im745 power wave 355 october, 2003 - lincoln electricpower wave 355 operator’s manual for use with...

POWER WAVE 355

OPERATOR’S MANUAL

For use with machines Code 10895

IM745October, 2003

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

WARNINGWARNING

AVISO DE

PRECAUCION

ATTENTION

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WARNING

REMOTE

POWER

OFF

ON

P O W

E R W A V E 3

5 5

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2003 Lincoln Global Inc.

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

POWER WAVE 355

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

POWER WAVE 355

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

POWER WAVE 355

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

POWER WAVE 355

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications - POWER WAVE 355 ....................................................A-1Safety Precautions.................................................................................................A-2Select Suitable Location ........................................................................................A-2

Stacking ..........................................................................................................A-2Tilting...............................................................................................................A-2Input and Grounding Connections ..................................................................A-2Power Cord Connection ..................................................................................A-2Undercarriage Mountings................................................................................A-2

Output Cables, Connections and Limitations.........................................................A-3Negative Electrode Polarity ...................................................................................A-3Voltage Sensing ............................................................................................A-3, A-4Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-4System Description................................................................................................A-5System Set-Up.........................................................................................A-6 thru A-8Welding with Multiple Power Waves......................................................................A-9Control Cable Specifications..................................................................................A-9I / O Receptacle Specifications............................................................................A-10

Dip Switch Settings and Locations...............................................................A-10Control Board Dip Switch ..............................................................................A-10________________________________________________________________________

Operation .........................................................................................................Section BSafety Precautions.................................................................................................B-1General Description ...............................................................................................B-1Recommended Processes and Equipment ...........................................................B-1

Recommended Processes ..............................................................................B-1Required Equipment .......................................................................................B-2Limitations .......................................................................................................B-2Duty Cycle and Time Period ...........................................................................B-2Case Front Controls ................................................................................B-2, B-3Nominal Procedures........................................................................................B-3Fringe Procedures...........................................................................................B-3Making a Weld ................................................................................................B-3Welding Adjustment ........................................................................................B-3Constant Voltage Welding...............................................................................B-4Pulse Welding .................................................................................................B-5Tig GTAW .......................................................................................................B-5________________________________________________________________________

Accessories .....................................................................................................Section COptional Equipment ...............................................................................................C-1

Factory Installed..............................................................................................C-1Field Installed..................................................................................................C-1Compatible Lincoln Equipment________________________________________________________________________

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Capacitor Discharge Procedure ............................................................................D-1Routine Maintenance.............................................................................................D-1Periodic Maintenance............................................................................................D-1Calibration Specification ........................................................................................D-1________________________________________________________________________

Troubleshooting ..............................................................................................Section EHow to use Troubleshooting Guide .......................................................................E-1Using the Status LED to Troubleshoot System Problems .....................................E-2Troubleshooting Guide.............................................................................E-3 thru E-7________________________________________________________________________

Wiring Diagram ............................................................................................Section F-1Connection Diagram ....................................................................................Section F-2Dimension Print............................................................................................Section F-3________________________________________________________________________Parts Lists ................................................................................................................P418________________________________________________________________________

A-1INSTALLATION

POWER WAVE 355

A-1

TECHNICAL SPECIFICATIONS - POWER WAVE 355INPUT AC VOLTAGE & DC OUTPUT

Product Ordering Input AC Rated DC Output Output Weight DimensionsName Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD

(continuous)

200 350A / 34V / 60% 14.8” x 13.3” xPOWER K2152-1 208-230/ 27.8”* WAVE 380-400/ AMPS (81.5 lbs.) (373 x 338 x355 415-460/ 5-425 (37.0 kg.) 706*)mm

575 300A / 32V /100%1& 3 Phase * Includes Handles

60/50 Hz

* Overall Length Including Handle, 21.6” (549mm) without handle.

Voltage

200

208230380

400

415460575

200208230380400415460575

Phases

1

111

1

111

33333333

300Amps @32Volts(100%)

NotRecommended

7669Not

RecommendedNot

Recommended413631

4139362322221916

350Amps @34Volts(60%)

NotRecommended

9485Not

RecommendedNot

Recommended644237

5050422827262318

Line CordAWG

24

---

688

66888888

Fuse size

---

125A125A

---

---

80A70A50A

80A80A70A40A40A40A40A30A

POWER WAVE 355 INPUT CURRENT

OUTPUT CABLES, CONNECTIONS AND LIMITATIONS

Recommemded Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs

Input 50/60 Hz Output Recommended

Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

Select The output cable size based upon the following chart.*Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:

DUTY CYCLE100%60%

CURRENT300350

LENGTH UP 200FT. (61m)2/02/0

200-250 FT. (61-76m)2/02/0

Notes

Note 1

Note 2Note 2Note 1

Note 1

Note 2

Note 2Note 2

*Lincoln Electric recommends using a mimimum of 2/0 welding cable for pulse welding.

A-2INSTALLATION

POWER WAVE 355

A-2

SELECT SUITABLE LOCATION

The Invertec POWER WAVE 355 will operate in harshenvironments. Even so, it is important that simple pre-ventative measures are followed in order to assurelong life and reliable operation.

