Summary of Contents for Lincoln Electric POWER WAVE S350
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NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. POWER WAVE S350 ® For use with machines having Code Numbers: 11589 SERVICE MANUAL Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation:...
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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 PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
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SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
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SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed cylinders explosion. containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used properly operating this is not possible, cover them to prevent the welding sparks regulators designed from starting a fire.
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SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
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2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
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SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other ac- tivities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-...
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .
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INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® S350 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Rated Output (1 Phase in parenthesis) 40% rating 39/35/20/17/14 200-208/230/380-415/ (NA/65***/37/32/25) K2823-1 460/575 300 Watts Max. 100% rating 50/60 Hz 30/28/16/14/11...
INSTALLATION LIFTING SAFETY PRECAUTIONS Both handles should be used when lifting POWER WAVE® S350. Read this entire installation section before you start When using a crane or overhead device a lifting strap should be installation. connected to both handles. Do not attempt to lift the POWER WAVE®...
INSTALLATION INPUT CONNECTION WARNING WARNING The POWER WAVE® S350 ON/OFF Only a qualified electrician should switch is not intended as a service connect the input leads to the disconnect for this equipment. Only POWER WAVE® S350. Connections a qualified electrician should con- should be made in accordance with nect the input leads to the POWER WAVE®...
INSTALLATION SMAW (STICK) WELDING CONNECTION DIAGRAMS Similar to TIG welding a user interface is required for GTAW (TIG) WELDING adjusting the Stick welding settings. A Power Feed wire feeder can be used as the user interface, or a K2828-1 A user interface is required for adjusting the TIG welding (user interface control panel) can be installed into the settings.
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INSTALLATION FIGURE A.4 - STICK WITH S-SERIES USER INTERFACE STICK WITH S-SERIES USER INTERFACE USER INTERFACE REMOTE CONTROL BOX CONTROL PANEL K857 K2828-1 TO POSITIVE TO NEGATIVE (+) STUD (-) STUD ELECTRODE HOLDER KIT K2394-1 KIT (INICLUDES GROUND CLAMP) WORK CLAMP WORK PIECE FIGURE A.5 - MIG PROCESS REGULATOR...
Cable Guidelines” below. Excessive voltage drops Connect the electrode and work cables between the ap- caused by undersized welding cables and poor con- propriate output studs of the Power Wave S350 per the nections often result in unsatisfactory welding perform- following guidelines: ance.
There are several factors that contribute to the overall inductance of the cabling sys- The Power Wave S350 has the ability to automatically tem including cable size, and loop area. The loop area sense when remote sense leads are connected. With...
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Work Voltage Sensing The Power Wave S350 is configured at the factory to sense work voltage at the negative output stud (positive output polarity with remote Work Voltage Sensing dis- abled).
A-11 A-11 INSTALLATION VOLTAGE SENSING CONSIDERATIONS If Sense Leads ARE Used: FOR MULTIPLE ARC SYSTEMS • Position the sense leads out of the path of the weld current. Especially any current paths common to ad- Special care must be taken when more than one arc is jacent arcs.
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A-12 A-12 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. (See Figure A.8) FIGURE A.8 POWER SOURCE...
Connection Between Power Source and Ethernet Networks General Guidelines The Power Wave S350 is equipped with an IP67 rated ODVA compliant RJ-45 Ethernet connector, which is lo- Genuine Lincoln control cables should be used at all cated on the rear panel. All external Ethernet equipment times (except where noted otherwise).
The duty cycle is based on a ten-minute period. A 40% duty cycle represents 4 minutes of welding and 6 min- utes of idling in a ten-minute period. Refer to the tech- nical specification section for the Power Wave S350ʼs duty cycle ratings. POWER WAVE ® S350...
Power Feed™ systems in- cluding 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...
OPERATION 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 fluctua- tions.
OPERATION CASE FRONT CONTROLS CASE BACK CONTROLS (See Figure B.1) (See Figure B.2) 1. USER INTERFACE (optional) 1. 115 VAC RECEPTACLE AND CIRCUIT BEAKER (OPTIONAL) 2. STATUS LED - (See Troubleshooting Section for op- erational functions) 2. ARCLINK (RECEPTACLE CIRCUIT BREAKER) 3.
