Lincoln Electric 11694 Service Manual
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Lincoln Electric 11694 Service Manual

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POWER WAVE ® S350
For use with machines having Code Numbers:
11694, 11782, 11753, 11783,
11589, 12371, 12394 and 11625
SERVICE MANUAL
SVM257
| Issue D ate 17-Sep
© Lincoln Global, Inc. All Rights Reserved.

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  • Page 1 POWER WAVE ® S350 For use with machines having Code Numbers: 11694, 11782, 11753, 11783, 11589, 12371, 12394 and 11625 SERVICE MANUAL SVM257 | Issue D ate 17-Sep © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • 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 SAFETY 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 SAFETY 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 ® POWER WAVE S350 TABLE OF CONTENTS MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance ................See Instruction Manual Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...

  • Page 7: Table Of Contents

    ® POWER WAVE S350 THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Main Input Switch, Input Rectifier, Soft Start/Input Relay, DC Link Capacitor, Buck-Boost Power Factor Correction Control Board ..........3 Planar Transformer, Output Rectification And Filtering .
  • Page 8 ® POWER WAVE S350 THEORY OF OPERATION Figure E.1 - Block logic diagram SWITCH BOARD (SECOND STAGE) INPUT HIGH FREQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER 50Khz OUTPUT 100V 400V CAPACITORS POSITIVE TERMINAL INPUT IGBT (THIRD STAGE) RELAY FULL WAVE MULTI-PHASE BUCK MAIN INPUT...

  • Page 9: Theory Of Operation

    ® POWER WAVE S350 THEORY OF OPERATION Figure E.2 - Main input switch, input rectifier, soft start/input relay, DC link capacitor, buck-boost and power factor correction control board SWITCH BOARD (SECOND STAGE) INPUT HIGH FREQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER 50Khz OUTPUT...

  • Page 10: Planar Transformer, Output Rectification And Filtering

    ® POWER WAVE S350 THEORY OF OPERATION Figure E.3 - Planar transformation, output rectification and filtering SWITCH BOARD (SECOND STAGE) INPUT HIGH FREQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER 50Khz OUTPUT 100V 400V CAPACITORS POSITIVE TERMINAL INPUT IGBT (THIRD STAGE) RELAY FULL WAVE MULTI-PHASE BUCK...

  • Page 11: Multi-Phase Chopper, Chopper Control Board, Current Transducer And Control Board

    ® POWER WAVE S350 THEORY OF OPERATION Figure E.4 - Multi-phase chopper control board, current transducer and control board SWITCH BOARD (SECOND STAGE) INPUT HIGH FREQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER 50Khz OUTPUT 100V 400V CAPACITORS POSITIVE TERMINAL INPUT IGBT (THIRD STAGE)

  • Page 12: Dc Bus Board And Optional User Interface Board

    ® POWER WAVE S350 THEORY OF OPERATION Figure E.5 - DC bus board and optional user interface board SWITCH BOARD (SECOND STAGE) INPUT HIGH FREQUENCY INVERTER OUTPUT CHOKE WITH PLANER TRANSFORMER RECTIFIER 50Khz OUTPUT 100V 400V CAPACITORS POSITIVE TERMINAL INPUT IGBT (THIRD STAGE) RELAY...

  • Page 13: Machine Protection

    ® POWER WAVE S350 THEORY OF OPERATION MACHINE PROTECTION PROTECTIVE CIRCUITS Protective circuits are designed into the Power Wave S350 to THERMAL PROTECTION sense trouble and shut down the machine before damage occurs Two normally closed (NC) thermostats protect the machine from to the machine’s internal components.
  • Page 14 ® POWER WAVE S350 NOTES...
  • Page 15 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........10 PC Board Troubleshooting Procedures .

  • Page 16: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. 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 17: Pc Board Troubleshooting Procedures

    ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 18: Troubleshooting Guide

    ON” in this section. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 Perform the Control Board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 20 Check the welding tip for blockage. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 22: Using The Status Led To Troubleshoot System Problems

    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 test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 23: Error Codes For The Power Wave S350

    CHOPPER Indicates communication link between main control board and chopper has errors. If cycling the input COMMUNICATION ERROR power on the machine does not clear the error, contact the Lincoln Electric service department at 1-888-935-3877. PRIMARY FAULT ERROR Review error code from input board status light or status beeper. Most likely caused by an over power condition which caused an under voltage on the primary bus.
  • Page 24 ® POWER WAVE S350 NOTES...