• The machine must be located where there is free cir-culation of clean air such that air movement in theback, out the sides and bottom will not be restricted.

• Dirt and dust that can be drawn into the machineshould be kept to a minimum. Failure to observethese precautions can result in excessive operatingtemperatures and nuisance shutdown.

• Keep machine dry. Shelter from rain and snow. Donot place on wet ground or in puddles.

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surfacedirectly under stationary or fixed elec-trical equipment, that surface shall becovered with a steel plate at least.06”(1.6mm) thick, which shall extend

not less than 5.90”(150mm) beyond the equipmenton all sides.-----------------------------------------------------------------------STACKINGPOWER WAVE 355 cannot be stacked.

TILTINGPlace the machine directly on a secure, level surfaceor on a recommended undercarriage. The machinemay topple over if this procedure is not followed.

INPUT AND GROUNDING CONNECTIONS• Only a qualified electrician should connect the

Invertec POWER WAVE 355. Installation should bemade in accordance with the appropriate NationalElectrical Code, all local codes and the informationdetailed below.

• When received directly from the factory, multiplevoltage machines are internally connected for460VAC. If 460VAC is the desired input, then themachine may be connected to the power systemwithout any setup required inside the machine.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• TURN THE INPUT POWER OFF AT

THE DISCONNECT SWITCH BEFOREATTEMPTING TO CONNECT OR DIS-CONNECT INPUT POWER LINES,

OUTPUT CABLES, OR CONTROL CABLES.• Only qualified personnel should perform this

installation.• Connect the green/yellow lead of the power

cord to ground per U.S.National ElectricalCode.

----------------------------------------------------------------------

WARNING

• Initial 200VAC - 415VAC and 575VAC operationwill require an Input voltage panel setup.

• Open the access panel on the rear of the machine.• For 200 or 230: Position the large switch to 200-

230.For higher voltages: Position the large switch to380-575.

• Move the "A" lead to the appropriate terminal.

POWER CORD CONNECTIONA 10 ft. power cord is provided and wired into themachine. Follow the power cord connection instruc-tions.

• Incorrect connection may result in equipmentdamage.

-----------------------------------------------------------------------

Single Phase InputConnect green lead to ground per National ElectricalCode.Connect black and white leads to power.Wrap red lead with tape to provide 600V insulation.Three Phase InputConnect green lead to ground per National ElectricCode.Connect black, red and white leads to power.

UNDERCARRIAGE MOUNTINGS

WARNINGWARNING

AVISO DE

PRECAUCION

ATTENTION

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WARNING

REMOTE

POWER

OFF

ON

P OW E R W

A V E 3 5 5

GREENRED

BLACK

WHITE

5.50

10.00

MOUNTING HOLE LOCATIONS

M19527

1/4-20 NUT (4 PLACES)

NOTE: MOUNTING SCREWS CA

10/01

N NOT PROTRUDE MORE THAN 0.5 INCHES INSIDE THE MACHINE.

11.84

3.50

CAUTION

CAUTION

NEGATIVE ELECTRODE POLARITYWhen negative electrode polarity is required, such asin some Innershield applications, reverse the outputconnections at the power source (electrode cable tothe negative (-) Twist-Mate terminal, and work cableto the positive (+) Twist-Mate terminal.

When operating with negative electrode polarity the"Electrode Sense Polarity" DIP switch must be set tothe "Negative" position on the Wire Drive Feed HeadPC Board. The default setting of the switch is positiveelectrode polarity. Consult the Power Feed instructionmanual for further details.

VOLTAGE SENSINGThe best arc performance occurs when thePowerWaves have accurate data about the arc condi-tions. Depending upon the process, inductance withinthe electrode and work lead cables can influence thevoltage apparent at the studs of the welder. Voltagesense leads improve the accuracy of the arc condi-tions and can have a dramatic effect on performance.Sense Lead Kits (K940-10, -25 or -50) are availablefor this purpose.

If the voltage sensing is enabled but the senseleads are missing, improperly connected, or if theelectrode polarity switch is improperly configured,extremely high welding outputs may occur.------------------------------------------------------------------------The ELECTRODE sense lead (67) is built into thecontrol cable, and is automatically enabled for allsemi-automatic processes. The WORK sense lead(21) connects to the Power Wave at the four pin con-nector. By default the WORK voltage is monitored atthe output stud in the POWER WAVE 355. For moreinformation on the WORK sense lead (21), see"WorkVoltage Sensing” in the following paragraph.

A-3INSTALLATION

POWER WAVE 355

A-3

OUTPUT CABLES, CONNECTIONS ANDLIMITATIONSConnect a work lead of sufficient size and lengthbetween the proper output terminal on the powersource and the work. Be sure the connection to thework makes tight metal-to-metal electrical contact. Toavoid interference problems with other equipment andto achieve the best possible operation, route all cablesdirectly to the work or wire feeder. Avoid excessivelengths and do not coil excess cable.

