Lincoln Electric S350 User Manual

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

POWER WAVE S350

OPERATORʼS MANUAL

IM10061-A

February, 2011

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.

For use with machines having Code Numbers:

11694, 11782

Copyright © Lincoln Global Inc.

®

RETURN TO MAIN MENU

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

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

____________________________________________________

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

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

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

___________________________________________________

1.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.

i

SAFETY

i

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.

WARNING

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

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

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

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

2.d.1.

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

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

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

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.

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

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.

The Above For Diesel Engines

The Above For Gasoline Engines

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.

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
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

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

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SAFETY

ii

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.

5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

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

5.f. Also see item 1.b.

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 manufacturerʼs
recommendations.

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

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.

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.

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.

iii

SAFETY

iii

Refer to http://www.lincolnelectric.com/safety for additional safety information.

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

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

b. Faire trés attention de bien sʼisoler de la masse quand on

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

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

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

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

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

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

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

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

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

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

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

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

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

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

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

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

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

iv

SAFETY

iv

vv

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

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

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

WARNING

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

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

CAUTION

Please Examine Carton and Equipment For Damage Immediately

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

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

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

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

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

• For On-Line Registration: Go to our

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

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

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 customerʼs 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.

vivi

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, A-6

Recommended Work Cable Sizes ................................................................................A-7

Cable Inductance and its Effects on Welding................................................................A-8

Remote Sense Lead Specifications.......................................................................A-8, A-9

Voltage Sensing Considerations for Multiple Arc Systems................................A-10, A-11

Control Cable Connections ................................................................................................A-12

________________________________________________________________________________

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

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

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

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

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

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

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

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

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

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

Case Front Controls .............................................................................................................B-3

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

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

________________________________________________________________________________

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

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

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

Stick Operations ....................................................................................................C-2

________________________________________________________________________

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

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

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

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

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

________________________________________________________________________________

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

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

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

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

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

________________________________________________________________________________

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

________________________________________________________________________

Parts Pages ...............................................................................................................P-654 Series

_______________________________________________________________________

________

A-1

INSTALLATION

POWER WAVE® S350

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE® S350

RECOMMENDED INPUT WIRE AND FUSE SIZES

1

INPUT

VOLTAGE / PHASE/

FREQUENCY

200-208/1/50/60
200-208/3/50/60

230/1/50/60
230/3/50/60

380-415/3/50/60

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

TIME DELAY FUSE

OR BREAKER

2

AMPERAGE

80
50
80
45
30
25
20

CORD SIZE

3

AWG SIZES

(mm2)

6 (13)
8 (10)
4 (16)
8 (10)
12 (4)
12 (4)

14 (2.5)

MAXIMUM

INPUT AMPERE RAT-

ING AND DUTY CYCLE

60A, 100%
39A, 40%
67A, 30%
35A, 40%
19A, 40%
17A, 40%
14A, 40%

RATED OUTPUT

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K2823-3

Duty Cycle

40% rating

100% rating

300

Amps

29

Volts

350

Amps

31.5

Volts

320

Amps

30

Volts

INPUT

VOLTAGE/PHASE/

FREQUENCY

200-208/1/50/60

230/1/50/60
380-415/1/50/60
200-208/3/50/60

230/3/50/60
380-415/3/50/60

460/3/50/60

575/3/50/60

Input Amperes

(1 Phase in parenthesis)

39/35/19/17/14

(60/67

1

/NA/NA/NA)

31/28/15/14/11

(60/53/NA/NA/NA)

Idle Power

300 Watts Max.

(fan on)

Power Factor @

Rated Output

.95

Input Voltage ± 10%

208/230/400*460/575

50/60 Hz

(*includes 380V to 413V)

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.

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

GMAW

40%*

60%

60%

100%

300 Amps / 29 Volts

250

Amps

30

Volts

325

Amps

33

Volts

275

Amps

31

Volts

SMAW

40%*

100%

250 Amps / 30 Volts

300

Amps

22 Volts

350

Amps

24 Volts

325

Amps

23Volts

GTAW-DC

40%

60%

100%

A-2

INSTALLATION

POWER WAVE® S350

A-2

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

HEIGHT

20.40 in ( 518 mm)

MODEL

K2823-3

WIDTH

14.00in ( 356 mm)

DEPTH

24.80in ( 630mm)

WEIGHT

85 lbs (39 kg)*

OPERATING TEMPERATURE RANGE

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

STORAGE TEMPERATURE RANGE

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

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

SMAW

OUTPUT RANGE (AMPERES)

40-350A

5-350A

55-325A

OCV (Uo)

Mean Peak

40-70V

100V
24V
60V

WELDING PROCESS

IP23 155º(F) Insulation Class

* Weight does not include input cord.

