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Lincoln Electric POWER WAVE F355I manual

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Table of contents for the manual

  • Page 1

    PO WER W A VE F355i (CE) OPERA TOR’S MANUAL For use with machines Code 10997, 11252 IM799-A January, 2005 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 thought- ful operation on your part. DO NOT INSTALL, OPERA[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS 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[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

  • Page 6

    v SAFETY v L10093 3-1-96H Conf ormance standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc W elding Equipment. It All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be received b y other equipment, electr ical interference ma y result. Electr ical emissions ma y affect [...]

  • Page 7

    vi SAFETY vi L10093 3-1-96H The size of the surrounding area to be considered will depend on the structure of the building and other activities Methods of Reducing Emissions Consideration should be giv en to shielding the supply cable of per manently installed welding equipment, in metallic conduit or equivalent. Shielding should be electr ically c[...]

  • Page 8

    vii vii 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.[...]

  • Page 9

    viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE 355 ....................................................A-1 Safety Precautions..........................................................................[...]

  • Page 10

    A-1 INST ALLA TION POWER WAVE F355i (CE) A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE F355i INPUT AC VOL T AGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous) POWER K2260-1 380-415 350A / 34V / 60% 14.6” x 17.2” x 27.6”* WAVE K[...]

  • Page 11

    A-2 INST ALLA TION POWER WAVE F355i (CE) A-2 SELECT SUIT ABLE LOCA TION The Invertec POWER WAVE F355i will operate in harsh environments. Even so, it is important that sim- ple preventative measures are followed in order to assure long life and reliable operation. • The machine must be located where there is free cir- culation of clean air such t[...]

  • Page 12

    When operating with electrode polarity negative the "Electrode Sense Polarity" DIP switch must be set to the "Negative" position on the Wire Drive Feed Head PC Board. The default setting of the switch is positive electrode polari- ty. Set the Negative Polarity switch on Wire Feed Head PC board as follows: ELECTRIC SHOCK can kill[...]

  • Page 13

    5 . Replace the wrap around and screws. The PC board will “ read ” the switch at power up, and config- ure the work voltage sense lead appropriately. ELECTRODE VOLTAGE SENSING Enabling or disabling electrode voltage sensing is automatically configured through software. The 67 electrode sense lead is internal to the cable to the wire feeder and [...]

  • Page 14

    A-5 INST ALLA TION POWER WAVE F355i (CE) A-5 ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. ---------------------------------------------------------------------- 1. Set the High/Low switch code on Feed Head PC board as follows: 2. Turn off power to the power source at th[...]

  • Page 15

    A-6 INST ALLA TION POWER WAVE F355i (CE) A-6 WELDING WITH MUL TIPLE POWER W A VES Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. ----------------------------------------------------------------------- Each power source requires a work lead[...]

  • Page 16

    GENERAL DESCRIPTION The Power Wave Robotic power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, constant power, pulse on pulse and pulse welding modes. The Power Wave power source is designed to be used with the Robotic family of Power Feed w[...]

  • Page 17

    LIMIT A TIONS • Only Arc Link compatible Power Feed automatic wire feeders and users interfaces may be used. Other Lincoln wire feeders or non-Lincoln wire feeders can- not be used. • POWER WAVE F355i (CE) Output Limitations The POWER WAVE F355i (CE) will support maxi- mum average output current of 350 Amps @ 60% duty cycle. DUTY CYCLE AND TIME[...]

  • Page 18

    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 oper- ator must adjust the voltage to compensate for any changes made to the WFS. • VOLTS / TRIM: In constant voltage modes (pulse on pulse GMAW, standard CV)[...]

  • Page 19

    CONST ANT VOL T AGE WELDING Non Synergic CV: This type of CV mode behaves more like a conventional CV power source. Voltage and WFS 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: Arc Control, often referred to as wave contr[...]

  • Page 20

    B-5 OPERA TION B-5 The Peak Current, Background Current, and Frequency are identical for the high energy and low energy pulses. In addition to cooling the weld down, the major effect of the low energy pulses is that they form a weld ripple. Since they occur at very regular time intervals, the weld bead obtained is very uniform with a very consisten[...]

  • Page 21

    C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED K940-[ ] Work Voltage Sense Lead Kit (Sense Lead Kits,10 Ft.,25 Ft.,50 Ft., or 75 Ft. lengths) K1796-Coaxial Welding Cable- (Requires Adapter K2176-1) K2176-1 Twist-mate to Lug Adapters Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE C[...]

  • Page 22

    D-1 MAINTENANCE D-1 POWER WAVE F355i (CE) SAFETY PRECAUTIONS CAP ACITOR DISCHARGE PROCEDURE 1. Obtain a power resistor (25 ohms, 25 watts). 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resis- tor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all f[...]

  • Page 23

    E-1 TROUBLESHOOTING E-1 POWER WAVE F355i (CE) 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 r[...]

  • Page 24

    E-2 TROUBLESHOOTING E-2 POWER WAVE F355i (CE) USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feed head) has a status light, and when a problem occurs it is important to note the condition of each. Included in this section is infor[...]

  • Page 25

    E-3 TROUBLESHOOTING E-3 POWER WAVE F355i (CE) 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 E[...]

  • Page 26

    E-4 TROUBLESHOOTING E-4 POWER WAVE F355i (CE) Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 27

    E-5 TROUBLESHOOTING E-5 POWER WAVE F355i (CE) Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 28

    E-6 TROUBLESHOOTING E-6 POWER WAVE F355i (CE) Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized L[...]

  • Page 29

    E-7 TROUBLESHOOTING E-7 POWER WAVE F355i (CE) 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 P[...]

  • Page 30

    F-1 DIAGRAMS F-1 POWER WAVE F355i (CE) 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 co[...]

  • Page 31

    F-2 DIAGRAMS F-2 POWER WAVE F355i (CE) 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 co[...]

  • Page 32

    F-3 CONNECTION DIAGRAM F-3 POWER WAVE F355i (CE) Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV / Pulse Configuration shown) SEE SECTION A-4, Power Wave / Power Feed Wire Feeder Interconnections POWER WAVE F355i COMMUNICATION INTERFACE OPTIONAL (K2436-1) NOT ON CODES 10997 OR BELOW. VOLTAGE SENSE LEADS (OPTIONAL[...]

  • Page 33

    F-4 DIMENSION PRINT F-4 POWER WAVE F355i (CE) M19982 A 14.64 .40 10.06 17.20 25.15 27.60 3.37 .81 .51[...]

  • Page 34

    NOTES POWER WAVE F355i (CE)[...]

  • Page 35

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

  • Page 36

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

  • Page 37

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]