When using an inverter type power source like thePowerWaves, use the largest welding (electrodeand work) cables that are practical. At least 2/0copper wire - even if the average output currentwould not normally require it. When pulsing, thepulse current can reach very high levels. Voltagedrops can become excessive, leading to poorwelding characteristics, if undersized weldingcables are used.------------------------------------------------------------------------Most welding applications run with the electrode beingpositive (+). For those applications, connect the elec-trode cable between the wire feeder and the positive(+) output Twist-Mate terminal on the power source.Connect the other end of the electrode cable to thewire drive feed plate. The electrode cable lug must beagainst the feed plate. Be sure the connection to thefeed plate makes tight metal-to-metal electrical con-tact. The electrode cable should be sized according tothe specifications given in the output cable connec-tions section. Connect a work lead from the negative(-) power source output Twist-Mate terminal to thework piece. The work piece connection must be firmand secure, especially if pulse welding is planned.

For additional Safety information regarding the elec-trode and work cable set-up, See the standard "SAFE-TY INFORMATION" located in the front of theInstruction Manuals.

Excessive voltage drops caused by poor workpiece connections often result in unsatisfactorywelding performance.------------------------------------------------------------------------

CAUTION

CAUTION

CAUTION

5. Replace the wrap around and screws. The PCboard will “read” the switch at power up, and config-ure the work voltage sense lead appropriately.

ELECTRODE VOLTAGE SENSINGEnabling or disabling electrode voltage sensing isautomatically configured through software. The 67electrode sense lead is internal to the cable to thewire feeder and always connected when a wire feederis present.

Important: The electrode polarity must be config-ured at the feed head for all semi-automaticprocesses. Failure to do so may result in extreme-ly high welding outputs.------------------------------------------------------------------------POWER WAVE TO SEMI-AUTOMATICPOWERFEED WIRE FEEDER INTERCON-NECTIONS

The POWER WAVE 355 and semi-automatic PowerFeed family communicate via a 5 conductor controlcable (K1543). The control cable consists of twopower leads, one twisted pair for digital communica-tion, and one lead for voltage sensing. The cables aredesigned to be connected end to end for ease ofextension. The output receptacle on the POWERWAVE 355 is on the case front. The input receptacleon the Power Feed is typically located at the back ofthe feeder, or on the bottom of the user interface.

Due to the flexibility of the platform the configurationmay vary. The following is a general description of thesystem. For specific configuration information, consultthe semi-automatic Power Feed instruction manual.

A-4INSTALLATION

POWER WAVE 355

A-4

TABLE A.1Process Electrode Voltage Work Voltage

Sensing 67 lead * Sensing 21 leadGMAW 67 lead required 21 lead optionalGMAW-P 67 lead required 21 lead optionalFCAW 67 lead required 21 lead optionalGTAW Voltage sense at studs Voltage sense at studsSMAW Voltage sense at studs Voltage sense at studsSAW 67 lead required 21 lead optionalCAC-C Voltage sense at studs Voltage sense at studs

* The electrode voltage 67 sense lead is integral to thecontrol cable to the wire feeder.

Work Voltage SensingThe standard POWER WAVE 355’s default to thework stud (work sense lead disabled).

For processes requiring work voltage sensing, con-nect the (21) work voltage sense lead (K940) from thePower Wave work sense lead receptacle to the workpiece. Attach the sense lead to the work piece asclose to the weld as practical, but not in the return cur-rent path of the electrode to the ground clamp. Enablethe work voltage sensing in the Power Wave as fol-lows:

• Do not touch electrically live parts orelectrodes with your skin or wetclothing.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

-----------------------------------------------------------

1. Turn off power to the power source at the discon-nect switch.

2. Remove the wrap around cover from the powersource.

3. The control board is on the center assembly facingthe case front. Locate the 8-position DIP switch andlook for switch 8 of the DIP switch.

4. Using a pencil or other small object, slide the switchto the OFF position if the work sense lead is NOTconnected. Conversely, slide the switch to the ONposition if the work sense lead is present.

WARNING

ON

1 2 3 4 5 6 7 8

CAUTION

A-5INSTALLATION

POWER WAVE 355

A-5

SYSTEM DESCRIPTION

The POWER WAVE 355 and Power Feed family ofwire feeder products utilize a digital communicationsystem called Linc-Net. Simply put, Linc-Net allowslarge amounts of information to be passed at veryhigh speeds between components (nodes) in the sys-tem. The system requires only two wires for communi-cation, and because of its bus-like structure, the com-ponents may be connected to the network in anyorder, thus simplifying the system set-up.

Each "system" must contain only one power source.The power source may be connected to a maximumof four feeder groups. Each group containing oneuser interface (UI), and up to seven Feed Heads(FH). SEE FIGURE A.1. The UI controls all of theFH’s of that group. The UI’s and FH’s are assigned togroups by setting a code on the DIP switches mount-ed on their individual control boards. For example allof the FH’s to be controlled by a given UI must havetheir "Group ID" switches set to the same group num-ber as the UI. In addition, each FH must be assigneda separate FH number within that group. See the sys-tem set-up section for further details.

From a network perspective, each component in thesystem is considered a separate node, regardless ofits physical location. For example, even though a UIand FH may be physically mounted together, they arestill viewed as separate pieces (nodes) by the net-work, and can only communicate via Linc-Net. TheLinc-Net connection is generally made externalthrough the Linc-Net Control Cable, but can also bemade internally, as with the Power Feed 10 benchmodel feeder.

