIECE

FOOT AMPTROL

FOOT AMPTROL K870

Page 13

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

Page 14

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

250

300

350

** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may

require cables larger than recommended, or cables rated higher than 167°F (75°C).

Cycle

100

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 0 to 50 Ft.

2/0

1/0

50 to 100 Ft.

2/0

1/0

POWER WAVE®S350

100 to 150 Ft.

2/0

167°F (75°C)]**

150 to 200 Ft.

1/0

2/0

200 to 250 Ft.

1/0

2/0

3/0

Page 15

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

POWER WAVE®S350

21 lead optional 21 lead optional

21 lead optional Voltage sense at studs Voltage sense at studs

WORK

Page 16

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

Page 17

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

Page 18

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

WER

PO SOURCE

A-11

POWER SOURCE #1

WER

PO SOURCE

POWER

SOURCE

WER

SOURCE

POWER WAVE®S350

Page 19

A-12

INSTALLATION

A-12

CONTROL CABLE CONNECTIONS

General Guidelines

Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Power Wave tems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 100ft. (30.5m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems). Always use the shortest length of control cable possible, and DO NOT coil excess cable.

Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables. These recommendations apply to all communication cables including ArcLink Ethernet connections.

/ Power Feed sys-

and

Connection Between Power Source and Ethernet Networks

The Power Wave

S350 is equipped with an IP67 rated ODVA compliant RJ-45 Ethernet connector, which is located on the rear panel. All external Ethernet equipment (cables, switches, etc.), as defined by the connection diagrams, must be supplied by the customer. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid conductor, shielded cat 5e cable, with a drain. The drain should be grounded at the source of transmission. For best results, route Ethernet cables away from weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field. For additional guidelines refer to ISO/IEC 11801. Failure to follow these recommendations can result in an Ethernet connection failure during welding.

Product specific Installation Instructions

Connection Between Power Source and ArcLink Compatible Wirefeeders (K1543 – ArcLink Control Cable)

The 5-pin ArcLink control cable connects the power source to the wire feeder. The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The 5pin ArcLink connection on the Power Wave

S350 is located on the rear panel above the power cord. The control cable is keyed and polarized to prevent improper connection. Best results will be obtained when control cables are routed separate from the weld cables, especially in long distance applications. The recommended combined length of the ArcLink control cable network should not exceed 200ft. (61.0m).

POWER WAVE®S350

Page 20

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.

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

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

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

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

• FUMES AND GASSES can be dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to

• remove fumes from breathing zone.

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

• WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

WARNING OR CAUTION

DANGEROUS VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

HIGH TEMPERATURE

STATUS

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

ARC RAYS can burn.

Wear eye, ear and body protec-

• tion.

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

SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE UAL.

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

FRONT OF THIS OPERATING MAN-

PROTECTIVE GROUND

EXPLOSION

POWER-UP SEQUENCE

When the POWER WAVE®S350 is powered up, it can take as long as 30 seconds for the machine to be ready to weld. During this time period the user inter-

face will not be active.

DUTY CYCLE

The duty cycle is based on a ten-minute period. A 40% duty cycle represents 4 minutes of welding and 6 minutes of idling in a ten-minute period. Refer to the technical specification section for the Power Wave®

S350ʼs duty cycle ratings.

POWER WAVE®S350

Page 21

B-2

OPERATION

B-2

PRODUCT DESCRIPTION

PRODUCT SUMMARY

The Power Wave power source with high-end functionality capable of Stick, DC TIG, MIG, Pulsed MIG and Flux-Cored welding. It is ideal for a wide variety of materials including aluminum, stainless, and nickel — where arc performance is critical.

The Power Wave ble welding system. Like existing Power Waveʼs, the software based architecture allows for future upgradeability. One significant change from the current range of Power Wave units is that the Ethernet communication feature is standard on the Power Wave which allows for effortless software upgrades through Powerwavesoftware.com. The Ethernet communication also gives the Power Wave run Production Monitoring™ 2. Also a Devicenet option which will allow the Power Wave used in a wide range of configurations. Also, the Power Wave ble with future advanced welding modules like STT

S350 is a portable multi-process

S350 is designed to be a very flexi-

S350

S350 the ability to

S350 to be

S350 is being designed to be compati-

PROCESS LIMITATIONS

The software based weld tables of the Power Wave S350 limit the process capability within the output range and the safe limits of the machine. In general the processes will be limited to .030-.052 solid steel wire, .030-.045 stainless wire, .035-1/16 cored wire, and .035 and 1/16 Aluminum wire.

EQUIPMENT LIMITATIONS

Only ArcLink compatible semiautomatic wire feeders and users interfaces may be used. If other Lincoln wire feeders or non-Lincoln wire feeders are used there will be limited process capability and performance and features will be limited.

RECOMMENDED PROCESSES AND EQUIPMENT

The Power Wave®S350 is recommended for semiautomatic welding, and may also be suitable for basic hard automation applications. The Power Wave number of configurations, some requiring optional equipment or welding programs.

RECOMMENDED EQUIPMENT

The Power Wave®S350 is designed to be compatible with the current range of Power Feed™ systems

including future versions of ArcLink

RECOMMENDED PROCESSES

The Power Wave® S350 is a high speed, multiprocess power source capable of regulating the current, voltage, or power of the welding arc. With an output range of 5 to 350 amperes, it supports a number of standard processes including synergic GMAW, GMAW-P, FCAW, FCAW-SS, SMAW, GTAW and GTAW-P on various materials especially steel, aluminum and stainless.