The standard weld set shipped with proper arc characteristics, the operator must adjust the the Power Wave S350 encompasses a wide range of voltage to compensate for any changes made to the common processes that will meet most needs. If a spe- WFS.
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OPERATION SMAW (STICK) WELDING The nominal preprogrammed voltage is the best aver- The welding current and Arc Force settings can be set age voltage for a given wire feed speed, but may be ad- through a Power Feed 10M or Power Feed 25M wire justed to preference.
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OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave® S350 will au- tomatically 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.
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Stick / Tig User Interface Kit Rear-wheeled cart includes front casters and no-lift gas Mounts inside the front panel of the Power Wave S350. bottle platform. Convenient handles allow for easy cable Allows stick and Tig operation without having a wire storage while full length side trays store parts and tools.
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Includes 200A stick electrode holder, welding cable, work clamp and Twist-Mate adapter. ORDER K2394-1 TIG OPTIONS Power Wave S350 Solenoid Kit Mounts inside the back of the Power Wave S350. Switches gas flow in the Power Wave S350 through the Twist-Mate™ con- nector.
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ACCESSORIES TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack Get everything you need for TIG welding in one com- plete easy-to-order kit packaged in its own portable car- rying case. Includes: PTA-17V torch, parts kit, Harris® flowmeter/regulator, 10 ft. (3.0 m) gas hose, and work clamp and cable.
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MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers re- moved. • Turn off power source before in- stalling 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.
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MAINTENANCE 1. FRONT PANEL ASSEMBLY 2. BASE AND POWER ASSEMBLY 3. VERTICAL DIVIDER PANEL ASSEMBLY 4. OUTPUT CHOKE ASSEMBLY 5. CASE BACK AND FAN ASSEMBLY 6. ROOF AND SIDES ASSEMBLY MAJOR COMPONENT LOCATION POWER WAVE ® S350...
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TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
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It offers such as STT. The POWER WAVE S350 is capable of premier welding performance solutions for specific producing a welding output from 5 to 350 amperes. It...
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DC Link Capacitor also functions as a voltage clamp for FACTOR CORRECTION BOARD the Buck-Boost circuit. The Power Wave S350 can be connected to a variety The Buck-Boost circuit, located on the switch board, of both three-phase or single phase input voltages. The...
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THEORY OF OPERATION FIGURE E.4 - PLANAR TRANSFORMER, OUTPUT RECTIFICATION AND FILTERING SWITCH BOARD (SECOND STAGE) INPUT HIGH FRQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER POSITIVE OUTPUT 100V 100V TERMINAL 60KHZ 60KHZ CAPACITORS 400V 400V INPUT (THIRD STAGE) IGBT RELAY MULTI-PHASE BUCK FULL WAVE...
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THEORY OF OPERATION FIGURE E.5 - CHOPPER, CURRENT TRANSDUCER AND CONTROL BOARDS SWITCH BOARD (SECOND STAGE) INPUT HIGH FRQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER POSITIVE OUTPUT 100V 100V TERMINAL 60KHZ 60KHZ CAPACITORS INPUT 400V 400V (THIRD STAGE) IGBT RELAY MULTI-PHASE BUCK FULL WAVE...
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THEORY OF OPERATION FIGURE E.6 - DC BUS BOARD AND OPTIONAL USER INTERFACE BOARD SWITCH BOARD (SECOND STAGE) INPUT HIGH FRQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER POSITIVE OUTPUT 100V 100V TERMINAL 60KHZ 60KHZ CAPACITORS INPUT 400V 400V (THIRD STAGE) IGBT RELAY MULTI-PHASE BUCK...
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PROTECTIVE CIRCUITS Protective circuits are designed into the Power Wave S350 to sense trouble and shut down the machine before damage occurs to the machineʼs internal components. Error Codes will be flashed out by the light on the Control Board and will help identify the reason for the shutdown.