The most common Linc-Net configuration (called asimple system) consists of one power source, oneuser interface and one feeder. Under these circum-stances the group and feed head ID DIP switches areignored and the system will function regardless oftheir position. The same is true for the minimum sys-tem consisting of a power source and one UI(Example: a stick welding system).

FIGURE A.1System Model

355

A-6INSTALLATION

POWER WAVE 355

A-6

FIGURE A.2Simple System

SYSTEM SET-UP

Basic Rules• Each group is required to have one user interface.

No group may have more than one user interface.

• Each group can have up to seven Feed Heads.Exception: Group 3 is limited to a maximum of sixFeed Heads.

• Each system has only one power source. For net-work purposes, the PS belongs to Group 3, which iswhy group 3 is only allowed 6 feed heads in additionit’s user interface.

• No two feed heads can have identical Group andFeed Head numbers.

• Group and Feed Head ID numbers must be set onthe appropriate dipswitches at each node. Consultthe appropiate Power Feed Wire Feeder InstructionManual for specific details regarding dipswitch set-tings.

• Feed head “0” not allowed. Exception: Simple sys-tem ignores all ID numbers, therefore “FH0” willfunction.

• Each node must be connected to the Linc-Net com-munication network. The order of connection is notimportant, as each node is identified by it’s uniqueGroup and Feed Head ID number as defined on it’sdipswitches. See Figures A.2 thru A.5.

Group and FeedHead ID numbers areignored in a simplesystem.

355

A-7INSTALLATION

POWER WAVE 355

A-7

FIGURE A.3

Multiple Group System

No “FH0 Alllowed!

FIGURE A.4

Single Group Multi-Head System

No “FH0 Alllowed!

The Dual Headoption allows the abil-ity to maintain 2 setsof procedures. Ifmore then 2 headsare used, odd #’s useFH1 settings, even#’s use FH2 settings.

355

355

A-8INSTALLATION

POWER WAVE 355

A-8

FIGURE A.5Single Group Multi-Head System (Alternate Method)

No “FH0 Alllowed!

When a standardUser Iterface is usedin a group with multi-ple Feed Heads, allof the Feed Headsuse a single set ofprocedures.

355

A-9INSTALLATION

POWER WAVE 355

A-9

WELDING WITH MULTIPLE POWERWAVES

Special care must be taken when more than onePower Wave is welding simultaneously on a singlepart. Arc blow and arc interference may occur orbe magnified.

Each power source requires a work lead from thework stud to the welding fixture. Do not combine all ofthe work leads into one lead. The welding travel direc-tions should be in the direction moving away from thework lead as shown below. Connect all of the worksense leads from each power source to the workpiece at the end of the weld. (See Figure A.6)

For the best results when pulse welding, set the wiresize and wire feed speed the same for all the PowerWaves. When these parameters are identical, thepulsing frequency will be the same, helping to stabilizethe arcs.

Every welding gun requires a seperate shielding gasregulator for proper flow rate and shielding gas cover-age.

Do not attempt to supply shielding gas for two or moreguns from only one regulator.

If an anti-spatter system is in use then each gun musthave its own anti-spatter system.

Connect All WorkSense Leads at the Endof the Joint

Connect All WeldingWork Leads at theBeginning of the Joint

TravelDirection

PPOWER WAVE 355POWER WAVE 355

TWO POWER WAVES

CONTROL CABLE SPECIFICATIONSIt is recommended that genuine Lincoln control cablesbe used at all times. Lincoln cables are specificallydesigned for the communication and power needs ofthe Power Wave / Power Feed system.

The use of non-standard cables, especially inlengths greater than 25 feet, can lead to communi-cation problems (system shutdowns), poor motoracceleration (poor arc starting) and low wire dri-ving force (wire feeding problems).------------------------------------------------------------------------The K1543 series of control cables can be connectedend to end for ease of extension. Do not exceed morethan 100 feet (30.5 m) total control cable length.

CAUTION

CAUTION

FIGURE A.6

A-10INSTALLATION

POWER WAVE 355

A-10

I / O RECEPTACLE SPECIFICATIONSTABLE A.2

WIRE FEEDER RECEPTACLEPIN LEAD# FUNCTIONA 53 Communication Bus LB 54 Communication Bus HC 67A Electrode Voltage SenseD 52 0vdcE 51 +40vdc

TABLE A.3VOLTAGE SENSE RECEPTACLE

PIN LEAD# FUNCTION3 21A Work Voltage Sense

TABLE A.4RS232 RECEPTACLE

PIN LEAD# FUNCTION2 253 RS232 Receive3 254 RS232 Transmit4 # Pin55 # Pin46 # # Pin2020 # # Pin67 251 RS232 Commom

DIP SWITCH SETTINGS AND LOCATIONSDIP switches on the P.C. Boards allow for customconfiguration of the Power Wave. To access the DIPswitches:

ELECTRIC SHOCK can kill.1. Turn off power to the power source at

the disconnect switch.------------------------------------------------------------------------2. Remove the wrap around cover from the power

source.

3. The control board is on the center assembly facingthe case front. Locate the 8-position DIP switch andlook for switch 8 of the DIP switch.

4. Using a pencil or other small object, slide the switchto the OFF position if the work sense lead is NOTconnected. Conversely, slide the switch to the ONposition if the work sense lead is present.