S350 can be set up in a

feeders.

POWER WAVE®S350

Page 22

B-3

OPERATION

DESIGN FEATURES

Loaded with Standard Features

• Multiple process DC output range: 5 - 350 Amps

• 200 – 600 VAC, 1/3 phase, 50-60Hz input power

• New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations.

B-3

• Utilizes next generation microprocessor control, based on the ArcLink

• State of the art power electronics technology yields superior welding capability.

• Electronic over current protection

• Input over voltage protection.

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

• Thermostatically protected for safety and reliability.

• Recessed connection panel for protection against accidental impact.

• Ethernet connectivity via IP-67 rated ODVA compliant RJ-45 connector.

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

• Potted PC boards for enhanced ruggedness/reliability.

platform.

• Enclosure reinforced with heavy duty aluminum extrusions for mechanical toughness

• Remote control/Foot amptrol ready.

• Waveform Control Technology™ for good weld appearance and low spatter, even when welding nickel alloys.

POWER WAVE®S350

Page 23

B-4

OPERATION

B-4

CASE FRONT CONTROLS

(See Figure B.1)

1. USER INTERFACE (optional)

2. STATUS LED - (See Troubleshooting Section for

operational functions)

3. THERMAL LED - Indicates when machine has

thermal fault.

4. POWER SWITCH - Controls power to the Power

5. WORK STUD

6. ELECTRODE STUD

7. WORK SENSE LEAD

8. 6-PIN REMOTE

Wave

S350.

CASE BACK CONTROLS

(See Figure B.2)

1. 115 VAC RECEPTACLE AND CIRCUIT BEAKER (OPTIONAL)

2. ARCLINK (RECEPTACLE AND CIRCUIT BREAKER)

3. RESERVED FOR FUTURE DEVELOPMENT

4. DEVICENET KIT (OPTIONAL)

5. ETHERNET

6. RESERVED FOR FUTURE DEVELOPMENT

7. SOLENOID KIT (OPTIONAL)

8. INPUT POWER CORD

FIGURE B.1

FIGURE B.2

POWER WAVE®S350

Page 24

B-5

OPERATION

B-5

COMMON WELDING PROCEDURES

WARNING

MAKING A WELD 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.

Choose the electrode material, electrode size, shielding gas, and process (GMAW, GMAW-P etc.) appropriate for the material to be welded.

Select the weld mode that best matches the desired welding process. The standard weld set shipped with the Power Wave common processes that will meet most needs. If a special weld mode is desired, contact the local Lincoln Electric sales representative.

All adjustments are made through the user interface. Because of the different configuration options your system may not have all of the following adjustments. See Accessories Section for Kits and Options avaliable to use with the Power Wave

S350 encompasses a wide range of

S350.

Basic Welding Controls

Weld Mode

Selecting a weld mode determines the output characteristics of the Power Wave

power source. Weld modes are developed with a specific electrode material, electrode size, and shielding gas. For a more complete description of the weld modes programmed into

the Power Wave

S350 at the factory, refer to the

Weld Set Reference Guide supplied with the machine or available at www.powerwavesoftware.com.

Wire Feed Speed (WFS)

In synergic welding modes (synergic CV, GMAW-P), WFS is the dominant control parameter. The user adjusts WFS according to factors such as wire size, penetration requirements, heat input, etc. The Power

Wave

S350 then uses the WFS setting to adjust the voltage and current according to settings contained in the Power Wave.

In non-synergic modes, the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments. Therefore, to maintain proper arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.

Amps

In constant current modes, this control adjusts the welding amperage.

Volts

In constant voltage modes, this control adjusts the welding voltage.

Definition of Welding Modes

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding process variables to be set by the operator.

SYNERGIC WELDING MODES

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

POWER WAVE®S350

Trim

In pulse synergic welding modes, the Trim setting adjusts the arc length. Trim is adjustable from 0.50 to

1.50. 1.00 is the nominal setting and is a good starting point for most conditions.

UltimArc™ Control

UltimArc™ Control allows the operator to vary the arc characteristics. UltimArc™ Control is adjustable from –10.0 to +10.0 with a nominal setting of 0.0.

Page 25

B-6

SMAW (STICK) WELDING

The welding current and Arc Force settings can be set through a Power Feed 10M or Power Feed 25M wire feeder. Alternatively an optional Stick / TIG UI (K2828-

1) can be installed into the power source to control these settings locally.

In a SMAW (STICK mode), Arc Force can be adjusted. It can be set to the lower range for a soft and less penetrating arc characteristic (negative numeric values) or to the higher range (positive numeric values) for a crisp and more penetrating arc. Normally, when welding with cellulosic types of electrodes (E6010, E7010, E6011), a higher energy arc is required to maintain arc stability. This is usually indicated when the electrode sticks to the work-piece or when the arc becomes unstable during manipulative technique. For low hydrogen types of electrodes (E7018, E8018, E9018, etc.) a softer arc is usually desirable and the lower end of the Arc Control suits these types of electrodes. In either case the arc control is available to increase or decrease the energy level delivered to the arc.