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THEORY OF OPERATION FIGURE E.7 - IGBT OPERATION MINIMUM OUTPUT 16.6 MAXIMUM OUTPUT 16.6 PULSE WIDTH MODULATION MAXIMUM OUTPUT The term PULSE WIDTH MODULATION (PWM) is used By holding the gate signals on for 7.3 microseconds to describe how much time is devoted to conduction in each and allowing only 2 microseconds of dwell or off the positive and negative portions of the cycle.
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THEORY OF OPERATION FIGURE E.8 - IGBT OPERATION POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE B. ACTIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor.
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Per- sonnel. 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.
OFF at the fuse box before working on equipment. Do - If you return a PC board to The Lincoln Electric Com- not touch electrically hot parts. pany for credit, it must be in the static-shielding bag.
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Board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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Board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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System OK CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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Service Department. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
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Other CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE ® S350...
DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-14 F-14 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CASE COVER SCREW LOCATION PROCEDURE 5. Recheck the voltage across the capacitor ter- 1. Disconnect the input power to the Power Wave minals.
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F-15 F-15 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.2 – CAPACITOR LOCATION CHOPPER CONTROL BOARD PLANAR TRANSFORMER DC LINK CAPACITOR CURRENT TRANSDUCER INPUT CHOKE CAPACITOR DISCHARGE PROCE- WARNING DURE ELECTRIC SHOCK can kill. 1.
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F-16 F-16 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. 7. Also carefully check for a DC Voltage at B48 - B49.
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CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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Table F.3. See Figure F.5 for test point loca- 4. Carefully apply the correct input voltage to the tions and Figure F.6 for lead locations. Power Wave S350 machine. 5. See Figure F.4 for LEDs status and functions. If Led #9 is green the proper input voltage is being applied to the control board.
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F-19 F-19 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE (continued) TABLE F.3 - CONTROL BOARD ASSOCIATED RESISTANCE Description Test Points Leads Expected Conditions Numbers Reading Connection to J9 pin 3 Lead 202 Zero Ohms No Input power Output applied to machine Terminals Negative Negative...
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F-20 F-20 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.4 – LED LOCATIONS G 48 0 0 C O N T R OL P .C . B OA R D LE D # C O L O R F U N C T IO N G R E E N S T A T U S "...
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F-21 F-21 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.5 – TEST POINT LOCATIONS Switch J12 - Chopper Control Board Communication Bank 2 CAN Communication - J11 J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications +48 Volt DC Connection - J4 J7 - Inverter Shutdown Command Fan Control...
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F-22 F-22 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.6 – PLUGS & LEAD LOCATIONS PLUG J4 PLUG J5 PLUG J6 PLUG J7 PLUG J9 PLUG J8 PLUG J12 POWER WAVE ® S350...
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SWITCH BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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3. Locate the switch board on the left side of the 10. Replace the case covers. machine. See Figure F.7. 4. Carefully apply the correct input power to the Power Wave S350. Check the LEDs per Table F.4. See Figure F.8 for LED locations. POWER WAVE ® S350...
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F-25 F-25 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.7 - SWITCH BOARD LOCATION INVERTER CHOKE CHOPPER CONTROL PCB PLANAR TRANSFORMER INPUT CHOKE DC LINK CAPACITOR PRE-CHARGE RELAY SWITCHBOARD PCB POWER WAVE ® S350...
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F-26 F-26 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.8 – SWITCH BOARD LEDʼs LED’S 5 THRU 10 LED 1 LED 4 LED 3 LED 11 LEDʼS 5 Thru 10 These six LEDʼs are used to indicate a turn-on of a chopper phase.
F-27 F-27 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) TABLE F.5 – SWITCH BOARD VOLTAGE MEASUREMENTS Description Test Points Expected Reading Conditions Pre-charge relay Plug J41 Pin 6(-) 15VDC Correct input power coil voltage applied to machine Plug J41 Pin5(+) and pre-charge completed.
