Lincoln Electric POWER WAVE S350 manual

• 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 • PO WER W A VE S350 OPERA T ORʼS MANUAL IM10061-A February, 2011 Safety Depends on You Lincoln arc welding a[...]

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. ________________________________________________[...]

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 and that of[...]

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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrod[...]

v v Thank Y ou 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. Pa[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications ...............................................................................................A-1, A-2 Safety Precautions .............................[...]

A-1 INST ALLA TION POWER WAVE® S350 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® 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 (mm 2 ) 6 ([...]

A-2 INST ALLA TION POWER WAVE® S350 A-2 PHYSICAL DIMENSIONS TEMPERA TURE 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[...]

A-3 INST ALLA TION POWER WAVE® S350 A-3 SAFETY PRECAUTIONS Read this entire installation section before you start installa- tion. 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[...]

A-4 INST ALLA TION 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-5 INST ALLA TION POWER WAVE® S350 A-5 CONNECTION DIAGRAMS GTAW (TIG) WELDING A user interface is required for adjusting the TIG weld- ing 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 p[...]

A-6 INST ALLA TION POWER WAVE® S350 A-6 MIG PROCESS REGULATOR FLOW METER GAS HOSE WO RK PI EC E WO RK CL A M P TO POSITIVE (+) STUD TO NEGATIVE (-) STUD PF10-M W IRE FEEDER ARCLINK CABLE K1543-[XX] FIGURE A.5[...]

A-7 INST ALLA TION 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[...]

A-8 INST ALLA TION POWER WAVE® S350 A-8 FIGURE A.6 B A C WORK POWER WAV E S350 CABLE INDUCT ANCE 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[...]

A-9 INST ALLA TION 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 connect- ed to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sens- ing is application specific, and automatically config- ured by the a[...]

A-10 INST ALLA TION POWER WAVE® S350 A-10 VOL T AGE SENSING CONSIDERA TIONS FOR MUL TIPLE 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 strong- ly recommended. If Sense Leads ARE [...]

A-11 INST ALLA TION 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) PO WER SOURCE #2 PO WER SOURCE #1 POWER PO WER SOURCE SOURCE #1 PO WER SOURCE #2 #2 PO WER [...]

A-12 INST ALLA TION 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 sys- tems. Most are designed to be connected end to end for e[...]

B-1 OPERA TION 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. -------------------------------------------------------[...]

B-2 OPERA TION 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 Wav[...]

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 CONNEC[...]

B-4 OPERA TION 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 (O[...]

B-5 OPERA TION B-5 POWER WAVE® S350 COMMON WELDING PROCEDURES MAKING A WELD The serviceability of a product or structure utiliz- ing 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 variabl[...]

B-6 OPERA TION 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 set- tings locally. In a SMAW (STICK mode), Arc Force can be adjust- ed. It can be set to the lower ran[...]

B-7 OPERA TION B-7 Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave® S350 will automatically recalculate the waveform parame- ters to maintain similar arc properties. The Power Wave® S350 utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding. (Electrical sti[...]

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) F ACTOR Y INST ALLED None Available FIELD INST ALLED OPTIONS GENERAL OPTIONS Stick / Tig User Interface Kit Mounts inside the front panel of the Power Wave S350. Allows stick and Tig operation wi[...]

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 el[...]

D-1 MAINTENANCE D-1 POWER WAVE® S350 SAFETY PRECAUTIONS W ARNING 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 [...]

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 repai[...]

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 ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Not all of t[...]

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[...]

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[...]

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 PROBL[...]

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 PROBL[...]

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 PROBL[...]

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 PROBL[...]

F-1 DIAGRAMS F-1 POWER WAVE® S350 G6536- 2 CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) 6 5 10 1 3 4 1 2 9 8 16 1 4 6 1 3 5 4 8 1 2 1 6 6 12 1 J10A1, J10B1, J811 J3, J4, J45, J61 J2, J5, J11, J31, J46, J51, J111 J9, J13, J16, J26, J27, J62, J112 J8, J24, J28, J29, J43, J47, J63 J12, J23, J25, J42 J6, J7, J41 INPUT SWITCH 3A[...]

F-2 DIMENSION PRINT F-2 POWER WAVE® S350 27.43 22.25 13.91 18.81 18.36 6.00[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND 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 F ABRICANTE P ARA EL U[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁ TICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head out of fumes. l Use ventilation or exhaust to remove fumes from b[...]

• 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 •[...]