CONTROL BOARD DIP SWITCH:switch 1 = reserved for future useswitch 2 = reserved for future useswitch 3 = reserved for future useswitch 4 = reserved for future useswitch 5 = reserved for future useswitch 6 = reserved for future useswitch 7 = reserved for future useswitch 8* = work sense lead

switch 8* work sense leadoff work sense lead not connectedon work sense lead connected

*Factory setting for Switch 8 is OFF.

CONTROL BOARD (DIP Switch Location)FIGURE A.7

ON

1 2 3 4 5 6 7 8

WARNING

5. Replace the wrap around and screws. The PCboard will “read” the switch at power up, and config-ure the work voltage sense lead appropriately.

GENERAL DESCRIPTIONThe Power Wave semi-automatic power source isdesigned to be a part of a modular, multi-processwelding system. Depending on configuration, it cansupport constant current, constant voltage, constantpower and pulse welding modes.

The Power Wave power source is designed to beused with the semi automatic family of Power Feedwire feeders, operating as a system. Each componentin the system has special circuitry to "talk with" theother system components, so each component (powersource, wire feeder, user interface) knows what theother is doing at all times. These components commu-nicate with Linc-Net.

The POWER WAVE 355 is a high performance, digi-tally controlled inverter welding power source capableof complex, high-speed waveform control. Properlyequipped, it can support the GMAW, GMAW-P,FCAW, SMAW, GTAW, and CAC-A processes. It car-ries an output rating of 350 Amps, 34 Volts at 60%duty cycle and 300 Amps, 32 volts at 100% dutycycle.

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSESThe POWER WAVE 355 can be set up in a number ofconfigurations, some requiring optional equipment orwelding programs. Each machine is factory prepro-grammed with multiple welding procedures, typicallyincluding GMAW, GMAW-P, FCAW, GTAW, andCAC-A for a variety of materials, including mild steel,stainless steel, cored wires, and aluminum.

The POWER WAVE 355 is recommended for semi-automatic welding, and may also be suitable for basichard automation applications.

• This Power Wave is not recommended for processesother than those listed.

B-1OPERATIONB-1

POWER WAVE 355

SAFETY PRECUATIONSRead this entire section of operating instructionsbefore operating the machine.

ELECTRIC SHOCK can kill.• Unless using cold feed feature, when

feeding with gun trigger, the elec-trode and drive mechanism arealways electrically energized andcould remain energized several sec-onds after the welding ceases.

• Do not touch electrically live parts or electrodeswith your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

-----------------------------------------------------------

FUMES AND GASES can be dangerous.• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

-----------------------------------------------------------

WELDING SPARKS can cause fire orexplosion.

• Keep flammable material away.

• Do not weld on containers that haveheld combustibles.

-----------------------------------------------------------ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in thebeginning of this manual.

WARNING

POWER WAVE 355 – Semi-Automatic Operation

Semi Automatic Power Waves can only be used withLinc-Net compatible Power Feed semi-automatic wirefeeders. In addition, the Power Feed semi-automaticwire feeders may require optional equipment toaccess certain weld modes in the Power Wave. Othermodels of Lincoln feeders, or any models of non-Lincoln wire feeders, cannot be used.

All welding programs and procedures are selectedthrough the Power Feed semi-automatic user inter-face

REQUIRED EQUIPMENTAny Linc-Net compatible semi-automatic wire feedingequipment. Specifically, the semi-automatic PowerFeed family (PF-10, PF-10X2, PF-11, PF-15).

LIMITATIONS• Only Linc-Net compatible Power Feed semi-auto-

matic wire feeders and users interfaces may beused. Other Lincoln wire feeders or non-Lincoln wirefeeders cannot be used.

• POWER WAVE 355 Output LimitationsThe POWER WAVE 355 will support maximum aver-age output current of 350 Amps @ 60% duty cycle.

DUTY CYCLE AND TIME PERIODThe duty cycle is based upon a ten minute period. A60% duty cycle represents 6 minutes of welding and 4minutes of idling in a ten minute period.

CASE FRONT CONTROLSAll operator controls are located on the case front ofthe Power Wave. (See Figure B.1)

1. POWER SWITCH: Controls input power to thePower Wave.

2. STATUS LIGHT: A two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated, per table B.1.

NOTE: The POWER WAVE 355 status light will flashgreen, and sometimes red and green, for up to oneminute when the machine is first turned on. This is anormal situation as the machine goes through a selftest at power up.

TABLE B.1

LightCondition

Steady Green

BlinkingGreen

A l t e r n a t i n gGreen andRed

Steady Red

Blinking Red

Meaning

System OK. Power source communicating normal-ly with wire feeder and its components.

Occurs during a reset, and indicates thePOWER WAVE 355 is mapping (identifying)each component in the system. Normal forfirst 1-10 seconds after power is turned on,or if the system configuration is changedduring operation

Non-recoverable system fault. If the PSStatus light is flashing any combination ofred and green, errors are present in thePOWER WAVE 355. Read the error codebefore the machine is turned off.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red witha long pause between digits. If more thanone code is present, the codes will be sepa-rated by a green light.

