Lincoln POWER WAVE S350 Operator's Manual
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Lincoln POWER WAVE S350 Operator's Manual

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POWER WAVE
®
S350 & S350 ALUMINUM

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Summary of Contents for Lincoln POWER WAVE S350

  • Page 1 POWER WAVE ® S350 & S350 ALUMINUM...
  • Page 2 (See below). SAFETY DEPENDS ON YOU USE NATURAL DRAFTS or fans to keep the fumes away Lincoln arc welding and cutting equipment is designed and built from your face. with safety in mind. However, your overall safety can be increased If you de velop unusual symptoms, see your supervisor.
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).

  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    POWER WAVE ® S350 & S350 ALUMINUM 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...

  • Page 7: Installation

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE ® S350 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Duty Cycle Rated Output (1 Phase in parenthesis) 40% rating 39/35/19/17/14 208/230/400*460/575...
  • Page 8 POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U Mean Peak GMAW 40-350A 40-70V GMAW-Pulse FCAW 100V GTAW-DC 5-350A SMAW 55-325A PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2823-3/ 24.80in ( 630mm) 85 lbs (39 kg)* 20.40 in ( 518 mm) 14.00in ( 356 mm) K4188-1...

  • Page 9: Safety Precautions

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION STACKING SAFETY PRECAUTIONS Read this entire installation The POWER WAVE ® S350 cannot be stacked. section before you start installation. TILTING WARNING WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform •...

  • Page 10: Input Connection

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION INPUT CONNECTION WARNING WARNING The POWER WAVE ® S350 ON/OFF switch is not intended as a service disconnect for this equipment. Only a qualified electrician Only a qualified electrician should connect should connect the input leads to the the input leads to the POWER WAVE ®...

  • Page 11: Connection Diagram

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION SMAW (STICK) WELDING CONNECTION DIAGRAMS Similar to TIG welding a user interface is required for adjusting GTAW (TIG) WELDING the Stick welding settings. A Power Feed wire feeder can be used as the user interface, or a K3001-2 (user interface control A user interface is required for adjusting the TIG welding settings.
  • Page 12 POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION FIGURE A.4 REGULATOR FLOWMETER MIG PROCESS GAS HOSE ARCLINK CABLE TO NEGATIVE (-) STUD K1543-[XX] WORK CLAMP TO POSITIVE (+) STUD WORK PIECE PF10-M WIRE FEEDER...

  • Page 13: Recommended Work Cable Sizes

    Always use the largest Connect the electrode and work cables between the appropriate welding cables (electrode and work) that are practical, and be output studs of the Power Wave S350 per the following sure all connections are clean and tight. guidelines: Note: Excessive heat in the weld circuit indicates undersized •...

  • Page 14: Cable Inductance And Its Effects On Welding

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION Remote voltage sense leads are used to improve the accuracy of CABLE INDUCTANCE AND ITS EFFECTS ON the arc voltage information supplied to the control pc board. WELDING Sense Lead Kits (K940-xx) are available for this purpose. The Power Wave ®...
  • Page 15 POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION 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.

  • Page 16: Voltage Sensing Considerations For Multiple Arc Systems

    POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION VOLTAGE SENSING CONSIDERATIONS FOR • Position the sense leads out of the path of the weld current. Especially any current paths common to adjacent arcs. MULTIPLE ARC SYSTEMS Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power Special care must be taken when more than one arc is welding sources, and result in arc interference.
  • Page 17 POWER WAVE ® S350 & S350 ALUMINUM INSTALLATION • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path.

  • Page 18: Control Cable Connections

    S350 & S350 ALUMINUM INSTALLATION 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 ®...
  • Page 19 NOTES A-13...

  • Page 20: Operation

    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 S350’s duty cycle ratings. CIRCUIT BREAKER...

  • Page 21: Product Description

    ® 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.

  • Page 22: Design Features

    POWER WAVE ® S350 & S350 ALUMINUM OPERATION CASE FRONT CONTROLS DESIGN FEATURES (See Figure B.1) Loaded with Standard Features 1. USER INTERFACE (optional) • Multiple process DC output range: 5 - 350 Amps 2. STATUS LED - (See Troubleshooting Section for operational functions) •...

