Lincoln Electric IM10007 User Manual

Operator’s Manual

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POWER WAVE

S350

For use with machines having Code Numbers:

11589

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IM10007 | Issue D ate Oct- 13

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIA L SI TUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

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

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

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

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

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

face.

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

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

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

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

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

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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

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

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

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

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

FOR ENGINE POWERED EQUIPMENT.

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

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

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

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

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

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

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

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

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

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

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

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

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

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.”

TABLE OF CONTENTS

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

Connection Diagram .....................................................................................................A-5

Recommended Work Cable Sizes ................................................................................A-6

Cable Inductance and its Effects on Welding................................................................A-7

Remote Sense Lead Specifications.......................................................................A-7, A-8

Voltage Sensing Considerations for Multiple Arc Systems..................................A-9, A-10

Control Cable Connections ................................................................................................A-11

________________________________________________________________________________

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

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

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

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

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

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

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

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

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

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

Case Front Controls .............................................................................................................B-4

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

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

________________________________________________________________________________

viivii

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

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

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

Stick Operations ............................................................................................C-2, C-3

________________________________________________________________________

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

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

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

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

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

________________________________________________________________________________

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

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

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

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

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

________________________________________________________________________________

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

________________________________________________________________________

Parts Pages ................................................................................................................P-609 Series

_______________________________________________________________________

________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE®S350

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

Duty Cycle

Input Voltage ± 10%

Input Amperes

(1 Phase in parenthesis)

Idle Power

A-1

Power Factor @

Rated Output

39/35/20/17/14

(NA/65***/37/32/25)

30/28/16/14/11

(56/51/29/25/20)

300 Watts Max.

(fan on)

K2823-1

40% rating

100% rating

200-208/230/380-415/

460/575 50/60 Hz

RATED OUTPUT

INPUT

VOLTAGE / PHASE /

FREQUENCY

200-208/1/50/60

230/1/50/60 460/1/50/60 575/1/50/60

200-208/3/50/60

230/3/50/60

380-415/3/50/60

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

*** On 230 Volt / 1 phase inputs the max. rating is at a duty cycle of 30%, except for GTAW processes.

40%***

350

Amps

31.5

Volts

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE / PHASE/

FREQUENCY

INPUT AMPERE RAT-

ING AND DUTY CYCLE

GMAW

60%

300 Amps / 29 Volts

320

Amps

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

A-2

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

SMAW

PHYSICAL DIMENSIONS

MODEL

HEIGHT

INSTALLATION

WELDING PROCESS

OUTPUT RANGE (AMPERES)

5-350

WIDTH

OCV (Uo)

Mean Peak

40-70 40-70 40-70 100V

24 60

DEPTH

A-2

WEIGHT

K2823-1

20.40 in ( 518 mm)

14.00in ( 356 mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

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

IP23 155º(F) Insulation Class

* Weight does not include input cord.

IEC 60974-1

24.80in ( 630mm)

STORAGE TEMPERATURE RANGE

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

85 lbs (39 kg)*

POWER WAVE®S350

A-3

INSTALLATION

A-3

SAFETY PRECAUTIONS Read this

entire installation section before you start installa-

tion.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE grounding lug to a proper safety (Earth) ground.

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

S350

SELECT SUITABLE LOCATION

The POWER WAVE®S350 will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation.

LIFTING

Both handles should be used when lifting POWER WAVE S350. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the POWER WAVE

S350 with accessories attached to it.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not operate machine while suspended when lifting.

FALLING

EQUIPMENT can

cause injury.

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

STACKING

The POWER WAVE®S350 cannot be stacked.

TILTING

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

• The machine must be located where there is free circulation of clean air such that air movement in the back, out the sides and bottom will not be restricted.

• Dirt and dust that can be drawn into the machine should be kept to a minimum. The use of air filters on the air intake is not recommended because normal air flow may be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.

• Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.

• Do not mount the POWER WAVE bustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060” (1.6mm) thick, which shall extend not less than 5.90” (150mm) beyond the equipment on all sides.