Thermal tests have been performed at ambient tem­perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

A-3

INSTALLATION

POWER WAVE® S350

A-3

SAFETY PRECAUTIONS Read this

entire installation section before you start installa­tion.

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® S350

grounding lug to a proper safety (Earth) ground.

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

SELECT SUITABLE LOCATION

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

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

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

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

• Do not mount the POWER WAVE® S350 over com­bustible surfaces. Where there is a combustible
surface directly under stationary or fixed electrical
equipment, that surface shall be covered with a
steel plate at least .060” (1.6mm) thick, which shall
extend not less than 5.90” (150mm) beyond the
equipment on all sides.

WARNING

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.

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.

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

Locate the POWER WAVE® S350 away from radio controlled
machinery. The normal operation of the POWER WAVE® S350
may adversely affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the equipment.

• 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.

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

WARNING

A-4

INSTALLATION

POWER WAVE® S350

A-4

INPUT CONNECTION

Only a qualified electrician should
connect the input leads to the
POWER WAVE® S350. Connections
should be made in accordance with

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

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

A 15 ft. (4.6m) power cord 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.

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.

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

a qualified electrician should con­nect the input leads to the POWER WAVE® S350.
Connections should be made in accordance with
all local and national electrical codes and the con­nection 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

Only a qualified electrician should
connect the input leads to the
POWER WAVE® S350. Connections
should be made in accordance with
all local and national electrical

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

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

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

WARNING

WARNING

WARNING

CONNECTION
BLOCK

GROUND
LUG

INPUT
POWER
CORD

A-5

INSTALLATION

POWER WAVE® S350

A-5

CONNECTION DIAGRAMS

GTAW (TIG) WELDING

A user interface is required for adjusting the TIG weld­ing settings. S-series user interface (K3001-1) can be
installed into the power source (Figure A.3). Refer to
the connection diagrams based on the user interface
that is being used. Alternate configurations are possi­ble depending on the wire feeder that is being used.
Refer to the wire feederʼs manual for alternative config­urations.

SMAW (STICK) WELDING

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
K3001-1 (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 (K3001-1). 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.

STICK WITH S-SERIES USER INTERFACE

K3001-1

REMOTE CONTROL BOX
K857-2

USER INTERFACE
CONTROL PANEL

TO POSITIVE
(+) STUD

ELECTRODE HOLDER KIT
K875 OR K704
(INCLUDES GROUND CLAMP)

TO NEGATIVE
(-) STUD

WORK PIECE

WORK CLAMP

K8787

0, K870-2 AND

K2909-1

FIGURE A.3

FIGURE A.4

REGULATOR
FLOWMETER

TIG WITH S-SERIES USER INTERFACE

GAS SOLENOID KIT
(INSIDE MACHINE)

K2825-1

USER INTERFACE
CONTROL PANEL

K3001-1

TO REMOTE CONTROL

RECEPTACLE

GAS HOSE

K960-3

TO NEGATIVE
(-) STUD

TIG TORCH
K1782-1,-3,12

TO POSITIVE
(+) STUD

WORK CLAMP

WORK PIECE

FOOT AMPTROL

0, K870-2 AND

K2909-1

A-6

INSTALLATION

POWER WAVE® S350

A-6

MIG PROCESS

REGULATOR
FLOWMETER

GAS HOSE

WORK PIECE

WORK CLAMP

TO POSITIVE
(+) STUD

TO NEGATIVE (-) STUD

PF10-M

WIRE FEEDER

ARCLINK CABLE
K1543-[XX]

FIGURE A.5

A-7

INSTALLATION

POWER WAVE® S350

A-7

RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING

Connect the electrode and work cables between the
appropriate output studs of the Power Wave S350 per
the following guidelines:

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

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

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

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

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

General Guidelines

• Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive volt-

age 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.