  • Page 25: Case Cover Removal And Replacement And Dc Link Capacitor Discharge Procedure

    DC LINK CAPACITOR 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 26 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) Figure F.1 – Case cover removal procedure ROOF HANDLE MOUNTING SCREWS TOP CORNER CAP MOUNTING MOUNTING SCREWS SCREWS (THREE FOR EACH CORNER CAP TWELVE TOTAL) CASE SIDE MOUNTING SCREWS (FOUR ON EACH SIDE)
  • Page 27 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) Figure F.2 – DC capacitor location DC LINK CAPACITOR Figure F.3 – Capacitor terminals and associated locations CAPACITOR TERMINAL DC LINK CAPACITOR CAPACITOR TERMINAL...
  • Page 28 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the roof onto the top of the machine. 2. Using a 5/16” nutdriver, attach the two screws securing the roof to the machine.

  • Page 29: Power Factor Correction Control Board Test

    POWER FACTOR CORRECTION CONTROL 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.
  • Page 30 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD TEST (continued) Figure F.4 – PFC control board location POWER FACTOR CORRECTION CONTROL BOARD (LOCATED ON REAR OF FRONT PANEL) 10. When testing is complete replace all previously removed plugs. PROCEDURE 11.
  • Page 31 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD TEST (continued) Figure F.5 – PFC control board plugs LED 2 BUZZER LED 1 G5915 PFC CONTROL BOARD LED # COLOR FUNCTION GREEN 15 VDC power supply function properly when on. Error code (LED will flash error and buzzer will sound).
  • Page 32 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD TEST (continued) Table F.2 – Power factor correction control board resistance checks DESCRIPTION METER TEST POINTS EXPECTED READINGS CONDITIONS AND POLARITY AUXILIARY POWER RECEPTACLE J27 PIN 3 (-) VERY HIGH RESISTANCE.
  • Page 33 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD TEST (continued) Figure F.6 – PFC control board plugs J23 and J27 Figure F.7 – Switch board location SWITCH BOARD...
  • Page 34 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD TEST (continued) Figure F.8 – Switch board test points...

  • Page 35: Control Board Test

    CONTROL 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 36 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) Figure F.9 – Control board location CONTROL BOARD PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 37 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) Table F.3 – Control board voltage tests DESCRIPTION TEST POINTS LEAD NUMBERS EXPECTED READING CONDITIONS INPUT SUPPLY TO BOARD J4 PIN 2 LEAD 356 (-) +40 VDC INPUT POWER APPLIED TO MACHINE.
  • Page 38 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) Figure F.10 – Control board LED locations G6682 CONTROL P.C. BOARD LED’S LED # COLOR FUNCTION GREEN STATUS “OK” STATUS “ERROR” (CHECK CODE FOR SPECIFIC ERROR) GREEN OUTPUT ENABLE GREEN SINGLE PHASE DETECT GREEN...
  • Page 39 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) Figure F.11 – Control board test point locations SECONDARY PRIMARY SW 3 SW 1 THERMOSTAT ERROR CONTROL CURRENT VOLTAGE CONNECTION COMMUNICATIONS STATUS LED FEEDBACK FEEDBACK CHOPPER CONTROL BOARD COMMUNICATION SWITCH 2 DEVICE NET +40 VOLT DC...
  • Page 40 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) Figure F.12 – Control board plug and lead locations 358 356 PLUG J5 PLUG J4 PLUG J6 PLUG J7 212 213 PLUG J8 PLUG J9 PLUG J12...