S350 over com-

INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the POWER WAVE S350. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information in this manual.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with a ground symbol is located next to the input power connection block.

See your local and national electrical codes for proper grounding methods.

HIGH FREQUENCY PROTECTION

The EMC classification of the POWER WAVE Industrial, Scientific and Medical (ISM) group 2, class A. The

POWER WAVE L10093 for further details).

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

S350 is for industrial use only. (See print

S350 away from radio controlled

S350 is

S350

POWER WAVE®S350

A-4

INSTALLATION

A-4

INPUT CONNECTION

WARNING

Only a qualified electrician should connect the input leads to the POWER WAVE should be made in accordance with

all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death.

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

A 10 ft. (3.0m) power cord is provided and wired into the machine.

For Single Phase Input

Connect green lead to ground per National Electrical Code.

Connect black and white leads to power.

Wrap red lead with tape to provide 600V insulation.

For Three Phase Input

Connect green lead to ground per National Electric Code.

S350. Connections

WARNING

The POWER WAVE®S350 ON/OFF switch is not intended as a service disconnect for this equipment. Only a qualified electrician should con-

nect the input leads to the POWER WAVE

S350. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect access door of the machine. Failure to do so may result in bodily injury or death.

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

POWER CORD REPLACEMENT

WARNING

Only a qualified electrician should connect the input leads to the POWER WAVE should be made in accordance with all local and national electrical

codes and the connection diagrams. Failure to do so may result in bodily injury or death.

S350. Connections

Connect black, red and white leads to power.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to Specification Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers). Choose input and grounding wire size according to local or national electrical codes. Using input wire sizes, fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

The POWER WAVE®S350 automatically adjusts to work with different input voltages. No reconnect switches settings are required.

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If the input power cord is damaged or needs to be replaced an input power connection block is located in the back of the machine with the access panel removed as shown Figure A.1.

ALWAYS CONNECT THE POWER WAVE GROUND- ING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH) GROUND.

FIGURE A.1

CONNECTION BLOCK

GROUND LUG

INPUT POWER CORD

POWER WAVE®S350

A-5

K87870

CONNECTION DIAGRAMS

INSTALLATION

SMAW (STICK) WELDING

A-5

GTAW (TIG) WELDING

A user interface is required for adjusting the TIG welding settings. A Power Feed wire feeder can be used as the user interface (Figure A.2), or a S-series user interface (K2828-1) can be installed into the power source (Figure A.3). Refer to the connection diagrams based on the user interface that is being used. For either setup the K2825-1 solenoid kit is recommended for controlling the gas. Alternate configurations are possible depending on the wire feeder that is being used. Refer to the wire feederʼs manual for alternative configurations.

FIGURE A.2

REGULATOR FLOWMETER

GAS HOSE

GAS SOLENOID KIT (INSIDE MACHINE) K2825-1

TIG WITH POWER FEED USER INTERFACE

Similar to TIG welding a user interface is required for adjusting the Stick welding settings. A Power Feed wire feeder can be used as the user interface, or a K2828-1 (user interface control panel) can be installed into the power source (Figure A.4). The connection diagram shown is based on the S-Series user interface (K2828-1). In this diagram the remote control box is optional.

GMAW (MIG) WELDING

An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.5 for the connection details.

TO REMOTE CONTROL RECEPTACLE

REGULATOR FLOWMETER

GAS HOSE

PF10-M WIRE FEEDER

GAS SOLENOID KIT (INSIDE MACHINE)

K2825-1

ARCLINK CABLE K1543-[XX]

TO NEGATIVE (-) STUD

TIG TORCH

K2266-1 KIT (INCLUDES WORK CLAMP, ADAPTER, AND REGULATOR)

FIGURE A.3

TIG WITH S-SERIES USER INTERFACE

USER INTERFACE CONTROL PANEL K2828-1

TO NEGATIVE (-) STUD

TIG TORCH K2266-1 KIT

(INCLUDES WORK CLAMP,

ADAPTER, AND REGULATOR)