CAUTION

Amperes

200

200

250

250

250

250

300

300

350

Percent Duty

Cycle

60

100

30

40

60

100

60

100

40

0 to 50 Ft.

2

2

3

2

1

1

1

2/0

1/0

50 to 100 Ft.

2

2

3

2

1

1

1

2/0

1/0

100 to 150 Ft.

2

2

2

1

1

1

1

2/0

2/0

150 to 200 Ft.

1

1

1

1

1

1

1/0

2/0

2/0

200 to 250 Ft.

1/0

1/0

1/0

1/0

1/0

1/0

2/0

3/0

3/0

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**

OUTPUT CABLE GUIDELINES (Table A.1)

** 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).

A-8

INSTALLATION

POWER WAVE® S350

A-8

FIGURE A.6

B

A

C

WORK

POWER
WAVE
S350

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 S350 has accurate data about the arc condi­tions.

Depending upon the process, inductance within the
electrode and work cables can influence the voltage
apparent at the studs of the welder, and have a dra­matic effect on performance. 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 S350 has the ability to automatically
sense when remote sense leads are connected. With
this feature there are no requirements for setting-up
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).

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)

CAUTION

Process

GMAW

GMAW-P

FCAW
GTAW
SMAW

Electrode Voltage Sensing

(1)

67 lead

67 lead required
67 lead required

67 lead required
Voltage sense at studs
Voltage sense at studs

Work Voltage Sensing

(2)

21 lead

21 lead optional

(3)

21 lead optional

(3)

21 lead optional

(3)

Voltage sense at studs
Voltage sense at studs

TABLE A.2

(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).

(3)

Negative polarity semi-automatic process operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode
Polarity attribute to be set.

A-9

INSTALLATION

POWER WAVE® S350

A-9

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into
the 5-pin arclink control cable 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

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

Negative Electrode Polarity

The Power Wave S350 has the ability to automatically
sense the polarity of the sense leads. With this fea­ture there are no set-up requirements for welding with
negative electrode polarity. This feature can be dis­abled through the Weld Manager Utility (available at
www.powerwavesoftware.com) or through the set up
menu (if a user interface is installed into the power
source).

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

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

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."

CAUTION

A-10

INSTALLATION

POWER WAVE® S350

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.

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)

FIGURE A.7

DIRECTION
OF TRAVEL

CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.

CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD.

A-11

INSTALLATION

POWER WAVE® S350

A-11

• For circumferential applications, connect all work

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

(See Figure 8.A)

FIGURE A.8

POWER
SOURCE
#1

POWER

SOURCE

#1

PO
SOURCE

#2

WER

PO

SOURCE

#2

WER

WER

PO
SOURCE

#1

POWER
SOURCE

#2

A-12

INSTALLATION

POWER WAVE® S350

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 / Power Feed sys­tems. Most are designed to be connected end to end
for ease of extension. Generally, it is recommended
that the total length not exceed 100ft. (30.5m). The
use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication prob­lems (system shutdowns), poor motor acceleration
(poor arc starting), and low wire driving force (wire
feeding problems). Always use the shortest length of
control cable possible, and DO NOT coil excess
cable.

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

Product specific Installation Instructions

Connection Between Power Source and ArcLink®
Compatible Wirefeeders (K1543, K2683 – ArcLink
Control Cable)

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

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.

B-1

OPERATION

POWER WAVE® S350

B-1

• 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.

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

ARC RAYS can burn.

•

Wear eye, ear and body protec­tion.

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

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

FRONT OF THIS OPERATING MAN-

UAL.

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

WARNING

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

POSITIVE OUTPUT

NEGATIVE OUTPUT

STATUS

PROTECTIVE
GROUND

COOLER

WARNING OR
CAUTION

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

HIGH TEMPERATURE

OUTPUT

OPERATORS
MANUAL

CIRCUIT BREAKER

WORK

DANGEROUS
VOLTAGE

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.

B-2

OPERATION

B-2

PRODUCT DESCRIPTION

PRODUCT SUMMARY

The Power Wave® S350 is a portable multi-process
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® S350 is designed to be a very flex­ible 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® S350
which allows for effortless software upgrades through
Powerwavesoftware.com. The Ethernet communica­tion also gives the Power Wave® S350 the ability to
run Production Monitoring™ 2. Also a Devicenet
option which will allow the Power Wave® S350 to be
used in a wide range of configurations. Also, the
Power Wave® S350 is being designed to be compati­ble with future advanced welding modules like STT

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® S350 can be set up in
a 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® feeders.

RECOMMENDED PROCESSES

The Power Wave S350 is a high speed, multi-process
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.

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 - 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.

POWER WAVE® S350

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

Wave® S350.

5. NEGATIVE WELD OUTPUT

6. POSITIVE WELD OUTPUT

7. WORK SENSE LEAD CONNECTOR

8. 12-PIN CONNECTOR (Optional)

B-3

OPERATION

B-3

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.

• Utilizes next generation microprocessor control,
based on the ArcLink® platform.

• 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.

• Ethernet connectivity.

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

• Potted PC boards for enhanced ruggedness/relia­bility.

• Enclosure reinforced with heavy duty aluminum
extrusions for mechanical toughness

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

• Sync Tandem installed.

• Cam-Lock type connectors

POWER WAVE® S350

1

2

3

4

6

5

7

8

FIGURE B.1

B-4

OPERATION

B-4

CASE BACK CONTROLS

(See Figure B.2a for Code 11782)

1. 115 VAC KIT (OPTIONAL)

2. ARCLINK CONNECTOR

3. CIRCUIT BREAKER

4. SYNC TANDEM/ STT CONNECTOR

5. DEVICENET KIT (OPTIONAL)

6. ETHERNET

7. GAS SOLENOID KIT (OPTIONAL)

POWER WAVE® S350

6

7

1

2

3

4

5

FIGURE B.2a

CASE BACK CONTROLS

(See Figure B.2 for Code 11694)

1. 115 VAC KIT (OPTIONAL)

2. ARCLINK CONNECTOR

3. CIRCUIT BREAKER

4. SYNC TANDEM/ STT CONNECTOR

5. DEVICENET KIT (OPTIONAL)

6. ETHERNET

7. RESERVED FOR FUTURE DEVELOPMENT

8. GAS SOLENOID KIT (OPTIONAL)

1

2

3

4

5

6

7

8

FIGURE B.2

B-5

OPERATION

B-5

POWER WAVE® S350

COMMON WELDING PROCEDURES

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 S350 encompasses a wide range of
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.

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.

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.

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.

WARNING

B-6

OPERATION

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 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.

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 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.
The Power Wave® S350 can be run in either a 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.

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® S350 automatically
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).

PULSE WELDING

Pulse welding procedures are set by controlling an
overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impracti­cal and instead the arc length is set by adjusting
“trim”.

Trim adjusts the arc length and ranges from 0.50 to

1.50 with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length. (See figure B.3)

POWER WAVE® S350

Trim .50

Arc Length Short

Trim 1.00

Arc Length Medium

Trim 1.50

Arc Length Long

FIGURE B.3

B-7

OPERATION

B-7

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.

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)

POWER WAVE® S350

OF F

Med ium Frequency and Width

+10.0

Hi gh F requ ency , Focused

UltimArc™ Control -10.0

Low F requency, Wide

UltimArc™ Control

UltimArc™ Control

FIGURE B.4

C-1

ACCESSORIES

C-1

POWER WAVE® S350

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 K3001-1

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-XX Series
Order K1811-XX Series

Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO

2

, Argon, or Argon-blend gas cylin-

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 Cam-Lock 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 K1803-2

Cam-Lock cable plug for 2/0 (50mm2)cable. Order
K2946-1

Coaxial Welding Cable

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

AWG 1/0 Coaxial Cables:
Order K1796-25 for 25 feet (7.6 m) cable length.
Order K1796-50 for 50 feet (15.2 m) cable length.
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length.

AWG #1 Coaxial Cables:
Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length.

K2909-1

12-pin to 6-pin adapter.

K2910-1

12-pin to 7-pin adapter.

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)

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 K2946-1.

ORDER K875

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 K2946-1.

ORDER K704

REMOTE OUTPUT CONTROL

Permits remote adjustment of output.
Order K857-2 for 25 ft (7.6m) with 12 pin
connector.

TIG OPTIONS

Pro-Torch™ TIG Torches

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

Request Lincoln publication E12.150
(See www.lincolnelectric.com)

Hand Amptrol®

Provides 25 ft. (7.6 m) of remote cur­rent control for TIG welding.

Order K963-4 for Hand Amptrol with 12 pin connector

Foot Amptrol®

Provides 25 ft. (7.6 m) of remote
current control for TIG welding.
Order K870-2 for Foot Amptrol
with 12 pin connector.

Cam-Lock Torch Adapter

For connecting K1782-1, K1782-3, K1782-12 torches
to the S350.

Order K960-3

C-2

ACCESSORIES

C-2

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® flowmeter/regulator, 10 ft. (3.0 m) gas hose,
and work clamp and cable.

Order K2265-1

MIG OPTIONS

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

Order K1803-2

COMPATIBLE LINCOLN EQUIPMENT

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

POWER WAVE® S350

D-1

MAINTENANCE

D-1

POWER WAVE® S350

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.

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.

E-1

TROUBLESHOOTING

E-1

POWER WAVE® S350

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.

CAUTION

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.

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

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.

WARNING

E-2

TROUBLESHOOTING

E-2

POWER WAVE® S350

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.

CAUTION

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.

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.

Light

Condition

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

Status LED off

Input control board

Not applicable.

Not applicable.

Not applicable.

Not applicable.

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.

System OK

Meaning

Main control board status light

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

configuration is changed during operation.

Indicates Auto-mapping has failed

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)

before the machine is turned off.

Error Code interpretation through the Status light is detailed in the

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

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

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

accessible through the Status Light.

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

historical information contained in the error logs.

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

reset.

Not applicable.

Not applicable.

Not applicable.

TABLE E.1

E-3

TROUBLESHOOTING

E-3

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

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.

Error Code #

36 Thermal error

54 Secondary (Output) over current error

56 Chopper communication error

58 Primary Fault error

Other

Indication

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.

MAIN CONTROL BOARD ( “STATUS” LIGHT)

E-4

TROUBLESHOOTING

E-4

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

INPUT CONTROL BOARD

Error Code #

331 Peak input current limit

333 Under-voltage lockout

336 Thermal Fault

337 Pre-charge timeout

346 Transformer primary over current

Other

Indication

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.

E-5

TROUBLESHOOTING

E-5

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Input fuses keep blowing

Machine will not power up (no lights)

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.

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.

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 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.

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” sec-
tion.

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

Basic Machine Problems

E-6

TROUBLESHOOTING

E-6

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Thermal LED is ON

Thermal LED is ON

“Real Time Clock” no longer func­tioning

General degradation of weld perfor­mance

Improper fan operation

1. Improper fan operation.

2. Open thermostat circuit.

1. Control PC Board Battery.

1. Wire feed problem.

2. Cabling problems.

3. Loss of, or improper Shielding
Gas.

4. Verify weld mode is correct for
process.

5. Machine calibration.

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.

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. 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).

Basic Machine Problems (Continued)

Weld and Arc Quality Problems

E-7

TROUBLESHOOTING

E-7

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

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

Machine output shuts down during a
weld.

Machine wonʼt produce full output.

Excessively long and erratic arc.

1. Burnback Time

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. On 460 or 575 the input may be
single phase.

3. Machine calibration.

1. Wire feed problem.

2. Loss of, or improper Shielding
Gas

3. Machine calibration.

1. Reduce burnback time and/or
work point.

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. Verify all 3 phases are present.

3. 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. Calibrate secondary current and
voltage.

Weld and Arc Quality Problems (Continued)

E-8

TROUBLESHOOTING

E-8

POWER WAVE® S350

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Cannot Connect

Connection Drops while welding

1. Physical connection.

2. IP address information.

3. Ethernet Speed

1. Cable Location

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.

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

Ethernet

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.

CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

ELECTRICAL SYMBOLS PER E1537.

GENERAL INFORMATION

5

10

6

3

1

2

1

1

LEAD COLOR CODING

J9, J13, J16,

J2, J5, J11,

J10A1,

B - BLACK

J31, J46,

J10B1,

8

16

4

1

6

1

9

5

J26, J27, J62,

J112

J3, J4,

J45, J61

4

4

8

3

1

5

J51, J111

J8, J24, J28,

J29, J43, J47,

J63

2

J811

R - RED

N- BROWN

V - VIOLET

G - GREEN

N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)

4

3

J6, J7,

J41

6

12

1

6

J12, J23,

J25, J42

REMOTE

AMPTROLS

ALIGNS WITH WHITE LEAD OF LED SOCKET.

S4

2

1

INPUT

SWITCH

3

4

1

S2

2

S18657 (INSERTION END)

)

A

D

N

B

E

G

N

I

R

E

D

L

O

S

(

E

3

7

S3

-

C

1

2

0

2

1

S

D

B

C

K

A

D

J

L

S1

E

H

M

F

G

ARC LINK

CONNECTOR

3A1A2A

T2

T1

T3

THERMAL LED

B

L3

L1

L2

2

1

S2

SENSE

VOLTAGE

RECEPTACLE

1

3

2

21

67E

4

3

373

4

OPTIONAL

B

W

A

B

C

DEF

H

J

L

G

K

STATUS

W

RED/GREEN LED

S1

REMOTE

AMPTROLS

ARC LINK

CONNECTOR

53F

2

3

1

J51

370

372

371

J31

PCB

USER

INTERFACE

ASSEMBLY

G5663-NEW

54F

1

4

5

2

D

2

3

5

1

D

3

2

5

4

D

4

5

3

D

1

5

2

C

6

6

7

D

5
4

5

1

C

5

4

C

3

2
1

5

3

C

2

75

76

77

200

2

4

75

76

77

51F

200

7

4

5

1

2

3

6

J115

J111

J114

(ASSEMBLY G6572-NEW)

REMOTE CONTROL PCB

M

4

51F

52F

L1

L2

53F

54F

52F

9

8

10

1
2

3

3

6

4

4

3

6

2

5

3

6

0

J112

6

3

6

3

7

3

5

9

3

6

1

8

+

901B

206

L5

WORK

-

M20305-1

903B

250 OHM 25 W

250 OHM 25 W

202

L6

B

G6536-2

+

LEM

2

1

3

4

CURRENT

52

51

358

356

8

7

4

6

5

3

2

1

J47

J46

BOARD

L15732

DC BUS

2

3

4

1

65

66

67D

67C

200 OHM

100 W

206A

207

TRANSDUCER

216

211

213

212

322

321

6

5

3

2

4

1

J27

G5915

BOARD

INPUT CONTROL

J26

6

543

2

301

303

309

J23

8

6

7

9

3

5

1

311

4

10

11

12

337

316

315

308

306

307

305

332

333

336

1

3

2

8
2
3
4

3

3

1
5

3

3

4

6

3

2

6

J

2

5

7
8

3

2

4

9

1

0

3

3

5

1

1

3

3

8

1

2
1

4

0

1

2

4

0

2

3

4

0

3

4

4

0

4

J

2

4

5
6

4

0

2

1

313

314

6

7

4

0

7

4

0

8

8

INPUT

1234567

8

9

10

J3

5

1

2

3

4

2

1

1

3

5

4

1

0

3

4

7

3

4

8

9
8

3

4

4

3

4

3

7

3

5

2

6

J

1

POWER WAVE S350

OPTIONAL

DEVICENET

317

318

318A

317A

5

D

N

G

8

B1

B2

7

3

2

A

6
5

3

3

A

J

6

3
4
3

3

2

2

3

3

1

6

115 VAC

OPTIONAL

4

1

8

5

INVERTER PCB

(ASSEMBLY G6571)

4

1

7

4

J

6

2
3

4

D

N

G

J61

4

2

1

6

4

1

5

1

6

1

2

7

414

413

411

412

xxxxxxx xxxxxx x

L1L3L2

V

U

TB

W

L3

L2

L1

TO

SUPPLY

2

3

4

9

5

3

5

7

3

4

1

3

4

6

3

4

5

8

9

4

8

9

1

8

9

3

8

9

2

6

4
3
2
1

6
5
4

J

1

3

3
2
1

G6682

J

7

CONTROL BOARD

4
3

J

1

1

5

3

2
1

5

4

4
3

J

2

2
1

J

8

1

0

5

5

3

9

3

6

3

4

1

6

8
7
6

J

4

5

3

6

4

4

3

6

2

3

3

6

1

2

3

5

6

1

3

5

8

33

33A

9

J15

32A

32

GND5

34

10A

CB1

CAPACITOR NOT

PRESENT ON

EARLIER MODELS

1
2

4

1

0

J

3

4

0

9

4

1

4

0

7
2
3

4

0

2
4

4

0

3

3

5

9

5

6

7

J

8

4

0

1
9

4

0

4

1

0

1

1

3

6

0

1

2

5

5

4

4

0

8

1

3

1

4

1

5

1

6

1
2

3

7

0

3
4

3

7

1

5

3

5

5

6

3

7

3

7

3

7

2

8

4

1

5

9
1

0

4

1

8

1

1

1

2

1

3

1

4

4

0

6

1

5

3

5

0

1

6

2

1

1

1

2

1

2

2

2

1

3

3
4
5

2

1

6

6

4

7

1

7

8

1

2

0

6

2

2

0

2

3

J

7

4
5

1

6

115V

(OPTIONAL)

(Neutral Bonded)

RECEPTACLE

ETHERNET

353

353

6

2

353A

1J56

R

CABLE

ETHERNET

RJ 45

TYPE

CONNECTOR

66

65A

350

9

876

10

8

CHOPPER

CONTROL BOARD

4

1

0

4

0

9

SINK

HEAT

351

351

351B

353B

351A

353C

351C

1J55

3J55

3J56

B

R

FAN

FAN

65

65A

10A

CB1

CHOKE

OUTPUT

355

351

353

432

5

1

AA2A3A4A5

BL1

BL2

BL4

BL3

B52

J45

345

347

341

344

346

343

342

348

1234567

8

7

2

1

654

3

J29

B

R

J28

B53

B38

B39

B40

1

2345678

553

554

54A

67A

52A

353D

351D

1J54

3J54

B

FAN

51A

554A

553A

GAS

(OPTIONAL)

SOLENOID

53B

54B

54A

53A

BED

A

ARCLINK +

ARCLINK -

CHOKE

332

333

322

335

336

334

331

337

338

8

2

1

5

3

7

6

4

10

12

A6

BL5

BL6

B32

B28

11

J43

3A

1A

2A

B31

B30

B29

318

317

317A

321

326

324

328

2

7

6

1

8

5

3

9

4

J42

1

3

0

1

2
3

3

0

3

4
5

3

0

5

6

3

0

6

7

3

0

7

8

3

0

8

J

4

1

9

3

0

9

1

0

3

1

1

1

1

1

2

3

1

1

3

3

TO EARTH GROUND PER THE

NATIONAL ELECTRIC CODE

3

1

4

1

4

3

1

5

1

5

3

1

6

1

6

318A

B41B37

G

BASE

G4770-1

GND3 CASEFRONT

3 STAGE INVERTER

GND2 CASEBACK

GROUND BOND CIRCUIT

GND1 VERTICAL PANEL

5354675251

53C

54C

52C

67C

51C

9

10

J55

53A

53B

54B

52B

67B

51B

L6

357

354

352

349

1

234

J50

GRN

RED

BLK/GRN

BLK/RED

L7

L5

L3

S3 ARCLINK

RECEPTACLE

GRN

RED

BLK/GRN

BLK/RED

A

B

C

DEF

S5

DIFF_1 HIGH

DIFF_1 LOW

DIFF_2 LOW

DIFF_2 HIGH

CONNECTOR

SYNC/TANDEM

891

893

892

894

1

2

3

4

5

S4

DNET CAN_L

DNET CAN_H

+24 VDC INPUT

DEVICENET

(OPTIONAL)

CONNECTOR

+24 VDC COMMON

L4

52B

51B

51A

52A

67A

67B

C

0 VDC

+40VDC

ELECTRODE

SENSE

F-2

DIMENSION PRINT

F-2

POWER WAVE® S350

27.43 22.25

13.91

18.81

18.36

6.00

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

l No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustible

fuera del área de trabajo.

l Gardez à l’écart de tout matériel

inflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-

dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y el

cuerpo.

l Protégez vos yeux, vos oreilles et

votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

l Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.
l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-

piración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

l Vermeiden Sie das Einatmen von

Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-

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

l Débranchez le courant avant l’entre-

tien.

l Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer

serviço.

l Não toque as partes elétricas nuas.

l Do not operate with panel open or

guards off.

l No operar con panel abierto o

guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

l Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

l Mantenha-se afastado das partes

moventes.

l Não opere com os paineis abertos

ou guardas removidas.

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