OPERATION

B-6

The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, the Power Wave adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range.

Non Synergic CV

In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.

All CV Modes

Pinch adjusts the apparent inductance of the wave shape. The “pinch” function is inversely proportional to inductance. Therefore, increasing Pinch Control greater than 0.0 results in a crisper arc (more spatter) while decreasing the Pinch Control to less than 0.0 provides a softer arc (less spatter).

S350 automatically

GTAW (TIG) WELDING

The welding current can be set through a Power Feed 10M or Power Feed 25M wire feeder. Alternatively an optional Stick / TIG UI (K2828-1) can be installed into the power source to control these settings locally.

The TIG mode features continuous control from 5 to 350 amps with the use of an optional foot amptrol (K870). The Power Wave Touch Start TIG mode or Scratch start TIG mode.

CONSTANT VOLTAGE WELDING Synergic CV

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

S350 can be run in either a

FIGURE B.3

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 vales less than 1.00 decrease the arc length. (See figure B.3)

POWER WAVE®S350

Page 26

B-7

OPERATION

Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave

S350 will automatically recalculate the waveform parameters to maintain similar arc properties.

B-7

The Power Wave

S350 utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The Power

Wave

S350 waveforms are optimized for a 0.75” stick-out. The adaptive behavior supports a range of stick-outs from 0.50 to 1.25”. At very low or high wire feed speeds, the adaptive range may be less due to reaching physical limitations of the welding process.

UltimArc™ Control adjusts the focus or shape of the arc. UltimArc™ Control is adjustable from -10.0 to +10.0 with a nominal setting of 0.0. Increasing the UltimArc™ Control increases the pulse frequency and background current while decreasing the peak current. This results in a tight, stiff arc used for high speed sheet metal welding. Decreasing the UltimArc™ Control decreases the pulse frequency and background current while increasing the peak current. This results in a soft arc good for out of position welding. (See Figure B.4)

FIGURE B.4

POWER WAVE®S350

Page 27

C-1

ACCESSORIES

C-1

KITS, OPTIONS AND ACCESSORIES

All Kits Options and Accessories are found on the Web site: (www.lincolnelectric.com)

FACTORY INSTALLED

None Available

FIELD INSTALLED OPTIONS

GENERAL OPTIONS

Stick / Tig User Interface Kit

Mounts inside the front panel of the Power Wave® S350. Allows stick and Tig operation without having a wire feeder.

Order K2828-1

115 VAC Auxiliary Power Kit

Mounts inside the back of the Power Wave® S350. Adds 115 VAC / 60 Hz auxiliary power capability to the Power Wave® S350 ( only compatible with the K2823-1 power source)

Order K2829-1

DeviceNet Kit

Mounts inside the back of the Power Wave® S350. Allows Devicenet objects to communicate with the Power Wave® S350.

Order K2827-1

Work Voltage Sense Lead Kit

Required to accurately monitor voltage at the arc.

Order K940-25 for 25 ft. (7.6 m) Order K1811-75 for 75 ft. (22.9 m)

Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO ders. Includes a cylinder pressure gauge, dual scale

flow gauge and 4.3 ft. (1.3 m) gas hose.

Order K586-1

Work and Wire Feeder 2/0 Weld Cable Package

Includes Twist-Mate™ connectors, work clamps, 15 ft. (4.5 m) work cable and 10 ft. (3.0 m) electrode cable. Rated 350 amps, 60% duty cycle.

Order K1803-1

, Argon, or Argon-blend gas cylin-

Twist-Mate™ Cable Receptacle

For connecting welding cable to Twist-Mate™ Cable Plug.

Order K1759-70 for 1/0-2/0 (50-70 mm2) cable Order K1759-95 for 2/0-3/0 (70-95mm2) cable

Twist-Mate™ to Lug Adapter

For connection of lugged cable to Twist-Mate™ connectors. 18" (457 mm) long.

Order K2176-1

Inverter and Wire Feeder Cart

Rear-wheeled cart includes front casters and no-lift gas bottle plat¬form. Convenient handles allow for easy cable storage while full length side trays store parts and tools. Shipped fully assembled. Small footprint fits through 30" (762 mm) door.

Order K1764-1 Dual Cylinder Kit

Dual Cylinder Kit

Permits side-by-side mounting of two full size gas cylinders, with easy loading. For use with K1764-1 cart.

Order K1702-1

Coaxial Welding Cable

Optimum weld cables for minimizing cable inductance and optimizing welding performance.

Order K1796-25 for 25 feet 25 ft. (7.6 m) cable length. Order K1796-50 for 50 feet 50 ft. (15.2 m) cable length. Order K1796-75 for 75 feet 75 ft. (22.9 m) cable length. Order K1796-100 for 100 feet 100 ft. (30.5 m) cable length.

Welding Fume Extractors

Lincoln offers a wide range of fume extraction environmental system solutions, ranging from portable systems easily wheeled around a shop to shop-wide central systems servicing many dedicated welding stations.

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

Twist-Mate™ Cable Plug

For connecting welding cable to output terminal recep-

tacles. For 1/0-2/0 (50-70 mm

Order K852-70

Twist-Mate™ Cable Plug

For connecting welding cable to output terminal receptacles. For 2/0-3/0 (70-95 mm

Order K852-95

) cable.