  • Page 23: Case Back Controls

    POWER WAVE ® S350 & S350 ALUMINUM OPERATION CASE BACK CONTROLS CASE BACK CONTROLS (See Figure B.2 for Code 11694) (See Figure B.2a for Code 11782/12371) 1. 115 VAC KIT (OPTIONAL) 1. 115 VAC KIT (OPTIONAL) (STANDARD ON K4188-1) 2. ARCLINK CONNECTOR 2.

  • Page 24: Common Welding Procedures

    S350 at the factory, refer to the builder/user. Many variables beyond the control of The the Weld Set Reference Guide supplied with the machine or Lincoln Electric Company affect the results obtained in available at www.powerwavesoftware.com. applying these programs. These variables include, but are...
  • Page 25 POWER WAVE ® S350 & S350 ALUMINUM OPERATION SMAW (STICK) WELDING CONSTANT VOLTAGE WELDING The welding current and Arc Force settings can be set through a Synergic CV Power Feed ™ 10M or Power Feed ™ 25M wire feeder. For each wire feed speed, a corresponding voltage is Alternatively an optional Stick / TIG UI can be installed into the preprogrammed into the machine through special software at the power source to control these settings locally.
  • Page 26 POWER WAVE ® S350 & S350 ALUMINUM OPERATION 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 ®...

  • Page 27: Accessories

    Mounts inside the back of the Power Wave ® S350. Adds 115 VAC K2910-1 / 60 Hz auxiliary power capability to the Power Wave S350 12-pin to 7-pin adapter. (compatible with the K2823-1 and K2823-3 power source) Order K2829-1 Welding Fume Extractors...
  • Page 28 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.

  • Page 29: Maintenance

    POWER WAVE ® S350 & S350 ALUMINUM MAINTENANCE 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.