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F-28 F-28 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) TABLE F.6 – SWITCH BOARD RESISTANCE MEASUREMENTS Meter Test Points Description Expected Readings Conditions and Polarity 100 Ohm Pre-Charge B10(+) 100 Ohm Machine “off” no Resistor input power applied B12(-) Pre-Charge Relay J41 Pin 5 (+) 15,000 to 30,000...
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F-29 F-29 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) TABLE F.7 – SWITCH BOARD RESISTANCE MEASUREMENTS (continued) Full Bridge Low Side B37(+) To High Resistance Machine “off” no IGBTs B49(-) Greater than input power applied. Also 10,000 ohms The Planar B41(+) To Typical failure is a Transformer...
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F-30 F-30 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.9 – SWITCH BOARD TEST POINTS INVERTER CHOKE PLUG J41 POWER WAVE ® S350...
POWER FACTOR CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-32 F-32 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) PROCEDURE 1. Disconnect the input power to the Power Wave S350 machine. 2. Perform the Case Cover and DC Link Capac- itor Discharge Procedure. 3. Locate the PFC Control Board. See Figure F.10.
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F-33 F-33 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.10 – PFC CONTROL BOARD LOCATION ETHERNET CONNECTOR PFC CONTROL BOARD DC LINK CAPACITOR ARCLINK CONNECTION PRE-CHARGE RELAY INPUT CORD GRIP CONNECTOR POWER WAVE ® S350...
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F-34 F-34 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.11 – PFC CONTROL BOARD PLUGS LED 1 LED 2 BUZZER G5915 PFC CONTROL BOARD P.C. BOARD LED # COLOR FUNCTION GREEN 15 VDC POWER SUPPLY FUNCTION PROPERLY WHEN ON ERROR CODE (LED WILL FLASH ERROR AND BUZZER WILL SOUND) SEE TABLE BELOW FOR DETAILS •...
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F-35 F-35 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) TABLE F.8 - POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS Meter Test Points Expected Readings Conditions Description and Polarity Auxiliary Power Receptacle J27 Pin Very High Input power Input Circuit 3 (-) resistance.
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F-36 F-36 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) TABLE F9 - POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS (continued) Input power Main Boost Gate Plug J23 Pin 8 (-) Resistance should removed. Remove Drive be greater than 500 Plug J43 from the Plug J23 Pin 7 (+) ohms...
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F-37 F-37 TROUBLESHOOTING AND REPAIR POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.12 – PLUG J23 PLUG J27 FIGURE F.13 – SWITCH BOARD TEST POINTS POWER WAVE ® S350...
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CURRENT AND VOLTAGE CALIBRATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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5. Launch the Diagnostic Utility and establish com- ters to the machine output. (See Materials munication with the Power wave S350 (Refer to Needed at the beginning of this Section). the Software Documentation to determine...
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F-41 F-41 TROUBLESHOOTING AND REPAIR CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) FIGURE F.14 – CALIBRATION SCREEN POWER WAVE ® S350...
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OPTIONAL USER INTERFACE BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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3. Carefully apply the correct input power to the Power Wave S350 machine. 4. If the displays light on the front of the machine the User Interface is receiving the correct input voltage.
F-45 F-45 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST PROCEDURE (continued) Table F.10 - Description of LED Functions Optional User Interface Board LED # COLOR FUNCTION PROCESS SELECT WAVE COTROL SELECT PRE-WELD CONTROL SELECT POST-WELD CONTROL SELECT SETUP MENU ENABLED THERMAL FAULT MEASURED WIRE FEED SPEED SELECT AMPS SELECT...
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F-46 F-46 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST PROCEDURE (continued) FIGURE F.15 – U.I. FRONT VIEW (G4760 Series) LED 13 LED 11 LED 14 LED 12 LED 10 LED 9 S T I C K LED 6 LED 2 LED 7 LED 3 POWER WAVE ®...
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F-47 F-47 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST PROCEDURE (continued) FIGURE F.16 – PLUG J31 LOCATION ON USER INTERFACE BOARD (rear view) 153D PLUG J 31 40 VDC 154D NOTE: Leads connect to user interface harness. (4 pin connection to 6 pin connection) POWER WAVE ®...
INPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-50 F-50 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.17 – INPUT RECTIFIER LOCATION CHOPPER CONTROL BOARD PLANAR TRANSFORMER INPUT RECTIFIER TEST POINTS CURRENT TRANSDUCER ON/OFF SWITCH INPUT CHOKE PROCEDURE 1. Remove the input power to the machine. 2.
PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-54 F-54 TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE (continued) FIGURE F.21 - TEST POINTS INVERTER CHOKE PROCEDURE 1. Disconnect the input power to the Power Wave S350 machine. 2. To gain access to the Planar Transformer test points first perform the Case Cover and DC Link Capacitor Discharge Procedure.
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F-55 F-55 TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE (continued) TABLE F.12 – RESISTANCE CHECKS Test Points E xpected Resistance Comments B37 to B 41 Zero ohms Continuity of Primary Winding B39 to B 40 Zero ohms Continuity of 1/2 of Secondary Winding Zero ohms B40 to B 38...
OUTPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-58 F-58 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.22 – TEST POINTS PROCEDURE 5. Using the ohmmeter check the resistances from 1. Disconnect the input power to the Power Wave B51 to B38/ B39. Polarity of the ohmmeter is S350 machine.
CURRENT TRANSDUCER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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15. Remove the input power to the PW S350 ma- chine. 8. Connect a load bank (or 50 Ft. weld cable) to the Positive and Negative output terminals on 16. Replace the case covers. the Power Wave S350. POWER WAVE ® S350...
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F-61 F-61 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.23 – PLUG LOCATIONS ON CONTROL BOARD J12 - Chopper Control Board Communication J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications J7 - Inverter Shutdown Command Fan Control Status LED J8 - Current Feedback...
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F-62 F-62 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.24 – CURRENT TRANSDUCER LOCATION CURRENT TRANSDUCER TABLE F.13 OUTPUT CURRENT (ACTUAL) TRANSDUCER FEEDBACK VOLTAGE POWER WAVE ® S350...
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F-63 F-63 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.25 – ETHERNET RECEPTACLE ETHERNET RECEPTACLE POWER WAVE ® S350...
DC BUS BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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Switch Board. See the wiring diagram. 4. Carefully apply the correct input voltage to the 9. If the correct input voltage is being applied to the Power wave S350 machine. DC Bus Board check for the correct output volt- ages.
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F-67 F-67 TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST (continued) FIGURE F.27 – DC BUS BOARD LOCATIONS LEAD LEAD LEAD LEAD LED 1 INDICATES OUTPUT LEAD LEAD POWER WAVE ® S350...
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REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-70 F-70 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.28 – CAPACITOR & PFC CONTROL BOARD LOCATION PFC CONTROL BOARD DC LINK CAPACITOR PROCEDURE 5. Remove the five molex type plugs from the 1.
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-72 F-72 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER (LEM) REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.29 – CURRENT TRANSDUCER LOCATION OUTPUT CHOKE CURRENT TRANSDUCER ON/OFF SWITCH INPUT CHOKE PROCEDURE 7. Take note of the arrow direction on Current 1. Disconnect the input power to the Power Wave Transducer Module.
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CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
F-74 F-74 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – CONTROL BOARD LOCATION CONTROL PC BOARD PROCEDURE 6. Install the new board and replace the molex 1. Disconnect the input power to the Power Wave type plugs and Ethernet cable previously re- S350 machine.
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F-75 F-75 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – BOARD PLUG REMOVAL Switch J12 - Chopper Control Board Communication Bank 2 CAN Communication - J11 J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications +48 Volt DC Connection - J4 J7 - Inverter Shutdown Command Fan Control...
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
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F-78 F-78 TROUBLESHOOTING AND REPAIR SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.32 – SWITCH BOARD LOCATION & MOUNTING SCREWS MOUNTING SCREWS (4) INPUT CHOKE SWITCH BOARD ASSEMBLY PROCEDURE 7. Using the 7/16” wrench, remove the two input 1.