POWER WAVE®S350

TO POSITIVE (+) STUD

WORK CLAMP

WORK PIECE

TO REMOTE CONTROL

RECEPTACLE

WORK CLAMP

WORK PIECE

FOOT AMPTROL

FOOT AMPTROL K870

A-6

INSTALLATION

FIGURE A.4

STICK WITH S-SERIES USER INTERFACE

A-6

TO NEGATIVE (-) STUD

WORK CLAMP

REGULATOR FLOWMETER

WORK PIECE

USER INTERFACE CONTROL PANEL

K2828-1

FIGURE A.5

MIG PROCESS

TO POSITIVE (+) STUD

REMOTE CONTROL BOX

K857

ELECTRODE HOLDER KIT K2394-1 KIT (INICLUDES GROUND CLAMP)

PF10-M

WIRE FEEDER

GAS HOSE

ARCLINK CABLE K1543-[XX]

TO POSITIVE (+) STUD

POWER WAVE®S350

TO NEGATIVE (-) STUD

WORK CLAMP

WORK PIECE

A-7

INSTALLATION

A-7

RECOMMENDED WORK CABLE SIZES FOR ARC WELDING

Connect the electrode and work cables between the appropriate output studs of the Power Wave per the following guidelines:

• Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source. Connect a work lead from the negative (-) power source output stud to the work piece

• When negative electrode polarity is required, such as in some Innershield applications, reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).

S350

CAUTION

Negative electrode polarity operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode Polarity attribute to be set. See the Remote Sense Lead Specification section of this document for further details.

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

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

OUTPUT CABLE GUIDELINES (Table A.1)

General Guidelines

• Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance. Always use the largest welding cables (electrode and work) that are practical, and be sure all connections are clean and tight.

Note: Excessive heat in the weld circuit indicates undersized cables and/or bad connections.

• Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil excess cable. Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit.

• Always weld in a direction away from the work (ground) connection.

Table A.1 shows copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.

Percent Duty

Amperes

200

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

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.

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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

A-9

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the 5-pin arclink control cable (K1543-xx) and is always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured by the active weld mode.

Work Voltage Sensing

The Power Wave sense work voltage at the negative output stud (positive output polarity with remote Work Voltage Sensing disabled).

S350 is configured at the factory to

INSTALLATION

A-9

Negative Electrode Polarity

The Power Wave ly sense the polarity of the sense leads. With this feature there are no set-up requirements for welding with negative electrode polarity. This feature can be disabled through the Weld Manager Utility (available at www.powerwavesoftware.com) or through the set up menu (if a user interface is installed into the power source).

S350 has the ability to automatical-

CAUTION

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

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

While most applications perform adequately by sensing the work voltage directly at the output stud, the use of a remote work voltage sense lead is recommended for optimal performance. The remote WORK sense lead (21) can be accessed through the four-pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit. It must be attached to the work as close to the weld as practical, but out of the weld current path. For more information regarding the placement of remote work voltage sense leads, see the section entitled "Voltage Sensing Considerations for Multiple Arc Systems."

POWER WAVE®S350

A-10

INSTALLATION

A-10

VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS

Special care must be taken when more than one arc is welding simultaneously on a single part. Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads, but they are strongly recommended.

If Sense Leads ARE NOT Used:

• Avoid common current paths. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources, and result in arc interference.

FIGURE A.7

DIRECTION OF TRAVEL

If Sense Leads ARE Used:

• Position the sense leads out of the path of the weld current. Especially any current paths common to adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources, and result in arc interference.

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

(See Figure A.7)

CONNECT ALL SENSE LEADS AT THE END OF THE WELD.

CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD.

POWER WAVE®S350

A-11

INSTALLATION

• For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path.

(See Figure 8.A)

FIGURE A.8

POWER

SOURCE

WER

PO SOURCE

A-11

POWER SOURCE #1

WER

PO SOURCE

POWER

SOURCE

WER

SOURCE

POWER WAVE®S350

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