POWER WAVE®S350

Page 28

C-2

ACCESSORIES

STICK OPTIONS

ACCESSORY KIT - 150 Amp

For stick welding. Includes 20 ft. (6.1m) #6 electrode cable with lug, 15 ft. (4.6m) #6 work cable with lugs, headshield, filter plate, work clamp, electrode holder and sample pack of mild steel electrode. For use with K2176-1 (Twist-Mate™ to Lug Adapter)

ORDER K875

Hand Amptrol

Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection)

Order K963-3

Foot Amptrol

Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6pin plug connection).

Order K870

C-2

ACCESSORY KIT - 400 AMP

For stick welding. Includes 35 ft. (10.7m) 2/0 electrode cable with lug, 30 ft. (9.1m) 2/0 work cable with lugs, headshield, filter plate, work clamp and electrode holder. For use with K2176-1 (Twist-Mate™ to Lug Adapter)

ORDER K704

REMOTE OUTPUT CONTROL

Portable current control provides the same dial range as the current control on the welder. Consists of a 6-pin Amphenol connector which plugs into the remote control Amphenol. 25 foot cable length.

ORDER K857 ORDER K857-1 for 100 ft. (30 m)

STICK ELECTRODE HOLDER AND CABLE ASSEMBLY

Includes 200A stick electrode holder and Twist-Mate connector. 12.5 ft. cable length.

ORDER K2374-1

STICK ELECTRODE HOLDER CABLE AND WORK CABLE ASSEMBLY

Includes 200A stick electrode holder, welding cable, work clamp and Twist-Mate adapter.

ORDER K2394-1

Arc Start Switch

May be used in place of the Foot or Hand Amptrol

. Comes with a 25 ft. (7.6 m) cable. Attaches to the TIG torch for convenient finger control to start and stop the weld cycle at the current set on the machine.

Order K814

Twist-Mate™ Torch Adapter

For connection of Pro-Torch™ TIG torches (1 piece cable) to power sources with gas passing through the Twist-Mate™ connection. For use with K2825-1.

Order K1622-1 For air-cooled PTA-9 or PTA-17 torches. Order K1622-3 For air-cooled PTA-26 torches. Order K1622-2 For water-cooled torches.

Twist-Mate™ Torch Adapter

For connection of PTA-9 or PTA-17V torches (1 piece cable) to power sources without gas passing through the Twist-Mate™ connection.

Order K960-1

TIG OPTIONS

Power Wave®S350 Solenoid Kit

Mounts inside the back of the Power

Wave Power Wave Mate™ connector. Includes gas hose and solenoid ( only compatible with the K2823-1 power source).

Order K2825-1

Pro-Torch™ TIG Torches

A full line of air-cooled and water-cooled torches available.

Request Lincoln publication E12.150

(See www.lincolnelectric.com)

S350. Switches gas flow in the

S350 through the Twist-

POWER WAVE®S350

Page 29

C-3

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

Get everything you need for TIG welding in one complete easy-to-order kit packaged in its own portable carrying case. Includes: PTA-17V torch, parts kit,

Harris and work clamp and cable.

Order K2265-1

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

Get everything you need for TIG welding in one complete easy-to-order kit packaged in its own portable carrying case. Includes: PTA-17 torch, parts kit, Harris Twist-mate™ adapter, and work clamp and cable.

Order K2266-1

TIG-Mate™ 20 Water-Cooled TIG Torch Starter Pack

Get everything you need for TIG welding in one complete easy-to-order kit packaged in its own portable carrying case. Includes: PTW-20 torch, parts kit, Harris Twist-Mate™ adapter, work clamp and cable and 10 ft. (3.0 m) water hose.

Order K2267-1

flowmeter/regulator, 10 ft. (3.0 m) gas hose,

ACCESSORIES

C-3

MIG OPTIONS

Work and Feeder Welding Cables 350 amps, 60% duty cycle with Twist-Mate connectors and Ground Clamp.

Order K1803-1

COMPATIBLE LINCOLN EQUIPMENT

Any Arclink compatible wire feeding equipment (See www.lincolnelectric.com)

POWER WAVE®S350

Page 30

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not operate with covers removed.

• Turn off power source before installing or servicing.

•Do not touch electrically hot parts.

• Turn the input power to the welding power source off at the fuse box before working in the terminal strip.

• Only qualified personnel should install, use or service this equipment.

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

ROUTINE MAINTENANCE

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

D-1

PERIODIC MAINTENANCE

Calibration of the Power Wave®S350 is critical to its operation. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and Current should be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the factory. Generally the machine calibration will not need adjustment. However, if the weld performance changes, or the yearly calibration check reveals a problem, use the calibration section of the Diagnostics Utility to make the appropriate adjustments.

The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. The Diagnostics Utility includes detailed instructions, and is available on the Service

Navigator CD or at www.powerwavesoftware.com.

POWER WAVE®S350

Page 31

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.

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

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

Observe all additional Safety Guidelines detailed throughout this manual.

CAUTION

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

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

POWER WAVE®S350

Page 32

E-2

TROUBLESHOOTING

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

Not all of the Power Wave®S350 errors will be displayed on the user interface (if it is installed). There are two status lights that display error codes. If a problem occurs it is important to note the condition of the status lights.

Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.

There is one externally mounted status lights located on the case front of the machine. This status light corresponds to the main control boardʼs status. A second status light is internal and is located on the input control board and can be seen by looking through the left case side louvers.

TABLE E.1

Light

Condition

Main control board status light

E-2

There is an audible beeper associated with this input control boardʼs status light. So the error codes on the input board can be detected through either the status light or the status beeper.

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

The status lights for the main control board is a dual-color LEDʼs. Normal operation for each is steady green. Where as the status light on the input control board is one color. Normal operation is for the status light to be off ( and the buzzer to be off).

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

Meaning

Input control board

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

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

healthy peripheral equipment connected to its ArcLink network.

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

WAVE

S350 is mapping (identifying) each component in the system.

Normal for first 1-10 seconds after power is turned on, or if the system

Non-recoverable system fault. If the Status lights are flashing any com-

bination of red and green, errors are present. Read the error code(s)

Error Code interpretation through the Status light is detailed in the

Service Manual. Individual code digits are flashed in red with a long

pause between digits. If more than one code is present, the codes will

be separated by a green light. Only active error conditions will be

Error codes can also be retrieved with the Diagnostics Utility (includ-

ed on the Service Navigator CD or available at www.power-

wavesoftware.com). This is the preferred method, since it can access

To clear the active error(s), turn power source off, and back on to

configuration is changed during operation.

Indicates Auto-mapping has failed

before the machine is turned off.

accessible through the Status Light.

historical information contained in the error logs.

reset.

Not applicable.

Error Code interpretation -

Individual code digits are flashed in red with a long pause between digits. These error codes are three digit codes that all start with a number three.

Status LED off

Not applicable.

System OK

CAUTION

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

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

POWER WAVE®S350

Page 33

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWER WAVE®S350

The following is a partial list of possible error codes for the POWER WAVE®S350. For a complete listing consult the Service Manual for this machine.

MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code #

Indication

36 Thermal error

54 Secondary (Output) over current error

56 Chopper communication error

58 Primary Fault 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

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

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

Review error code from input board status light or status beeper. Most likely caused by an over power condition which caused an under voltage on the primary bus. If cycling the input power on the machine does not clear the error, contact the Service Department.

Error codes that contain three or four digits are defined as fatal errors. These codes generally indicate internal errors on the Power Source Control Board. If cycling the input power on the machine does not clear the error, contact the Service Department.

CAUTION

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

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

POWER WAVE®S350

Page 34

E-4

Error Code #

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

INPUT CONTROL BOARD

Indication

E-4

331 Peak input current limit

333 Under-voltage lockout

336 Thermal Fault

337 Pre-charge timeout

346 Transformer primary over current

Other

Input current limit has been exceeded. Typically indicates short term power overload. If problem persists contact Service Department.

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

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

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

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

Contact the Service Department.

CAUTION

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

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

POWER WAVE®S350

Page 35

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

Basic Machine Problems

E-5

RECOMMENDED

COURSE OF ACTION

Input fuses keep blowing

Machine will not power up (no lights)

1. Improperly sized input fuses.

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

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

1. No Input Power

2. Input voltage is too low or too high.

1. Make sure fuses are properly sized. See installation section of this manual for recommended sizes.

2. Reduce output current, duty cycle, or both.

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

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

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

Machine wonʼt weld, canʼt get any output.

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

Input voltage is too low or too high.

2. Thermal Error.

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

3a. Input control board fault (see

input control board error status).

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

2. See “Thermal LED is ON” section.

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

CAUTION

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

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

POWER WAVE®S350

Page 36

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-6

RECOMMENDED

COURSE OF ACTION

Thermal LED is ON

“Real Time Clock” no longer functioning

General degradation of weld performance

Improper fan operation

Basic Machine Problems (Continued)

1. Improper fan operation.

2. Open thermostat circuit.

1. Control PC Board Battery.

Weld and Arc Quality Problems

1. Wire feed problem.

2. Cabling problems.

1. Check for proper fan operation. Fan should run in a low speed setting when the machine is idle and in a high speed when the output is triggered. Check for material blocking intake or exhaust louvers, or for excessive dirt clogging cooling channels in machine.

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

1. Replace the battery (Type: BS2032)

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

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

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

3. Loss of, or improper Shielding Gas.

4. Verify weld mode is correct for process.

5. Machine calibration.

6. Wire feed problem.

3. Verify gas flow and type are correct.

4.Select the correct weld mode for

the application.

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

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

CAUTION

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

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

POWER WAVE®S350

Page 37

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Weld and Arc Quality Problems (Continued)

Wire burns back to tip at the end of the weld.

TROUBLESHOOTING

POSSIBLE

CAUSE

1. Burnback Time

E-7

RECOMMENDED

COURSE OF ACTION

1. Reduce burnback time and/or work point.

Machine output shuts down during a weld.

Machine wonʼt produce full output.

Excessively long and erratic arc.