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F-79 F-79 TROUBLESHOOTING AND REPAIR SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.33 – SWITCH BOARD LEADS HEAT SINK THERMOSTAT CHOPPER POSITIVE OUTPUT BOARD CABLE CONNECTION PLUG J45 CONNECTOR OUTPUT CHOKE CONNECTIONS LEAD A LEAD A2 LEAD A3 LEAD A4 LEAD A5 LEAD A6...
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DC BUS BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
F-82 F-82 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.34 – DC BUS BOARD LOCATIONS DC BUS BOARD PROCEDURE 6. Carefully remove the DC Bus Board from the 1. Disconnect the input power to the Power Wave four mounting studs.
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F-83 F-83 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.35 – DC BUS BOARD LOCATIONS OUTPUT LED 1 INDICATES OUTPUT INPUT POWER WAVE ® S350...
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REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
F-86 F-86 TROUBLESHOOTING AND REPAIR REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – REMOTE PC BOARD LOCATIONS REMOTE PC BOARD PROCEDURE 1. Disconnect the input power to the Power Wave 5. Using the phillips head screwdriver remove the S350 machine.
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F-87 F-87 TROUBLESHOOTING AND REPAIR REMOTE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.37 – REMOTE PC BOARD LOCATIONS J111 J112 J113 POWER WAVE ® S350...
Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in testing the Power wave S350 output after the repair or replacement of a part or PC board. MATERIALS NEEDED...
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F-90 F-90 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR (continued) PROCEDURE 1. Be certain that the machine is properly con- nected for the input voltage being applied. 2. Turn the Power Switch ON and see that it goes through the Start-up routine and the Status Light is steady Green.
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ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMPLETE MACHINE (G6536) POWER WAVE S350 GENERAL INFORMATION CAVITY NUMBERING SEQUENCE ELECTRICAL SYMBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) LEAD COLOR CODING INPUT SUPPLY B - BLACK J10A1, J2, J5, J11, J9, J13, J16,...
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ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE (G6535 PG 1) ENGINEERING CONTROLLED CHANGE DETAIL: ADDED 10J3 TO CONTROL P.C. BOARD MANUFACTURER: STUD+ S3 REMOTE RECEPTACLE STUD - LEM COMMON LEM FEEDBACK LOCATED ON -15VDC LEM SUPPLY CASE FRONT +15VDC LEM SUPPLY OPTIONAL (ASSEMBLY G5663) 153D...
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SWITCHBOARD CONTROL P.C. BOARD PFC CONTROL P.C. BOARD P.C. BOARD Description of LED functions on Power Wave S350 Description of LED functions For reference only INPUT CONTROL & PWR on Power Wave S350 For reference only G5 9 1 5 - 1 G4770 SWITCHBOARD P.C.
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G-16 G-16 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 12) ISOV+P V+3.3BUS V+5BUS ISOV+P ISOV+P V+3.3BUS LED ON PARALLEL OUTPUT LOW C114 0.063W LED OFF OUTPUT HIGH 0.22uF DE HIGH C120 C112 C113 B HIGH, A LOW 10uF 0.22uF 0.22uF...
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TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. 26.7 0.063W 2.67K SINCE COMPONENTS OR CIRCUITRY ON A EQUIPMENT TYPE: 0.063W DESIGN INFORMATION POWER WAVE S350 PAGE 0.063W 1A/FR PRINTED CIRCUIT BOARD MAY CHANGE 400V WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY:...
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PROPRIETARY & CONFIDENTIAL: FTP5 TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. EQUIPMENT TYPE: POWER WAVE S350 SINCE COMPONENTS OR CIRCUITRY ON A DESIGN INFORMATION PAGE PRINTED CIRCUIT BOARD MAY CHANGE...
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THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. SINCE COMPONENTS OR CIRCUITRY ON A EQUIPMENT TYPE: POWER WAVE S350 DESIGN INFORMATION PAGE PRINTED CIRCUIT BOARD MAY CHANGE...
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