Lincoln Electric POWER WAVE S350 Service Manual
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Lincoln Electric POWER WAVE S350 Service Manual

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POWER WAVE
®
For use with machines having Code Numbers:
11589
SERVICE MANUAL
SVM203-A
| Issue D ate 10-Oct
© Lincoln Global, Inc. All Rights Reserved.
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.
S350
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

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  • Page 1 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:...
  • Page 2 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.
  • Page 3 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”...
  • Page 4 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.
  • Page 5 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...
  • Page 6 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.
  • Page 7 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-...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 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...

  • Page 11: Installation

    INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U Mean Peak GMAW 40-70 GMAW-Pulse 40-70 5-350 40-70 100V FCAW GTAW-DC SMAW PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2823-1 24.80in ( 630mm) 85 lbs (39 kg)* 20.40 in ( 518 mm) 14.00in ( 356 mm) TEMPERATURE RANGES STORAGE TEMPERATURE RANGE...

  • Page 12: Safety Precautions

    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®...

  • Page 13: Input Connection

    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®...

  • Page 14: Connection Diagram

    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.
  • Page 15 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...

  • Page 16: Recommended Work Cable Sizes

    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.

  • Page 17: Cable Inductance And Its Effects On Welding

    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...
  • Page 18 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).

  • Page 19: Voltage Sensing Considerations For Multiple Arc Systems

    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.
  • Page 20 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...

  • Page 21: Control Cable Connections

    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).
  • Page 22 A-14 A-14 NOTES POWER WAVE ® S350...
  • Page 23 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 24: Operation

    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...

  • Page 25: Product Description

    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...

  • Page 26: Design Features

    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.

  • Page 27: Case Front Controls

    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.

  • Page 28: Common Welding Procedures

    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.
  • Page 29 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.
  • Page 30 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.
  • Page 31 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Kits, Options / Accessories .
  • Page 32 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.
  • Page 33 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.
  • Page 34 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.
  • Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 36 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.
  • Page 37 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...
  • Page 38 NOTES POWER WAVE ® S350...
  • Page 39 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
  • Page 40 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...
  • Page 41 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...
  • Page 42 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...
  • Page 43 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...
  • Page 44 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...
  • Page 45 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.
  • Page 46 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.
  • Page 47 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.
  • Page 48 E-10 E-10 NOTES POWER WAVE ® S350...
  • Page 49 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 50: How To Use Troubleshooting Guide

    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.

  • Page 51: Pc Board Troubleshooting Procedures

    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.
  • Page 52 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...
  • Page 53 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...
  • Page 54 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...
  • Page 55 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...
  • Page 56 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...
  • Page 57 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...
  • Page 58 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...
  • Page 59 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...
  • Page 60 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...

  • Page 61: Case Cover Removal And Dc Link Capacitor Discharge Procedure

    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.
  • Page 62 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.
  • Page 63 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.
  • Page 64 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.
  • Page 65 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.
  • Page 66 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.
  • Page 67 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...
  • Page 68 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 "...
  • Page 69 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...
  • Page 70 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...
  • Page 71 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.
  • Page 72 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...
  • Page 73 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...
  • Page 74 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.

  • Page 75: Control Board Test

    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.
  • Page 76 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...
  • Page 77 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...
  • Page 78 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...

  • Page 79: Power Factor Control Board Test

    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.
  • Page 80 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.
  • Page 81 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...
  • Page 82 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 •...
  • Page 83 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.
  • Page 84 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...
  • Page 85 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...
  • Page 86 F-38 F-38 NOTES POWER WAVE ® S350...
  • Page 87 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.
  • Page 88 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...
  • Page 89 F-41 F-41 TROUBLESHOOTING AND REPAIR CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) FIGURE F.14 – CALIBRATION SCREEN POWER WAVE ® S350...
  • Page 90 F-42 F-42 NOTES POWER WAVE ® S350...
  • Page 91 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.
  • Page 92 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.

  • Page 93: Optional User Interface Board

    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...
  • Page 94 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 ®...
  • Page 95 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 ®...
  • Page 96 F-48 F-48 NOTES POWER WAVE ® S350...

  • Page 97: Input Rectifier Test

    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.
  • Page 98 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.
  • Page 99 F-51 F-51 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.18 – INPUT RECTIFIER LEAD LOCATIONS TABLE F.11 – PROBE READINGS +Probe (RED) -Probe (BLACK) RESULT Terminal B32 Terminal B10 0.3V - 1.0V Terminal B31 Terminal B10 0.3V - 1.0V Terminal B30 Terminal B10 0.3V - 1.0V...
  • Page 100 F-52 F-52 NOTES POWER WAVE ® S350...