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

2. System Fault

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

2. Machine calibration.

1. Wire feed problem.

2. Loss of, or improper Shielding Gas

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

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

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

2. Calibrate secondary current and voltage.

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

2. Verify gas flow and type are correct

3. Machine calibration.

3. Calibrate secondary current and voltage.

CAUTION

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

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

POWER WAVE®S350

Page 38

E-8

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

Ethernet

E-8

RECOMMENDED

COURSE OF ACTION

Cannot Connect

1. Physical connection.

2. IP address information.

3. Ethernet Speed

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

1a. Verify the cables are fully insert-

ed into the bulk head connector.

1b. The LED under the PC board

ethernet connector will be lit when the machine is connected to another network device.

2. Use the appropriate PC utility to verify the correct IP address information has been entered.

2a. Verify no duplicate the IP

addresses exist on the network.

3. Verify that the network device connected to the Power Wave is either a 10-baseT device or a 10/100-baseT device.

Connection Drops while welding

1. Cable Location

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

CAUTION

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

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

POWER WAVE®S350

Page 39

F-1

DIAGRAMS

F-1

POWER WAVE®S350

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 40

F-2

DIMENSION PRINT

F-2

POWER WAVE®S350

Page 41

PARTS LIST FOR

POWER WAVE

P-609P-609

S350

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

POWER WAVE®S350

Page 42

ILLUSTRATION OF SUB-ASSEMBLIES

P-609-AP-609-A

POWER WAVE

S350

06-05-2009

Page 43

P-609-A.1P-609-A.1

POWER WAVE®S350

For Code: 11589

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

Optional Equipment

PAGE NO.

CODE NO.

11589 1 1 1 1111

P-609-B.1

Miscellaneous Items

P-609-B.2

Case Front Assembly

P-609-C

Base & Power Conversion

Assembly

P-609-D

Vertical Divider Panel Asbly

P-609-E

Output Choke Assembly

P-609-F

Case Back Assembly

P-609-G

Roof Assembly

P-609-H

POWER WAVE

S350

11-17-2009

Page 44

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Gas Solenoid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2825-1

Devicenet Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2827-1

Stick/TIG UI Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2828-1

115V Auxiliary Power Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2829-1

S350/STT Field Retrofit Kit (Code 11589 Only), Includes: . . . . . . . . . . . . . . . . . . . . .Order S28481

P-609-B.1P-609-B.1

POWER WAVE

S350

04-07-2010

Page 45

P-609-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-609-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 123456789

Wiring Harness (Primary) G6094 1 X Plug & Lead Assembly (J5) M17192-38 1 X Flex Tube T10642-217 1 X Secondary Control Harness (J8, J12, J24, P50) G6095-1 1 X Ethernet Patch Cable M19969-13 1 X Input Lead Assembly S18573-17 1 X

POWER WAVE

S350

06-05-2009

Page 46

Case Front Assembly

23A

29B

29C

29A

36A

36B

24A

26A

25A

22A

22B

37A

37B

P-609-CP-609-C

36A

22A

22B

25A

37A

37B

24A

26A

36B

23A

29B

29C

29A

06-05-2009

POWER WAVE

S350

Page 47

P-609-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front Assembly (G6519), Includes: NSS 1X 1 Case Front G6513 1 X 2A Gusset S27254-1 1 X 2B #10-24 HLN T9187-13 2 X 3 UI Trim G6529 1 X 4A P.C. Board Mounting Bracket L13263-1 1 X 4B #10-24 HN CF000010 2 X 4C Plain Washer S9262-27 2 X 4D Lock Washer E106A-1 2 X 5A Line Switch S20030-1 1 X 5B Line Switch Spacer S27237 1 X 5C Switch Cover S25384 1 X 5D Lock Washer (Not Shown) T9695-1 2 X 5E #10-32 x .625 HHCS (Not Shown) CF000084 2 X 6 Bottom Nameplate (G6549-1) (Part of G6549) NSS 1X 15 MOV Assembly (Not Shown) S18491-3 1 X 17 Copper Strap T11655-8 1 X 18 Plain Washer S9262-41 2 X 19 Internal Tooth Star Washer T9695-16 1 X 20 5/8-11 HJN CF000140 1 X 21 Hose Nipple T14557-8 1 X 22A LED Lens - Clear, Includes: S23093-1 2 X 22B LED Retaining “O” Ring S23094-1 2 X 22C LED Harness (Not Shown), Includes: L15111 1 X

LED Panel Mount Assembly S23740-1 2 X Yellow LED T13657-4FA 1 X

Bi-Color LED T13657-7H24 1 X 23A Output Stud M13896-3 1 X 23B Thread Forming Screw S9225-63 2 X 24A Output Stud M13896-7 1 X 24B Thread Forming Screw S9225-63 2 X 25A P.C. Board Mounting Bracket L13263-2 1 X 25B #10-24 HN CF000010 2 X 25C Plain Washer S9262-27 2 X 25D Lock Washer E106A-1 2 X 26A Input Control & Power Supply P.C. Board G5915-[ ] 1 X 26B #10-24 HLN T9187-13 3 X 28 Thread Forming Screw (Not Shown) S9225-94 4 X 29A 6 Pin Connector (Part of M22137 Remote Harness) S12021-68 1 X 29B Self Tapping Screw S8025-96 2 X 29C Cap - Cable Connector S17062-10 1 X 30

Sq. Flange Female Receptacle (Part of G6095-2 Harness) S18657 1 X 36A Cover Plate L15069 1 X 36B Self Tapping Screw S9225-94 4 X 37A Snubber Asbly , Includes: S25304-5 1 X 37B Bushing T12380-4 1 X 37C #10-24 HLN (Not Shown) T9187-13 1 X 38 Decal - UI Cover Plate (Not Shown) G6601 1 X

NSS - Not Sold Separately

POWER WAVE

S350

11-11-2010

Page 48

P-609-C.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates.