To clear the error, turn power source off,and back on to reset. See TroubleshootingSection.

Non recoverable hardware fault. Generallyindicates nothing is connected to thePOWER WAVE 355 wire feeder receptacle.See Trouble Shooting Section.

Not applicable.

B-2OPERATIONB-2

POWER WAVE 355

3. HIGH TEMPERATURE LIGHT (thermal overload):A yellow light that comes on when an over temper-ature situation occurs. Output is disabled and thefan continues to run, until the machine cools down.When cool, the l ight goes out and output isenabled.

4. CB1 WIRE FEEDER CIRCUIT BREAKER:Protects 40 volt DC wire feeder power supply.

The steps for operating the Power Wave will varydepending upon the options installed in the user inter-face (control box) of the welding system. The flexibilityof the Power Wave system lets the user customizeoperation for the best performance.

First, consider the desired welding process and thepart to be welded. Choose an electrode material,diameter, shielding gas and process (GMAW, GMAW-P, etc.)

Second, find the program in the welding software thatbest matches the desired welding process. The stan-dard software shipped with the Power Waves encom-passes a wide range of common processes and willmeet most needs. If a special welding program isdesired, contact the local Lincoln Electric sales repre-sentative.

To make a weld, the Power Wave needs to know thedesired welding parameters. The Power Feed (PF)family of feeders communicate settings to the PowerWave through control cable connection. Arc length,wire feed speed, arc control, etc. are all communicat-ed digitally via the control cable.

WELDING ADJUSTMENTS

All adjustments are made on the system componentknown as the User Interface (Control Box), which con-tains the switches, knobs, and digital displays neces-sary to control both the Power Wave and a PowerFeed wire feeder. Typically, the Control Box is sup-plied as part of the wire feeder. It can be mounteddirectly on the wire feeder itself, or mounted separate-ly, as might be done in a welding boom installation.

Because the Control Box can be configured with manydifferent options, your system may not have all of thefollowing adjustments. Regardless of availability, allcontrols are described below. For further information,consult the Power Feed wire feeder instruction manu-al.

• WFS / AMPS:In synergic welding modes (synergic CV, pulseGMAW) WFS (wire feed speed) is the dominant con-trol parameter, controlling all other variables. The useradjusts WFS according to factors such as weld size,penetration requirements, heat input, etc. The PowerWave then uses the WFS setting to adjust its outputcharacteristics (output voltage, output current) accord-ing to pre-programmed settings contained in thePower Wave.

B-3OPERATION

POWER WAVE 355

B-3

5. Internal POWER CIRCUIT BREAKER: Protects 115volt AC circuit.

6. LEAD CONNECTOR (SENSE LEAD)7. DIAGNOSTIC CONNECTOR (RS-232)8. WIRE FEEDER RECEPTACLE (5-PIN)9. NEGATIVE TWIST- MATE TERMINAL10. POSITIVE TWIST- MATE TERMINAL

NOMINAL PROCEDURESThe Power Wave is designed to operate with 3/4"electrode stick-out for CV and Pulse processes.

FRINGE PROCEDURESExcessively short or long electrode stick-outs mayfunction only on a limited basis, if at all.

MAKING A WELD

The serviceability of a product or structure utiliz-ing the welding programs is and must be the soleresponsibility of the builder/user. Many variablesbeyond the control of The Lincoln ElectricCompany affect the results obtained in applyingthese programs. These variables include, but arenot limited to, welding procedure, plate chemistryand temperature, weldment design, fabricationmethods and service requirements. The availablerange of a welding program may not be suitablefor all applications, and the build/user is and mustbe solely responsible for welding program selec-tion.------------------------------------------------------------------------

FIGURE B.1

10

46

1

32

5

7

8

9

CASE FRONT LAYOUTPOWER WAVE 355

WARNING

CONSTANT VOLTAGE WELDINGSynergic CV:For each wire feed speed, a corresponding voltage ispreprogrammed into the machine through special soft-ware at the factory. The nominal preprogrammed volt-age is the average voltage for a given wire feedspeed, but may be adjusted to preference. When thewire feed speed changes, the Power Wave automati-cally adjusts the voltage level correspondingly tomaintain similar arc characteristics throughout theWFS range.

Non Synergic CV:This type of CV mode behaves more like a conven-tional CV power source. Voltage and WFS are inde-pendent adjustments. Therefore to maintain the arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS.

All CV Modes:Arc Control, often referred to as wave control, adjuststhe inductance of the waveshape. The wave controladjustment is similar to the "pinch" function in that it isinversely proportional to inductance. Therefore,increasing wave control greater than 0.0 results in aharsher, colder arc while decreasing the wave controlto less than 0.0 provides a softer, hotter arc.(See Figure B.2)

FIGURE B.2

Current

Time

CURRENT WAVE FORM (CV)

B-4OPERATIONB-4

In non-synergic modes, the WFS control behavesmore like a conventional CV power source whereWFS and voltage are independent adjustments.Therefore to maintain the arc characteristics, the oper-ator must adjust the voltage to compensate for anychanges made to the WFS.

In constant current modes (stick, TIG) this controladjusts the output current, in amps.

• VOLTS / TRIM:In constant voltage modes (synergic CV, standardCV) the control adjusts the welding voltage.

