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POWER WAVE 355M
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.
And, most
importantly, think before you act
and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
For use with machines Code 11141,11489
W A
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• World's Leader in Welding and Cutting Products •
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Copyright © 2007 Lincoln Global Inc.
IM845-A
October, 2007
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Related Manuals for Lincoln Electric POWER WAVE IM845-A
Summary of Contents for Lincoln Electric POWER WAVE IM845-A
- Page 1 POWER WAVE 355M For use with machines Code 11141,11489 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
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Page 2: California Proposition 65 Warnings
351040, 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Safety Precautions
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Installation ...Section A Technical Specifications ...A-1 Safety Precautions...A-2 Select Suitable Location ...A-2 Stacking ...A-2 Tilting...A-2 Input and Grounding Connections ...A-2 Power Cord Connection ...A-2 Undercarriage Mountings...A-2 Output Cables, Connections and Limitations...A-3 Negative Electrode Polarity ...A-3 Voltage Sensing ... A-4 Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections...A-5 System Description...A-5 System Set-Up ...A-6, A-7 Welding with Multiple Power Waves...A-8... -
Page 8: Installation
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75°C rated: DUTY CYCLE CURRENT 100% Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding. INSTALLATION POWER WAVE 355M 350A / 34V / 60% AMPS... -
Page 9: Safety Precautions
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS- CONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES. • Only qualified personnel should perform this installation. •... -
Page 10: Output Cables, Connections And Limitations
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS Connect a work lead of sufficient size and length (per table A.1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. -
Page 11: Voltage Sensing
Depending upon the process, inductance within the electrode and work lead cables can influence the apparent voltage at the studs of the welder. Voltage sense leads improve the accuracy of the arc condi- tions and can have a dramatic effect on performance. -
Page 12: Power Wave To Semi-Automatic Power Feed Wire Feeder Interconnections
INSTALLATION POWER WAVE TO SEMI-AUTOMATIC POWER FEED WIRE FEEDER INTERCON- NECTIONS The POWER WAVE 355M and semi-automatic Power Feed family communicate via a 5 conductor control cable (K1543). The control cable consists of two power leads, one twisted pair for digital communica- tion, and one lead for voltage sensing. - Page 13 DIP switches to configure the system. If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the welder output will be disabled. SINGLE HEAD FEEDER UP TO 4 WIRE FEEDERS ALLOWED...
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Page 14: Alternate Hard Automatic Application
ALTERNATE HARD AUTOMATIC APPLICATION (using a User Interface, Wire Drive Module, and POWER FEED-10R) COMBINATION HARD AUTOMATION APPLICATION (w/ Semi-Auto Feeder, Wire Drive Module, and POWER FEED-10R) DUAL HEAD System that is NOT "Auto Mappable" DUAL HEAD BOOM FEEDER (using two single heads) POWER WAVE 355M In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE... -
Page 15: Welding With Multiple Power Waves
WELDING WITH MULTIPLE POWER WAVES Special care must be taken when more than one Power Wave is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. - Page 16 INSTALLATION MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES POWER WAVE 355M...
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Page 17: I / O Receptacle Specifications
A-10 I / O RECEPTACLE SPECIFICATIONS TABLE A.2 WIRE FEEDER RECEPTACLE LEAD# FUNCTION Communication Bus L Communication Bus H Electrode Voltage Sense 0vdc +40vdc + TABLE A.3 VOLTAGE SENSE RECEPTACLE LEAD# FUNCTION Work Voltage Sense TABLE A.4 RS232 RECEPTACLE LEAD# FUNCTION RS232 Receive RS232 Transmit... -
Page 18: Operation
ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. WELDING SPARKS can cause fire or explosion. ARC RAYS can burn. OPERATION GENERAL DESCRIPTION The Power Wave 355M semi-automatic power source is designed to be a part of a modular, multi-process welding system. -
Page 19: Required Equipment
POWER WAVE 355M – Semi-Automatic Operation Power Wave 355M can only be used with ArcLink compatible Power Feed M semi-automatic wire feed- ers. In addition, the Power Feed semi-automatic wire feeders may require optional equipment to access certain weld modes in the Power Wave. Other models of Lincoln feeders, or any models of non-Lincoln wire feeders, cannot be used. -
Page 20: Nominal Procedures
Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative. To make a weld, the Power Wave needs to know the desired welding parameters. -
Page 21: Constant Voltage Welding
• ARC CONTROL Also known as Inductance or Wave Control. Allows operator to vary the arc characteristics from "soft" to "harsh" in all weld modes. It is adjustable from -10.0 to +10.0, with a nominal setting of 00.0 (The nominal set- ting of 00.0 may be displayed as OFF on some Power Feed wire feeder control panels). -
Page 22: Pulse Welding
PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. -
Page 23: Arc Gouging
BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse-on-Pulse. The welds made to obtain the values in the table were fillet welds in the flat position. -
Page 24: Power Mode
POWER MODE™ The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For alu- minum welding, it provides excellent control and the ability to maintain constant arc length. -
Page 25: Accessories
ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead Kit K1764-1-Undercarriage* K1838-1-Valet Style Undercarriage K1796-Coaxial Welding Cable-(Requires Adapter K2176-1) K2176-1 Twist-mate to Lug Adapters * Dual Cylinder Kit for K1764-1 is K1702-1 Welding Cable Connectors: K852-70 1/0-2/0 CABLE K852-95 2/0-3/0 CABLE COMPATIBLE LINCOLN EQUIPMENT Any ArcLink compatible wire feeding equipment. -
Page 26: Maintenance
Generally speaking the machine calibration will not need adjustment. However, if the weld perfor- mance changes, or the yearly calibration check reveals a problem, contact the Lincoln Electric Company for the calibration software utility. The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and cur- rent. -
Page 27: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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 28: Using The Status Led To Troubleshoot System Problems
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feedhead) has a status light, and when a problem occurs it is important to note the condition of each. - Page 29 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWERWAVE The following is a list of possible error codes that the POWER WAVE 355M can output via the status light (see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11 these error codes will generally be accompanied by an "Err 006"...
- Page 30 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF...
- Page 31 Machine wonʼt weld, canʼt get any output. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S) 1.
- Page 32 Machine wonʼt produce full output. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S) 1.Secondary current limit has been...
- Page 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) General degradation of the weld per- formance Excessively long and erratic arc. If Wire Feed Speed is in Question. Inch Per Minute = (IPM) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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Page 34: Wiring Diagram
WIRING DIAGRAMS POWER WAVE 355M... - Page 35 DIAGRAMS POWER WAVE 355M...
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Page 36: Connection Diagram
CONNECTION DIAGRAM Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER WORK CONTROL CABLE K1543 POWER WAVE 355M... - Page 37 DIMENSION PRINT POWER WAVE 355M...
- Page 38 NOTES POWER WAVE 355M...
- Page 39 NOTES POWER WAVE 355M...
- Page 40 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 41 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 42 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...