POWER WAVE

S350

06-05-2009

Page 49

NOTES

POWER WAVE®S350

Page 50

Base & Power Conversion Assembly

10A

10C

10B

16A

16B

12A

12B

12C

12D

P-609-DP-609-D

12D

12A

12B

12C

10B

10C

10A

16A

16B

16A

POWER WAVE

S350

04-07-2010

Page 51

P-609-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Base L15067 1 X 1B Thread Forming Screw (Not Shown) S9225-94 6 X 2 Base Extrusion M21251-2 2 X 3A Attachment Kit Bracket L15091 2 X 3B 1/4-20 HHCS CF000013 4 X 3C Mounting Foot S28070 4 X 3D Lock Washer (Not Shown) E106A-2 4 X 3E Thread Forming Screw S9225-94 4 X 3F Shakeproof Lock Washer T9695-1 2 X 4A Corner Cap L13138 4 X 4B Plain Washer S9262-178 8 X 4C Thread Forming Screw S9225-95 8 X 6 Power Conversion Assembly, Includes: G6037-1 1 X 6A Thermostat T13359-29 1 X 6B Upper Power Board Bracket M21469-2 1 X 6C Thread Forming Screw (Not Shown) S9225-95 4 X 6D Lock Washer (Not Shown) E106A-1 4 X 6E Plain Washer (Not Shown) S9262-27 4 X 6F #10-24 x .50 SHWHS1 CF000371 2 X 7A Power Board Bracket M21469-1 1 X 7B #10-24 HLN (Not Shown) T9187-13 2 X 8 Foam M15045-100 3 X 10A Input Choke M21489-1 1 X 10B Choke Mounting Bracket M21468 1 X 10C #10-24 HLN T9187-13 2 X 12A Horizontal Divider Panel L15068-1 1 X 12B Thread Forming Screw S9225-94 6 X 12C Thread Forming Screw S8025-92 1 X 12D #10-24 HLN T9187-13 2 X 15 Earth Ground Connection Decal T13260-4 1 X 16A #10-24 HN CF000010 2 X 16B Lock Washer E106A-1 1 X

# #

POWER WAVE

S350

04-07-2010

Page 52

Vertical Divider Panel Assembly

16C

16D

16E

16B

16A

16B

P-609-EP-609-E

16B

16A

16E

16C

16D

16B

POWER WAVE

S350

06-05-2009

Page 53

P-609-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Vertical Divider Panel Asbly (G6589), Includes: NSS 1X 1 Vertical Divider Panel G6511 1 X 2A Terminal Block S20763-3 1 X 2B Mylar Insulation S28105 1 X 2C #8-32 x 1.25 RHS CF000193 2 X 3

Decal - Input Power identification (G6549-2) (Part of G6549)

NSS 1X 4 Grommet T12380-1 1 X 5A 40V DC Buss Board L11832-[ ] 1 X 5B #10-24 HLN T9187-13 4 X 6A Cover Plate G6590 1 X 6B #10-24 HLN T9187-13 4 X 7A Remote Control PC Board G6572-[ ] 1 X 7B PCB Standoff S14020-4 3 X 7C Self Tapping Screw (Not Shown) S8025-98 3 X 8A Control PC Board S28057-[ ] 1 X 8B #10-24 HLN T9187-13 4 X 11 115V Option Cover Decal S28078-2 1 X 12 Noise Suppressor (Not Shown) S18858-11 1 X 15A #10-24 HLN T9187-13 2 X 15B Thread Forming Screw S8025-92 2 X 16A Resistor S10404-129 1 X 16B Insulating Washer T4479-A 2 X 16C #10-24 x 2.75 RHS CF000049 1 X 16D Lock Washer E106A-1 1 X 16E Plain Washer S9262-27 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