In pulse synergic welding modes (pulse GMAW only)the user can change the Trim setting to adjust the arclength. It is adjustable from 0.500 to 1.500. A Trim set-ting of 1.000 is a good starting point for most condi-tions.

• WELDING MODE

May be selected by name (CV/MIG, CC/Stick Crisp,Gouge, etc.) or by a mode number (10, 24, 71, etc.)depending on the Control Box options. Selecting awelding mode determines the output characteristics ofthe Power Wave power source. For a more completedescription of the welding modes available in thePower Wave, see the explanation below.

• ARC CONTROL

Also known as Inductance or Wave Control. Allowsoperator 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 PowerFeed wire feeder control panels). See the WeldingMode descriptions, below, for detailed explanations ofhow the Arc Control affects each mode.

POWER WAVE 355

PULSE-ON-PULSE™ (GMAW-PP)Pulse on Pulse™ is a Lincoln process specificallydesigned for use in welding relatively thin (less than1/4" thick) aluminum (See Table B.3). It gives weldbeads with very consistent uniform ripple.

In Pulse on Pulse modes, two distinct pulse types areused, instead of the single pulse type normally used inGMAW-P. A number of high energy pulses are usedto obtain spray transfer and transfer metal across thearc. Such pulses are shown in Figure B.4. After anumber "N" of such pulses, depending on the wirefeed speed used, an identical number "N" of low ener-gy pulses are performed. These low energy pulses,shown in Figure B.6, do not transfer any filler metalacross the arc and help to cool the arc and keep theheat input low.

The Peak Current, Background Current, andFrequency are identical for the high energy and lowenergy pulses. In addition to cooling the weld down,the major effect of the low energy pulses is that theyform a weld ripple. Since they occur at very regulartime intervals, the weld bead obtained is very uniformwith a very consistent ripple pattern. In fact, the beadhas its best appearance if no oscillation of the weldinggun ("whipping") is used.(See Figure B.5)

When Arc Control is used in the Pulse on Pulsemodes, it does the same things it does in the otherpulsed modes: decreasing the Arc Control decreasesthe droplet transfer and weld deposit ion rate.Increasing the Arc Control increases the droplet trans-fer and weld deposition rate. Since Arc Control variesweld droplet transfer rate, the Arc Control can be usedto vary the ripple spacing in the weld bead.

PEAK AMPS

BACKGROUND AMPS

TIME

HIGH HEATPULSES

LOW HEATPULSES

"N" PULSES "N" PULSES

FIGURE B.4

FIGURE B.5

B-5OPERATIONB-5

POWER WAVE 355

PULSE WELDING

Pulse welding procedures are set by controlling anoverall "arc length" variable. When pulse welding, thearc voltage is highly dependent upon the waveform.The peak current, back ground current, rise time, falltime and pulse frequency all affect the voltage. Theexact voltage for a given wire feed speed can only bepredicted when all the pulsing waveform parametersare known. Using a preset voltage becomes impracti-cal, and instead the arc length is set by adjusting"trim".

Trim adjusts the arc length and ranges from 0.50 to1.50, with a nominal value of 1.00. Trim values greaterthan 1.00 increase the arc length, while values lessthan 1.00 decrease the arc length.

All pulse welding programs are synergic. As the wirefeed speed is adjusted, the Power Wave will automati-cally recalculate the waveform parameters to maintainsimilar arc properties.

The Power Wave utilizes "adaptive control" to com-pensate for changes in electrical stick-out while weld-ing. (Electrical stick-out is the distance from the con-tact tip to the work piece.) The Power Wave wave-forms are optimized for a 0.75" (19mm) stick-out. Theadaptive behavior supports a range of stickouts from0.50" (13mm) to 1.25" (32mm). At very low or highwire feed speeds, the adaptive range may be less dueto reaching physical limitations of the welding process.

Arc Control, often referred to as wave control, in pulseprograms usually adjusts the focus or shape of thearc. Wave control values greater than 0.0 increase thepulse frequency while decreasing the background cur-rent, resulting in a tight, stiff arc best for high speedsheet metal welding. Wave control values less than0.0 decrease the pulse frequency while increasing thebackground current, for a soft arc good for out-of-posi-tion welding.(See Figure B.3)

FIGURE B.3

Current

Time

CURRENT WAVE FORM (PULSE)

B-6OPERATIONB-6

POWER WAVE 355

BENEFITS OF PULSE ON PULSE FROMLINCOLN ELECTRIC

• Excellent appearance of the weld bead• Improved cleaning action• Reduced porosityTable B.2 shows WFS and Trim settings for commonaluminum types and wire sizes when welding withPulse-on-Pulse. The welds made to obtain the valuesin the table were fillet welds in the flat position. Thevalues in the table can be helpful as a starting point toestablish a welding procedure. From there, adjust-ments need to be made to set the proper procedurefor each specific application (out-of-position, othertypes of joints, etc.).The comments on Table B.3 show values of WFSbelow which it is not recommended to weld. The rea-son is, that below these values the weld transfer willchange from a spray arc to a short-arc, which is notadvisable when welding aluminum.