  • Page 30: Troubleshooting

    Observe all additional Safety Guidelines detailed throughout this manual. CAUTION 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.
  • Page 31 Status LED off Not applicable. System OK CAUTION 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.
  • Page 32 Service Department. CAUTION 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.
  • Page 33 Contact the Service Department. Other CAUTION 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.
  • Page 34 CAUTION 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.
  • Page 35 5. The power source may require calibration. (current, voltage, WFS). CAUTION 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.
  • Page 36 3. Calibrate secondary current and voltage. CAUTION 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.
  • Page 37 CAUTION 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.
  • Page 38 POWER WAVE ® S350 & S350 ALUMINUM DIAGRAMS xxxxxxx xxxxxxx...
  • Page 39 POWER WAVE ® S350 & S350 ALUMINUM DIAGRAMS 27.43 22.25 13.91 18.81 6.00 18.36...
  • Page 40 Power Wave S350 Aluminum - 12371...
  • Page 41 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 42 P-855-A INDEX OF SUB ASSEMBLIES P-855-B.2 MISCELLANEOUS ITEMS P-855-C CASE FRONT ASSEMBLY P-855-D BASE & POWER CONVERSION ASSEMBLY P-855-E VERTICAL DIVIDER PANEL ASBLY P-855-F OUTPUT CHOKE ASSEMBLY P-855-G CASE BACK ASSEMBLY P-855-H ROOF ASSEMBLY Power Wave S350 Aluminum - 12371...
  • Page 43 Index of Sub Assemblies - 12371 P-855-A.jpg Power Wave S350 Aluminum - 12371...
  • Page 44 Miscellaneous Items PART NUMBER DESCRIPTION 9SG6094 PRIMARY CONTROL HARNESS 9SM19969-2 ETHERNET PATCH CABLE Power Wave S350 Aluminum - 12371...
  • Page 45 Miscellaneous Items No Image Power Wave S350 Aluminum - 12371...
  • Page 46 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SG8226 NAMEPLATE 9ST10397-3 PLUG BUTTON 9ST10397-23 PLUG BUTTON 9SS9225-99 SELF TAPPING SCREW 9SS9262-80 PLAIN WASHER 9SE106A-15 LOCKWASHER 9SCF000021 1/2-13X1.00HHCS 9SS18657 SQUARE FLANGE FEMALE RECEPTACLE 9SS8025-118 SELF TAPPING SCREW 9SL15069 COVER PLATE Power Wave S350 Aluminum - 12371...
  • Page 47 Case Front Assembly PART NUMBER DESCRIPTION 9SS9225-99 SELF TAPPING SCREW 9SG6529 UI TRIM 9SG6601 DECAL Power Wave S350 Aluminum - 12371...
  • Page 48 Case Front Assembly P-855-C.jpg Power Wave S350 Aluminum - 12371...
  • Page 49 PLAIN WASHER 9SS9225-100 SELF TAPPING SCREW 9SM21469-3 POWERBOARD BOTTOM BRACKET 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SG6037-1 POWER BOARD ASBLY 9ST13359-29 THERMOSTAT 9SS9225-100 SELF TAPPING SCREW 9SE106A-1 LOCKWASHER 9SS9262-27 PLAIN WASHER 9SM15045-100 ACOUSTICAL FOAM 9SCF000010 #10-24HN 9SE106A-1 LOCKWASHER Power Wave S350 Aluminum - 12371...
  • Page 50 Base & Power Conversion Assembly P-855-D.jpg Power Wave S350 Aluminum - 12371...
  • Page 51 TERMINAL BLOCK 9SCF000193 #8-32X1.25RHS 9SS31170-3 CONTROL PC BD ASBLY 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9ST12380-1 BUSHING 9SS18858-11 SUPPRESSOR ASBLY 9SG8226 NAMEPLATE 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS8025-99 SCREW #10 x 1.50 GIMLET POINT SLOTTED 9ST13260-4 DECAL-EARTH GROUND CONN Power Wave S350 Aluminum - 12371...
  • Page 52 Vertical Divider Panel Asbly P-855-E.jpg Power Wave S350 Aluminum - 12371...
  • Page 53 1/4-20HN 9SM22372 BUS BAR 9SCF000015 1/4-20X1.00HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SCF000015 1/4-20X1.00HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SS10404-137 RESISTOR-WW100W2005% 9ST4479-A INSULATING WASHER 9SS9262-27 PLAIN WASHER 9ST9695-1 LOCKWASHER 9SCF000191 #10-24X7.50RHS Power Wave S350 Aluminum - 12371...
  • Page 54 Output Choke Assembly PART NUMBER DESCRIPTION 9SS9225-99 SELF TAPPING SCREW Power Wave S350 Aluminum - 12371...
  • Page 55 Output Choke Assembly P-855-F.jpg Power Wave S350 Aluminum - 12371...
  • Page 56 PLUG AND LEAD ASBLY 9SS12021-79 BOX RECEPTACLE SOLID SHELL 9SS25438-2 CONNECTOR ADAPTER PLATE 9SS8025-96 SELF TAPPING SCREW 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SL16762 LOUVER PLATE 9SS9225-99 SELF TAPPING SCREW 9SS9225-99 SELF TAPPING SCREW 9SS28056-2 RATING PLATE Power Wave S350 Aluminum - 12371...
  • Page 57 9SS18573-17 INPUT LEAD ASBLY 9SM22519 CONNECTOR & LEAD ASBLY 9SS12021-73 BOX RECEPTACLE SOLID SHELL 9SS8025-118 SELF TAPPING SCREW 9SS17062-10 CABLE CONNECTOR CAP 9SS17062-9 CABLE CONNECTOR CAP 9SS31115 SOLENOID MTG PLATE 9SS9225-99 SELF TAPPING SCREW Power Wave S350 Aluminum - 12371...
  • Page 58 Case Back Assembly P-855-G.jpg Power Wave S350 Aluminum - 12371...
  • Page 59 ALUMINUM SOLUTIONS LOGO 9SL16760 LOUVER INSERT 9ST12584-13 BLIND RIVET 9SM25325-1 RIGHT CASE SIDE ASBLY 9SL16748-1 RIGHT CASE SIDE 9SS27368-4 DECAL LE LOGO 9SS27468-1 POWER WAVE LOGO 9SS28039-2 DECAL GREEN INITIATIVE 9SL16760 LOUVER INSERT 9ST12584-13 BLIND RIVET Power Wave S350 Aluminum - 12371...
  • Page 60 Roof Assembly PART NUMBER DESCRIPTION 9SS9262-182 PLAIN WASHER 9SS9225-100 SELF TAPPING SCREW 9SS9225-99 SELF TAPPING SCREW Power Wave S350 Aluminum - 12371...
  • Page 61 Roof Assembly P-855-H.jpg Power Wave S350 Aluminum - 12371...
  • Page 62 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 63 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 64 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.

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