  • Page 101: Planar Transformer Resistance Test

    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.
  • Page 102 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.
  • Page 103 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...
  • Page 104 F-56 F-56 NOTES POWER WAVE ® S350...

  • Page 105: Output Rectifier Test

    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.
  • Page 106 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.

  • Page 107: Current Transducer Test

    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.
  • Page 108 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...
  • Page 109 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...
  • Page 110 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...
  • Page 111 F-63 F-63 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.25 – ETHERNET RECEPTACLE ETHERNET RECEPTACLE POWER WAVE ® S350...
  • Page 112 F-64 F-64 NOTES POWER WAVE ® S350...

  • Page 113: Dc Bus Board Test

    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.
  • Page 114 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.
  • Page 115 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...
  • Page 116 F-68 F-68 NOTES POWER WAVE ® S350...
  • Page 117 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.
  • Page 118 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.

  • Page 119: Removal And Replacement Procedures

    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.
  • Page 120 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.
  • Page 121 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.

  • Page 122: Control Board

    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.
  • Page 123 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...
  • Page 124 F-76 F-76 NOTES POWER WAVE ® S350...

  • Page 125: Switch Board Assembly

    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.
  • Page 126 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.
  • Page 127 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...
  • Page 128 F-80 F-80 NOTES POWER WAVE ® S350...
  • Page 129 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.

  • Page 130: Dc Bus Board

    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.
  • Page 131 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...
  • Page 132 F-84 F-84 NOTES POWER WAVE ® S350...
  • Page 133 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.

  • Page 134: Remote Pc Board

    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.
  • Page 135 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...
  • Page 136 F-88 F-88 NOTES POWER WAVE ® S350...