  • Page 41: Switch Board Test

    SWITCH 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 42 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Figure F.13 – Switch board location SWITCH BOARD PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 43 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Figure F.14 – Switch board LED locations LED’S 5 THRU 10 LED 4 LED 1 LED 3 LED 2 Table F.5 – Switch board LED’s DESCRIPTION INDICATES LIGHT CONDITIONS LED 1 +48 VDC SUPPLY POWER APPLIED TO POWER...
  • Page 44 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Table F.6 – Switch board voltage measurements DESCRIPTION TEST POINTS EXPECTED READING CONDITIONS PRE-CHARGE RELAY COIL PLUG J41 PIN 6 (-) 15 VDC CORRECT INPUT POWER APPLIED VOLTAGE TO MACHINE AND PRE-CHARGE PLUG J41 PIN 5 (+) COMPLETED.
  • Page 45 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Table F.7 – Switch board resistance measurements DESCRIPTION METER TEST POINTS AND EXPECTED READINGS CONDITIONS POLARITY 100 OHM PRE-CHARGE B10 (+) 100 OHM MACHINE “OFF” NO INPUT RESISTOR POWER APPLIED. B12 (-) PRE-CHARGE RELAY COIL J41 PIN 5 (+)
  • Page 46 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Figure F.15 – Switch board test points INVERTER CHOKE PLUG J41...

  • Page 47: Optional User Interface Board Test

    OPTIONAL USER INTERFACE 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 48 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST (continued) Table F.8 – Description of LED functions OPTIONAL USER INTERFACE BOARD LED # COLOR FUNCTION PROCESS SELECT WAVE CONTROL SELECT PRE-WELD SELECT POST-WELD SELECT SETUP MENU ENABLED THERMAL FAULT MEASURED WIRE FEED SPEED SELECT AMPS SELECT...
  • Page 49 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR OPTIONAL USER INTERFACE BOARD TEST (continued) Figure F.16 – User interface 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...
  • Page 50 ® POWER WAVE S350 NOTES...

  • Page 51: Input Rectifier Test

    INPUT RECTIFIER 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 52 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST (continued) Figure F.18 – Input rectifier location INPUT RECTIFIER TEST POINTS PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 53 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST (continued) Figure F.19 – Input rectifier lead locations Table F.9 – 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 54 ® POWER WAVE S350 NOTES...

  • Page 55: Planar Transformer Resistance Test

    PLANAR TRANSFORMER RESISTANCE 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 56 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST (continued) Figure F.20 – Planar transformer location PLANAR TRANSFORMER PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 57 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR PLANAR TRANSFORMER RESISTANCE TEST (continued) Figure F.21 – Planar transformer test points INVERTER CHOKE Table F.10 – Planar transformer resistance checks TEST POINTS EXPECTED RESISTANCE COMMENTS B37 TO B41 ZERO OHMS CONTINUITY OF PRIMARY WINDING. B39 TO B40 ZERO OHMS CONTINUITY OF 1/2 OF SECONDARY WINDING.
  • Page 58 ® POWER WAVE S350 NOTES...

  • Page 59: Output Rectifier Test

    OUTPUT RECTIFIER 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 60 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST (continued) Figure F.22 – Output rectifier test points 11. If faulty, perform the Switch Board Removal And PROCEDURE Replacement Procedure. 1. Remove the input power to the Power Wave S350 machine. 12.

  • Page 61: Current Transducer Test

    CURRENT TRANSDUCER 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 62 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) Figure F.23 – Plug locations on control board 214 OR 216 CURRENT FEEDBACK For Steps 8 through 14 refer to the information in the Diagnostic PROCEDURE Utility found on the Lincoln Service Navigator or at 1.
  • Page 63 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) Figure F.24 – Current transducer location CURRENT TRANSDUCER 12. Repeat the test at several other current levels. If the transducer feedback voltage is correct for the actual current, the current transducer is functioning properly.
  • Page 64 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) Table F.11 – Current transducer voltage tests OUTPUT CURRENT (ACTUAL) TRANSDUCER FEEDBACK VOLTAGE Figure F.25 – Ethernet receptacle ETHERNET RECEPTACLE...

  • Page 65: 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 66 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST (continued) Figure F.26 – DC bus board location DC BUS BOARD 10. Check for the presence of 40VDC at Plug J47 Pin1 (Lead 51-) PROCEDURE to Plug J47 Pin 8 (Lead 52+). See Figure F.27. See Wiring 1.
  • Page 67 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST (continued) Figure F.27 – DC bus board locations LED 1 LEAD 66 (INDICATES OUTPUT) LEAD 52 LEAD 358 LEAD 65 LED 1 LEAD 51 LEAD 356 L15732-1...
  • Page 68 ® POWER WAVE S350 NOTES...