NSS - Not Sold Separately

POWER WAVE

S350

01-18-2010

Page 54

Output Choke Assembly

10A

11A

11E

11D

11C

12A

10A

13D

13C

13B

12B

12C

10D

10C

10B

12C

12D

12E

13A

20A

20B

20C

3C 3D 3E

20B

20E

11E

11A

11D

P-609-FP-609-F

10A

11C

20C

20B

20A

20B

13A

13B

13C

13D

3C 3D 3E

12E

12D

12C

10A

POWER WAVE

12A

12C

12B

S350

10B

10C

10D

06-05-2009

Page 55

P-609-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Output Choke Assembly, Includes: L13270-1 1 X 1 Bottom Choke Bracket M21472-1 1 X 2A Insulation, Bottom Bracket (Not Shown) S27259-4 1 X 3A Current Transducer S18504-6 1 X 3B #8-32 x .50 RHS CF000033 2 X 3C Plain Washer S9262-3 2 X 3D Lock Washer T4291-A 2 X 3E #8-32 HN CF000042 2 X 5 Spacer Washer S25781-1 6 X 6 Spacer T14605 1 X 7 Output Choke S26801-2 3 X 8 Top Choke Bracket M21471-1 1 X 9 Insulation, Top Bracket (Not Shown) S27259-3 1 X 10A 1/4-20 x 9.00 Carriage Bolt T11827-3 1 X 10B Plain Washer S9262-98 1 X 10C Lock Washer E106A-2 1 X 10D 1/4-20 HN CF000017 1 X 11A Heatsink Holder S22168 2 X 11B 1/4-20 x 1.00 HHCS (Not Shown) CF000015 2 X 11C Plain Washer S9262-98 4 X 11D Lock Washer E106A-2 2 X 11E 1/4-20 HN CF000017 2 X 12A Bus Bar M21485 1 X 12B 1/4-20 x 1.00 HHCS CF000015 2 X 12C Plain Washer S9262-98 4 X 12D Lock Washer E106A-2 2 X 12E 1/4-20 HN CF000017 2 X 13A 1/4-20 x .75 HHCS CF000014 3 X 13B Plain Washer S9262-98 6 X 13C Lock Washer E106A-2 3 X 13D 1/4-20 HN CF000017 3 X 20A Resistor S10404-137 1 X 20B Insulating Washer T4479-A 2 X 20C Plain Washer S9262-27 1 X 20D Lock Washer (Not Shown) T9695-1 1 X 20E #10-24 x 7.50 RHS CF000191 1 X 25 Thread Forming Screw (Not Shown) S9225-94 4 X

POWER WAVE

S350

10-09-2009

Page 56

Case Back Assembly

15A

19A

19B

20B

20A

17A

27A

15B

17B

35A

35B

P-609-GP-609-G

20B

20A

27A

35B

35A

17A 17B

19A

15A

15B

19B

POWER WAVE

S350

06-05-2009

Page 57

P-609-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Back Assembly, Includes: G6523 1 X 1 Rear Panel G6510 1 X 2A Fan Bracket L15066 1 X 2B #10-24 HLN T9187-13 4 X 3A Fan Assembly M22149 3 X 3B #8-32 x 2.00 HHMS CF000408 12 X 3C Plain Washer S9262-3 12 X 3D Lock Washer T4291-A 12 X 4A Cord Grip Connector S19999 1 X 4B Conduit Lock Nut T14370-3 1 X 5 Ethernet Connector M19969-3 1 X 6 Ethernet Receptacle Cover M19969-4 1 X 8 Fan Harness (Not Shown) L15109 1 X 13 Plug Button T10397-22 1 X 15A Circuit Breaker T12287-20 1 X 15B Sealing Boot S22061-3 1 X 17A Receptacle Cover M22177-1 1 X 17B Shake Proof Lock Washer T9695-1 2 X 17C #10-24 HN CF000010 2 X 19A Cover Plate S25438-3 2 X 19B #10-24 HLN T9187-13 4 X 20A Louver Plate L15108 1 X 20B Thread Forming Screw S9225-94 6 X 27A Cover Plate S25438-6 1 X 27B #10-24 HLN (Not Shown) T9187-13 2 X 29 Decal - Circuit Breaker (G6549-4) (Part of G6549) NSS 1X 30 Thread Forming Screw (Not Shown) S9225-94 4 X 31 Decal Rating Plate S28056 1 X 35A Air Baffle L15123 1 X 35B #10-24 HLN T9187-13 2 X 36

5 Socket Connector (Part of G6095-2 Arclink Connector Harness)

S12021-73 1 X

NSS - Not Sold Separately

POWER WAVE

S350

06-05-2009

Page 58

Roof Assembly

P-609-HP-609-H

POWER WAVE

S350

06-05-2009

Page 59

P-609-H.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Roof Assembly, Includes: M22129-1 1 X 1A Roof L12763 1 X 1B Warranty Decal G6549-3 1 X 1C Warning Decal L8064-1 1 X 1D Wiring Diagram G6536 1 X 1E Thread Forming Screw (Not Shown) S9225-94 10 X 2 Roof Frame Asbly (L13273), Includes: NSS 1X 2A Top Extrusion M21251-1 2 X 2B Handle Bracket L12780 2 X 2C Thread Forming Screw S9225-94 8 X 2D Handle Gasket L13274 2 X 2E Handle M15446 2 X 2F Thread Forming Screw S9225-53 4 X 2G Handle Reinforcement M21736 2 X 2K Thread Forming Screw (Not Shown) S9225-94 8 X 3A Corner Cap L13138 4 X 3B Plain Washer S9262-178 12 X 3C Thread Forming Screw S9225-95 12 X 4A Left Case Side Assembly, Includes: M22191 1 X 4B Decal - LECO Logo S27368-4 1 X 4C Decal - Powerwave Logo S27468 1 X 5A Right Case Side Assembly, Includes: M22192 1 X 5B Decal - LECO Logo S27368-4 1 X 5C Decal - Powerwave Logo S27468 1 X 5D Green Initiative Decal S28039-2 1 X 8A Plain Washer (Not Shown) S9262-178 4 X 8B Thread Forming Screw (Not Shown) S9225-95 4 X 8C Thread Forming Screw S9225-94 8 X

NSS - Not Sold Separately

POWER WAVE

S350

06-08-2011

Page 60

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

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

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

Lincoln Electric IM10007 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual