Lincoln POWER WAVE S350, Operator'S Manual

Page 1: ...achines having Code Numbers 11694 11753 11782 12371 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for futur...

Page 2: ...N A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ...ers 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 th...

Page 4: ...m to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes an...

Page 5: ...ent 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...

Page 6: ...dures 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 ___...

Page 7: ...1 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 tripping action that decreases as the magnitude of the current increases 3 Type SO cord or similar i...

Page 8: ...entally 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 A 2 INSTALLATION POWER WAVE S350 S350 ALUMINUM 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 determi...

Page 9: ...ry 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 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 ...

Page 10: ... machine is not being used at high currents INPUT VOLTAGE SELECTION The POWER WAVE S350 automatically adjusts to work with dif ferent input voltages No reconnect switches settings are required An input cord is provided with the POWER WAVE S350 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 ...

Page 11: ...rce Figure A 3 The connection diagram shown is based on the S Series user interface K3001 2 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 4 for the connection details A 5 INSTALLATION POWER WAVE S350 S350 ALUMINUM FIGURE A 2 FIGURE A 3 K3001 2 TIG WITH S SERIES USER INTERFACE FOOT AMPTROL WORK ...

Page 12: ...A 6 INSTALLATION POWER WAVE S350 S350 ALUMINUM 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 4 ...

Page 13: ...nce 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 m...

Page 14: ...y 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 vol...

Page 15: ...y 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 featu...

Page 16: ... 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 t...

Page 17: ...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 A 7 A 11 INSTALLATION POWER WAVE S350 S350 ALUMINUM POWER SOURCE 2 POWER SOURCE 1 POWER POWER SOURCE SOURCE 1 POWER SOURCE 2 2 POWER SOURCE 1 FIGURE A 7 ...

Page 18: ...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 5 pin 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 route...

Page 19: ...A 13 NOTES ...

Page 20: ...UTIONS AND IN THE FRONT OF THIS OPERATING MANUAL 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 S...

Page 21: ...y 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...

Page 22: ...ext 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 facilita...

Page 23: ...R FUTURE DEVELOPMENT 8 GAS SOLENOID KIT OPTIONAL B 4 OPERATION POWER WAVE S350 S350 ALUMINUM 6 6 8 8 1 1 2 2 3 3 4 4 5 5 7 7 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 1 2 2 3 3 4 4 5 5 6 6 7 7...

Page 24: ...gic 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 ...

Page 25: ...age 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 s...

Page 26: ...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 i...

Page 27: ...ylinder 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 o...

Page 28: ...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 S3...

Page 29: ...y 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 i...

Page 30: ...erstand 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 w...

Page 31: ... 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 erro...

Page 32: ...d 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...

Page 33: ...urrent 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...

Page 34: ...too high 1 Input voltage is too low or too high 2 Thermal Error 3 Secondary current limit has been exceed ed see error 54 3a Input control board fault see input con trol 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 facili...

Page 35: ...rrect 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 th...

Page 36: ...t 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...

Page 37: ...or cross over cable is being used refer to local IT department for assistance 1a Verify the cables are fully inserted 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 e...

Page 38: ...CK GND1 VERTICAL PANEL BASE GROUND BOND CIRCUIT 21 67 373 372 2 1 4 3 J51 STATUS RED GREEN LED THERMAL LED W 372 373 370 371 206 901B 903B 2 1 4 3 J46 66 53 54 349 352 354 357 347 342 343 J15 410 H G6536 2PRINT LEM 356 358 J47 2 3 6 7 200 OHM 100 W B52 206A 207 TO EARTH GROUND PER THE NATIONAL ELECTRIC CODE FAN FAN B R B FAN R 1J56 3J56 353A 351A 1J55 3J55 353C 351C 1J54 3J54 353D 351D 353B 351B B...

Page 39: ...F 2 DIAGRAMS POWER WAVE S350 S350 ALUMINUM 27 43 22 25 13 91 18 81 18 36 6 00 ...

Page 40: ...Power Wave S350 Aluminum 12371 ...

Page 41: ...ii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 42: ...SE FRONT ASSEMBLY AR 2 P 855 D BASE POWER CONVERSION ASSEMBLY AR 3 P 855 E VERTICAL DIVIDER PANEL ASBLY AR 4 P 855 F OUTPUT CHOKE ASSEMBLY AR 5 P 855 G CASE BACK ASSEMBLY AR 6 P 855 H ROOF ASSEMBLY AR Index of Sub Assemblies 12371 Power Wave S350 Aluminum 12371 1 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 43: ...P 855 A jpg Index of Sub Assemblies 12371 2 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 44: ...KEY PART NUMBER DESCRIPTION QTY 9SG6094 PRIMARY CONTROL HARNESS 1 9SM19969 2 ETHERNET PATCH CABLE 1 Miscellaneous Items Power Wave S350 Aluminum 12371 3 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 45: ...No Image Miscellaneous Items 4 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 46: ... NYLON INSERT 2 7A 9SS20030 1 LINE SWITCH 1 7B 9SS25384 1 SWITCH COVER WEATHER RESISTANT 1 9ST9695 1 LOCKWASHER 2 9SCF000084 10 32X 625HHCS 2 9SS18491 3 M O V ASBLY 1 15A 9SM13896 9 OUTPUT TERMINAL MOLDING 2 15B 9SS9225 101 SELF TAPPING SCREW 4 16A 9SG6758 1 INPUT CONTROL POWER SUPPLY PC BD ASBLY 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 3 18 9SG8226 NAMEPLATE 1 19 9ST10397 3 PLUG BUTTON 1 21 9ST1...

Page 47: ...ART NUMBER DESCRIPTION QTY 31B 9SS9225 99 SELF TAPPING SCREW 4 31C 9SG6529 UI TRIM 1 31D 9SG6601 DECAL 1 Case Front Assembly 6 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 48: ...P 855 C jpg Case Front Assembly Power Wave S350 Aluminum 12371 7 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 49: ...7 1 NYLON INSERT 2 10A 9SL13138 CORNER CAP 4 10B 9SS9262 182 PLAIN WASHER 8 10C 9SS9225 100 SELF TAPPING SCREW 8 12A 9SM21469 3 POWERBOARD BOTTOM BRACKET 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 13 9SG6037 1 POWER BOARD ASBLY 1 13A 9ST13359 29 THERMOSTAT 1 9SS9225 100 SELF TAPPING SCREW 4 9SE106A 1 LOCKWASHER 4 9SS9262 27 PLAIN WASHER 4 14 9SM15045 100 ACOUSTICAL FOAM 3 16A 9SCF000010 10 24HN 2...

Page 50: ...P 855 D jpg Base Power Conversion Assembly Power Wave S350 Aluminum 12371 9 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 51: ...0 63 2 4A 9SS28105 MYLAR INSULATION 1 4B 9SS20763 3 TERMINAL BLOCK 1 9SCF000193 8 32X1 25RHS 2 5A 9SS31170 3 CONTROL PC BD ASBLY 1 5B 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 4 7 9ST12380 1 BUSHING 1 9SS18858 11 SUPPRESSOR ASBLY 1 11 9SG8226 NAMEPLATE 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 9SS8025 99 SCREW 10 x 1 50 GIMLET POINT SLOTTED 2 9ST13260 4 DECAL EARTH GROUND CONN 1 Vertical Divider P...

Page 52: ...P 855 E jpg Vertical Divider Panel Asbly Power Wave S350 Aluminum 12371 11 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 53: ... 1 14A 9SS22168 HEAT SINK HOLDER 2 9SCF000015 1 4 20X1 00HHCS 2 14C 9SS9262 98 PLAIN WASHER 4 14D 9SE106A 2 LOCKWASHER 2 14E 9SCF000017 1 4 20HN 2 15A 9SM22372 BUS BAR 1 15B 9SCF000015 1 4 20X1 00HHCS 2 15C 9SS9262 98 PLAIN WASHER 4 15D 9SE106A 2 LOCKWASHER 2 15E 9SCF000017 1 4 20HN 2 16A 9SCF000015 1 4 20X1 00HHCS 3 16B 9SS9262 98 PLAIN WASHER 6 16C 9SE106A 2 LOCKWASHER 3 16D 9SCF000017 1 4 20HN ...

Page 54: ...KEY PART NUMBER DESCRIPTION QTY 9SS9225 99 SELF TAPPING SCREW 4 Output Choke Assembly Power Wave S350 Aluminum 12371 13 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 55: ...P 855 F jpg Output Choke Assembly 14 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 56: ...2287 20 CIRCUIT BREAKER 10A250VAC 1 10B 9SS22061 3 SEALING BOOT 1 11A 9SS31114 COVER PLATE 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 12A 9SS31116 COVER PLATE 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 13B 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 13C 9SG6602 RECEPTACLE ASSEMBLY 1 14 9ST10397 4 PLUG BUTTON 1 9SM21927 1 PLUG AND LEAD ASBLY 1 15A 9SS12021 79 BOX RECEPTACLE SOLID SHELL 1 15B 9SS254...

Page 57: ...BLY 1 9SM22519 CONNECTOR LEAD ASBLY 1 25A 9SS12021 73 BOX RECEPTACLE SOLID SHELL 1 9SS8025 118 SELF TAPPING SCREW 2 25C 9SS17062 10 CABLE CONNECTOR CAP 1 26 9SS17062 9 CABLE CONNECTOR CAP 1 9SS31115 SOLENOID MTG PLATE 1 9SS9225 99 SELF TAPPING SCREW 2 Case Back Assembly 16 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 58: ...P 855 G jpg Case Back Assembly Power Wave S350 Aluminum 12371 17 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 59: ... CORNER CAP 4 5B 9SS9262 182 PLAIN WASHER 12 5C 9SS9225 100 SELF TAPPING SCREW 12 6A 9SG6525 1 HANDLE SAND CAST 2 6B 9SCF000410 1 4 20x 75HHCS FULL GR2 4554 8 9SE106A 27 LOCK WASHER 8 9SM25327 1 LEFT CASE SIDE ASBLY 1 7A 9SL16747 1 LEFT CASE SIDE 1 7B 9SS27368 4 DECAL LE LOGO 1 7C 9SS27468 1 POWER WAVE LOGO 1 9SS31176 ALUMINUM SOLUTIONS LOGO 1 9SL16760 LOUVER INSERT 1 9ST12584 13 BLIND RIVET 6 9SM...

Page 60: ...MBER DESCRIPTION QTY 9SS9262 182 PLAIN WASHER 4 9SS9225 100 SELF TAPPING SCREW 4 9C 9SS9225 99 SELF TAPPING SCREW 8 Roof Assembly Power Wave S350 Aluminum 12371 19 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 61: ...P 855 H jpg Roof Assembly 20 Power Wave S350 Aluminum 12371 Printed 08 02 2016 at 10 04 29 Produced by Enigma ...

Page 62: ...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 moja da 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 ...

Page 63: ... 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 öff nen Maschine anhalten l Não o...

Page 64: ...uch 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 prod...