  • Page 137: Retest After Repair

    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...
  • Page 138 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.
  • Page 139 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Complete Machine (G6536) .
  • Page 140 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,...
  • Page 141 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...
  • Page 142 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.
  • Page 143 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 1) V+3.3BUS ANALOG_IO COMMUNICATION ISOV+R ISOV+C V+3.3BUS ISOV+P V+5BUS CLUSTER 2 CLUSTER 1 V+3.3BUS V+15 V+1.2R V+3.3BUS V+USB VBUS+ V+5BUS V+USB VBUS VBUS+ VBUS+ V+3.3BUS V+15 USB_DATA+ VBUS- ISOV+P USB_DATA+ +DATA VBUS- VBUS-...
  • Page 144 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 2) V+3.3BUS ABSOLUTE VALUE AMPLIFIER AND POLARITY DETECTION R191 VPOLARITY V+3.3BUS 0.063W 0.063W V+3.3BUS INPUT 0.063W DSP_ANALOG R586 2.67K 0.1W R189 0.063W 0.1% STUD+ MULTIPLEXER VOLTAGE 22pF R169 R177 0.1W 56.2K 56.2K 0.1%...
  • Page 145 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 3) R287 CLUSTER 1 0.063W +5VA MAIN LEM CURRENT C128 0.1uF PRIMARY POS_LEM FPGA_ANALOG +5VA R605 OVER CURRENT +2.5V C331 5.11K 0.022uF 0.063W TRIP ADJUST 39.2K Q_OUT 0.1W PRI_OC R285 Q_OUT +2.5V R549...
  • Page 146 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 4) V+15 V+15 CLUSTER 1 V+15 V+15 V+15 V+15 400V 400V 2.21K 15V_RELAYS 0.1W 47.5 0.063W FETA_C FETA_DRIVE THERMAL_C THERMO1 OUT7 R130 R127 GND4 OUT6 AHC1G08 400V 400V 0.1uF MIC4452YM GND5 4.7uF 5.1V 1.3K...
  • Page 147 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 5) CLUSTER 1 CF_MEM FDSP_MEM DSP_MEM CF_MEM FDSP_MEM DSP_MEM V+1.5BUS DSP_DATA15 DSP_ADDR9 CF_ADDR10 I/O63 I/O78 I/O13 EP1C6F256I8 FDSP_DATA15 DSP_PWM10 DSP_DATA14 DSP_ADDR8 CF_DATA31 EP1C6F256I8 CF_ADDR9 I/O93 I/O109 I/O64 I/O79 BANK3 I/O1 I/O14 BANK1 FDSP_DATA14...
  • Page 148 G-10 G-10 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 6) CLUSTER 1 V+3.3BUS FPGA_CPLD CLR_CAP_IN 3.32K 0.063W RESET_RAMP_IN CF_CPLD IN_PWR_/INT CF_SPI_MOSI CF_SPI_MOSI I/O1A CF_SPI_MISO I/O2A CPLD_ANALOG CF_SPI_CLK CF_SPI_CLK I/O3A SYSTEM CF_SPI_CS5 POT_/CS I/O4A BLOCK 1 CF_SPI_CS3 PWR_/RESET I/O5A I/O1B CF_SPI_CS2...
  • Page 149 G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 7) FTP8 FTP7 FTP6 DSP_FPGA DSP_MEM DSP_MEM DSP_CMP0 DSP_PWM7 PWM1 PWM7 DSP_DATA15 PWM2 PWM8 DSP_DATA14 DSP_CMP2 PWM3 PWM9 DSP_DATA13 DSP_PWM10 PWM4 PWM10 DSP_DATA12 DSP_CMP4 PWM5 PWM11 DSP_DATA11 PWM6 PWM12 DSP_DATA10 DSP_TMR1_OUT...
  • Page 150 G-12 G-12 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 8) V+3.3BUS FDSP_FPGA 3.32K FDSP_FPGA SETS HPI TO 32-BIT WIDTH 0.063W V+3.3BUS FDSP_GP7_/INT7 V+3.3BUS FDSP_MEM R527 FDSP_GP3 CF_MEM CF_MEM FTP5 FDSP_GP0 FTP4 TMS320C6413 FDSP_HPI_/CS FDSP_ADDR22 FDSP_DATA31 CF_DATA0 AEA22 AED31 FDSP_ADDR21 FDSP_DATA30...
  • Page 151 G-13 G-13 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 9) COLDFIRE FLEXBUS V+3.3BUS CF_MEM V+3.3BUS FLASH CF_MEM COLDFIRE 4 - 16MBYTES CF_DATA31 EEPROM ADDR31 INTERRUPTS & CF_DATA30 C198 ADDR30 64KBYTE 0.22uF CF_DATA29 SERIAL BUSSES ADDR29 CF_ADDR23 CF_DATA28 ADDR28 CF_ADDR22 CONFIGURATION...
  • Page 152 G-14 G-14 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 10) CF_SDRAM COLDFIRE SDRAM CONTROLLER CF_DDATA31 CF_DADDR12 SDDATA31 SDADDR12 CF_DDATA30 CF_DADDR11 SDDATA30 SDADDR11 CF_DDATA29 CF_DADDR10 SDDATA29 SDADDR10 CF_DDATA28 CF_DADDR9 SDDATA28 SDADDR9 CF_DDATA27 CF_DADDR8 SDDATA27 SDADDR8 CF_DDATA26 CF_DADDR7 SDDATA26 SDADDR7 SDRAM CF_DDATA25...
  • Page 153 G-15 G-15 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 11) CF_COMM ISOV+5 V+3.3BUS ISOV+C ISOV+5 LM1117I V+3.3BUS 0.1W C269 C306 0.22uF C271 C307 0.22uF 0.1uF 10uF 0.063W 0.1W LVC1G14GW CLUSTER 1 1.5K CF_CAN_RX0 0.063W OCI6 ISO5C GND NC 0.5A ISO5C ISOV+5...
  • Page 154 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...
  • Page 155 G-17 G-17 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD (G4799 PG 13) CLUSTER 1 V+15 BULK SUPPLY FOR +15V SUPPLY +3.3V ISOLATED V+15 COSMETIC RS-232 TRACE 100V 600V 1.5K 1.5K ISOV+R V+5BUS 0.0033uF 630V R393 OCI12 0.063W HMA124 VDC_IN+ R394 1.82K 82uF...
  • Page 156 G-18 G-18 ELECTRICAL DIAGRAMS SCHEMATIC - 3 STAGE INVERTER PC BOARD (G4769 PG 1) +15V_PRI 1.5K 400V 400V 0.0027uF 400V 12VDC 1.5K 0.0027uF R141 PRIMARY AND SECONDARY C110 0.0015uF 2000V D140 1500V D139 400V BUS_SEC R161 DZ13 D133 1000V 1.5K 0.0027uF 100K DZ14...
  • Page 157 G-19 G-19 ELECTRICAL DIAGRAMS SCHEMATIC - 3 STAGE INVERTER PC BOARD (G4769 PG 2) BUS_SEC +15V SUPPLY +15V_SEC CHOKE1 FTP15V DZ18 0.1uF 82uF +15V_SEC +3.3V 600V 61.9K 0.8A R113 D112 1.5K 600V OCI5 R121 1 CNY17-3 LED5 .025A D111 1.5K 600V 400V 0.1uF...
  • Page 158 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:...
  • Page 159 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...
  • Page 160 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...
  • Page 161 G-23 G-23 ELECTRICAL DIAGRAMS SCHEMATIC - 40 VDC BUSS POWER SUPPLY PC BOARD (M19330) + 40 VDC J47 8 45 - 120 VDC 500V 100uH 2 J46 LED1 .05A 1000V 47.5 Work Lead Disconnect 500V Protection MOV1 Circuitry 470uF 100V MOV2 0.47uF 175V...

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