RETURN TO MAIN MENU Operator’s Manual ® POWER WAVE S350CE For use with machines having Code Numbers: 11625, 11783 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator 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. Save for future reference Date Purchased After hours? Use “Ask the Experts” at lincolnelectric.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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 sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 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.
SAFETY vi Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities 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 recommendations.
vii Thank You vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications ...............................................................................................A-1, A-2 Safety Precautions ...............................................................................................................A-3 Location, Lifting .......................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® S350CE POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes 230/380-415/ 460/575 50/60 Hz 35/20/17/14 Idle Power Power Factor @ Rated Output 300 Watts Max. (fan on) .95 40% rating K2823-2 100% rating 28/16/14/11 RATED OUTPUT GMAW INPUT VOLTAGE / PHASE / FREQUENCY 40% 60% 100% 40% 60% 100% 40% 60% 100% 230/3/50/60 380-415/3/50/60 460/3/50/60 575/3/50/60 350 Amps 31.
A-2 A-2 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) GMAW GMAW-Pulse FCAW GTAW-DC SMAW 5-350 OCV (Uo) Mean Peak 40-70 40-70 40-70 100V 24 60 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2823-2 20.40 in ( 518 mm) 14.00in ( 356 mm) 24.80in ( 630mm) 85 lbs (39 kg)* TEMPERATURE RANGES OPERATING TEMPERATURE RANGE -4°F to 104°F (-20C to 40C) STORAGE TEMPERATURE RANGE -40°F to 185°F (-40C to 85C) IP23 155º(F) Insulation Class * Weight does not include input cord.
A-3 A-3 INSTALLATION SAFETY PRECAUTIONS LIFTING Read this entire installation section before you start installation. WARNING Both handles should be used when lifting POWER WAVE® S350CE. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the POWER WAVE® S350CE with accessories attached to it. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation.
A-4 A-4 INSTALLATION INPUT CONNECTION POWER CORD REPLACEMENT WARNING WARNING Only a qualified electrician should connect the input leads to the POWER WAVE® S350CE. Connections should be made in accordance with all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death. ------------------------------------------------------------A 15 ft. (4.5m) power cord is provided and wired into the machine.
A-5 A-5 INSTALLATION CONNECTION DIAGRAMS GTAW (TIG) WELDING TIG welding from a LF-45 wire feeder can be used with the power source as shown in (Figure A.2), FIGURE A.2 ArcLink + POSITIVE GTAW BACK CONNECTIONS ON LF-45 REGULATOR FLOWMETER ArcLink POWER WAVE® S350 CE GAS HOSE + POSITIVE - WORK CLAMP K870-2 WORK LF-45 TORCH SMAW (STICK) WELDING Stick welding from a LF-45 wire feeder can be used with the power source as shown in (Figure A.3). FIGURE A.
A-6 A-6 INSTALLATION RECOMMENDED WORK CABLE SIZES FOR ARC WELDING Connect the electrode and work cables between the appropriate output studs of the Power Wave® S350CE per the following guidelines: • Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source.
A-7 A-7 INSTALLATION Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder, and have a dramatic effect on performance. Remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board. Sense Lead Kits (K940-xx) are available for this purpose. CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade.
A-8 INSTALLATION Electrode Voltage Sensing The remote ELECTRODE sense lead (67) is built into the 5-pin arclink control cable (K1543-xx) and is always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured by the active weld mode.
A-9 A-9 INSTALLATION VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS Special care must be taken when more than one arc is welding simultaneously on a single part. Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads, but they are strongly recommended. If Sense Leads ARE NOT Used: • Avoid common current paths.
A-10 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 8.A) FIGURE A.
A-11 INSTALLATION CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Power Wave® / Power Feed® systems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 100ft. (30.5m).
B-1 B-1 OPERATION SAFETY PRECAUTIONS CIRCUIT BREAKER READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING OR CAUTION WARNING • ELECTRIC SHOCK CAN KILL. • Do not touch electrically live part or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. • Do not operate with covers, panels or guards removed or open. --------------------------------------------------------------------• FUMES AND GASSES can be dangerous.
B-2 OPERATION B-2 PRODUCT DESCRIPTION PROCESS LIMITATIONS PRODUCT SUMMARY The POWER WAVE® S350CE is a portable multiprocess power source with high-end functionality capable of Stick, DC TIG, MIG, Pulsed MIG and FluxCored welding. It is ideal for a wide variety of materials including aluminum, stainless, and nickel — where arc performance is critical. The software based weld tables of the Power Wave® S350CE limit the process capability within the output range and the safe limits of the machine.
B-3 B-3 OPERATION CASE FRONT CONTROLS DESIGN FEATURES (See Figure B.1) Loaded with Standard Features 1. (NO OPTIONAL) USER INTERFACE • 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 fluctuations. • Utilizes next generation microprocessor control, based on the ArcLink® platform. 2. STATUS LED - (See Troubleshooting Section for operational functions) 3.