  • Page 69: Power Factor Correction Control Board Removal And Replacement Procedure

    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 70 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.28 – Power factor correction control board and mounting nuts location POWER FACTOR CORRECTION CONTROL BOARD MOUNTING NUTS (3) REMOVAL PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2.
  • Page 71 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.29 – Power factor correction control board plug locations REPLACEMENT PROCEDURE 1. Carefully connect plugs J23, J24, J25, J26 and J27 to the new power factor correction control board.
  • Page 72 ® POWER WAVE S350 NOTES...

  • Page 73: Control Board Removal And Replacement Procedure

    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 74 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.30 – Control board location CONTROL BOARD REMOVAL PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 75 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.31 – Control board plug locations (ETHERNET CONNECTION) Figure F.32 – Mounting hole location MOUNTING HOLES MOUNTING HOLES...
  • Page 76 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new control board onto the mounting studs. 2. Using a 3/8” nutdriver, attach the three nuts securing the control board to the machine. 3.

  • Page 77: Switch Board Removal And Replacement Procedure

    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 78 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.33 – Switch board location SWITCH BOARD 10. Using a 5/16” nutdriver, remove the four screws and washers REMOVAL PROCEDURE securing the switch board to the chassis frame. See Figure 1.
  • Page 79 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.34 – Switch board lead and plug locations HEATSINK THERMOSTAT (NOT SHOWN) POSITIVE OUTPUT CABLE CONNECTION...
  • Page 80 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.35 – Switch board mounting screw locations MOUNTING SCREWS REPLACEMENT PROCEDURE 1. Carefully position the new switch board onto the mounting studs. 2. Using a 5/16” nutdriver, attach the four screws securing the switch board to the chassis frame.

  • Page 81: Current Transducer Removal And Replacement Procedure

    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 82 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.36 – Current transducer plug location CURRENT TRANSDUCER PLUG LOCATION NEGATIVE OUTPUT CABLE CONNECTION REMOVAL PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2.
  • Page 83 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.37 – Current transducer removal TOP CHOKE BRACKET MOUNTING SCREW CHOKE LEADS (THREE PAIRS) BOTTOM CHOKE BRACKET MOUNTING SCREW Figure F.38 – Current transducer mounting screw location CURRENT TRANSDUCER MOUNTING SCEW CURRENT...
  • Page 84 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new current transducer into the machine. 2. Using a slotted screwdriver, attach the screw securing the current transducer to the bottom choke bracket. 3.

  • Page 85: Dc Bus Board Removal And Replacement Procedure

    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 86 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.39 – DC bus board location DC BUS BOARD REMOVAL PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 2. Perform the Case Cover Removal and DC Link Capacitor Discharge Procedure.
  • Page 87 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.40 – DC bus board plug and mounting hole location LED 1 MOUNTING MOUNTING HOLES HOLES L15732-1 REPLACEMENT PROCEDURE 1. Carefully position the new DC bus board onto the mounting studs. 2.
  • Page 88 ® POWER WAVE S350 NOTES...

  • Page 89: Auxiliary Power Board Removal And Replacment Procedure

    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 90 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR OPTIONAL AUXILIARY POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.41 – Auxiliary power board location AUXILIARY POWER BOARD (MOUNTING LOCATION) REMOVAL PROCEDURE DISCONNECT PROCEDURE 1. Remove the input power to the Power Wave S350 machine. 1.
  • Page 91 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR OPTIONAL AUXILIARY POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.42 – Auxiliary power board plug locations MOUNTING NUTS G6571-1 LED 3 LED 1 TERMINAL B5 TERMINAL B6 (LEAD 317) (LEAD 318) MOUNTING NUTS REPLACECMENT PROCEDURE 1.
  • Page 92 ® POWER WAVE S350 NOTES...

  • Page 93: Retest After Repair

    RETEST AFTER REPAIR 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 94 ® POWER WAVE S350 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR (continued) PROCEDURE 1. Be certain the machine is properly connected for the input voltage being applied. 2. Turn the power switch ON and see that the machine goes through the Start-up routine and the status light is steady green. 3.
  • Page 95 ® POWER WAVE S350 DIAGRAMS TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams ..............G-2...

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