B-4 B-4 OPERATION CASE BACK CONTROLS CASE BACK CONTROLS (See Figure B.2 for Code 11625) (See Figure B.2a for Code 11783) 1. ETHERNET 1. ETHERNET 2. ARCLINK (OPTIONAL) 2. 115 VAC KIT (OPTIONAL) 3. SYNC-PULSE (OPTIONAL) 3. SYNC-PULSE (OPTIONAL) 4. DEVICENET KIT (OPTIONAL) 4. CIRCUIT BREAKER 5. INPUT POWER CORD 5. SYNC TANDEM/ STT CONNECTOR (OPTIONAL) 6. COOLER OUTPUT POWER PANEL (OPTIONAL) 6. DEVICENET KIT (OPTIONAL) 7. CIRCUIT BREAKER 7. INPUT POWER CORD 8.
B-5 OPERATION COMMON WELDING PROCEDURES WARNING MAKING A WELD The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
B-6 OPERATION B-6 SMAW (STICK) WELDING The welding current and Arc Force settings can be set through a Power Feed 10M, LF45 or Power Feed 25M wire feeder. Alternatively an optional Stick / TIG UI (K2828-1) can be installed into the power source to control these settings locally. The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference.
B-7 OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the POWER WAVE® S350CE will automatically recalculate the waveform parameters to maintain similar arc properties. The POWER WAVE® S350CE utilizes “adaptive control” to compensate for changes in the electrical stickout while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The POWER WAVE® S350CE waveforms are optimized for a 0.75” stick-out.
C-1 ACCESSORIES KITS, OPTIONS AND ACCESSORIES All Kits Options and Accessories are found on the Web site: (www.lincolnelectric.com) FACTORY INSTALLED None Available FIELD INSTALLED OPTIONS GENERAL OPTIONS DeviceNet Kit Mounts inside the back of the Power Wave® S350CE. Allows Devicenet objects to communicate with the Power Wave® S350CE. Order K2827-1 Work Voltage Sense Lead Kit Required to accurately monitor voltage at the arc.
C-2 ACCESSORIES STICK OPTIONS ACCESSORY KIT - 150 Amp For stick welding. Includes 20 ft. (6.1m) #6 electrode cable with lug, 15 ft. (4.6m) #6 work cable with lugs, headshield, filter plate, work clamp, electrode holder and sample pack of mild steel electrode. For use with K2176-1 (Twist-Mate™ to Lug Adapter) ORDER K875 ACCESSORY KIT - 400 AMP For stick welding. Includes 35 ft. (10.7m) 2/0 electrode cable with lug, 30 ft. (9.
D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. • Only qualified personnel should install, use or service this equipment.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
E-2 E-2 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Not all of the Power Wave® S350CE errors will be displayed on the user interface (if it is installed). There are two status lights that display error codes. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.
E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE® S350CE The following is a partial list of possible error codes for the POWER WAVE® S350CE. For a complete listing consult the Service Manual for this machine. MAIN CONTROL BOARD ( “STATUS” LIGHT) 36 Error Code # Indication Thermal error Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation.
E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual INPUT CONTROL BOARD Indication Error Code # 331 Peak input current limit Input current limit has been exceeded. Typically indicates short term power overload. If problem persists contact Service Department. 333 Under-voltage lockout +15 VDC supply on Input control board too low. Verify input voltage is within the acceptable range. If problem persists contact service department.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Basic Machine Problems Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly sized. See installation section of this manual for recommended sizes. 2. Improper Weld Procedure requir- 2. Reduce output current, duty cycle, or both. ing output levels in excess of machine rating. 3. Major physical or electrical dam- 3.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Thermal LED is ON Thermal LED is ON POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Improper fan operation Basic Machine Problems (Continued) 1. Improper fan operation. 1. Check for proper fan operation. Fan should run in a low speed setting when the machine is idle and in a high speed when the output is triggered.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of 1. Burnback Time 1. Reduce burnback time and/or the weld. work point. Machine output shuts down during a 1. Secondary current limit has been 1. Adjust procedure or reduce load weld. exceeded, and the machine shuts to lower current draw from the down to protect itself. machine.
E-8 E-8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Ethernet Cannot Connect 1. Physical connection. 1. Verify that the correct patch cable or cross over cable is being used (refer to local IT department for assistance). 1a. Verify the cables are fully inserted into the bulk head connector. 1b.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2 F-2 DIMENSION PRINT 27.43 27 22.25 22 13.91 13 18.81 18 6.00 18.35 18 A.
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
Keep your head out of fumes. Use ventilation or exhaust to remove Turn power off before servicing. Do not operate with panel open or Los humos fuera de la zona de res- Desconectar el cable de alimentación No operar con panel abierto o Gardez la tête à l’écart des fumées.
CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time.