TIG GTAWThe TIG mode features continuous control from 5 to425 amps. The TIG mode can be run in either theTouch Start TIG or Scratch start mode.

The Arc Control level selects the starting mode.

Between –10 and 0, the Touch Start TIG mode isselected. The OCV is controlled below 10V and theshort circuit "TIG touch" current is maintained atapproximately 25 amps, independent of the presetcurrent. When the tungsten is lifted, an arc is initiatedand the output is regulated at the preset value. A set-ting of 0, results in the most positive arc initiation. Asetting of -10 reduces hot start. Procedure to start theweld, and from there, to ramp to the welding procedure overa specified amount of time. Typically starting procedure on ahigher “+” setting is known as a “Hot Start”. Setting a start-ing procedure on a lower setting is known as a “Cold Start”.

Between 0 and 10, the Scratch starting TIG mode isselected. In this range, the OCV of the machine iscontrolled between 50 and 70 volts

Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356

100% Ar. 100% Ar. 100% Ar. 100% Ar.

E4043 E4043 E5356 E5356

0.035 3/64 0.035 3/64

98 99 101 102

14 ga. 250 / 1.0 200 / 1.0 230 / 1.0 225 / 1.0

10 ga. 400 /1.0 280 / 1.0 425 / 1.0 400 / 1.0

3/16 550 / 1.0 340 / 1.0 670 / 1.0 500 / 1.0

1/4 600 / 1.0 400 / 1.0 700 / 1.0 550 / 0.9

WF

S /

TR

IM

MA

TE

RIA

L

TH

ICK

NE

SS

MATERIAL

GAS

WIRE

WIRE SIZE

WELD MODE

Not Recommended below 200 WFSCOMMENTS Not Recommended

below 200 WFSNot Recommended

below 100 WFSNot Recommended

below 200 WFS

WELDING PROCEDURES FOR PULSE-ON-PULSE (TABLE B.2)

SMAWIn SMAW (STICK mode), arc control adjusts the arcforce. It can be set to the lower range for a soft andless penetrating arc characteristic (negative numericvalues) or to the higher range (positive numeric val-ues) for a crisp and more penetrating arc. Normally,when welding with cellulosic types of electrodes(E6010, E7010, E6011), a higher energy arc isrequired to maintain arc stability. This is usually indi-cated when the electrode sticks to the work-piece orwhen the arc pops-out during manipulative technique.For low hydrogen types of electrodes (E7018, E8018,E9018, etc.) a softer arc is usually desirable and thelower end of the Arc Control suits these types of elec-trodes. In either case the arc control is available toincrease or decrease the energy level delivered to thearc.

ARC GOUGINGGouging is basically removing metal to form a bevel orgroove in a piece of steel with controlled forced airand a carbon rod.

The common procedures for Arc Gouging metal are:

• Removing poor welds from a weldment so that newwelds can be made.

• Creating a welding groove or grooves in two piecesof steel butted together. (See Example below)

Mode 9 in the PW355 is specifically for gouging.Gouging can also be done in the stick soft and crispmodes. Setting the output of the Stick Soft mode to425 amps will enable the arc-gouging mode. Theactual output current will depend on the size of carbonused. The recommended maximum size carbon is5/16".

STEEL BUTTED TOGTHER

WELD GROOVES CREATED BY ARC GOUGING

B-7OPERATIONB-7

POWER WAVE 355

POWER MODE™The Power Mode™ process was developed byLincoln to maintain a stable and smooth arc at lowprocedure settings which are needed to weld thinmetal without pop-outs or burning-through. ForAluminum welding, it provides excellent control andthe ability to maintain constant arc length. This resultsin improved welding performance in two primary typesof applications.

• Short Arc MIG at low procedure settings.

• Aluminum MIG welding.

Power Mode™ is a method of high speed regulationof the output power whenever an arc is established. Itprovides a fast response to changes in the arc. Thehigher the Power Mode Setting, the longer the arc. If awelding procedure is not established, the best way todetermine the Power Mode Setting is by experimenta-tion until the desired output result is established.

In the Power Mode two variables need to be set:

• Wire Feed Speed

• Power Mode Trim

Setting up a Power Mode procedure is similar to set-ting a CV MIG procedure. Select a shielding gasappropriate for a short arc process.

• For steel, use 75/25 Ar/CO2 shield gas.

• For Stainless, select a Helium blend Tri-Mix.

• For Aluminum, use 100% Ar.

Start by setting the wire feed speed based upon mate-rial thickness and appropriate travel speed. Thenadjust the Volts/Trim knob as follows:

• For steel, listen for the traditional “frying egg”sound of a good short-arc MIG procedure to knowyou have the process set correctly.

• For aluminum, simply adjust the Volts/Trim knobuntil the desired arc length is obtained.

Note the Volts/Trim display is simply a relative numberand DOES NOT correspond to voltage.

Some procedure recommendations appear in TableB.3.

Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel

E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L

0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035

100% Ar. 100% Ar. 100% CO2 75/25 Ar/CO2 100% CO2 75/25 Ar/CO2 100% CO2 75/25 Ar/CO2 Tri-mix Tri-mix

22 ga. Not Recommended 100 / 0.8 Not Recommended 90 / 1.0

20 ga. 120 / 1.0 120 / 1.0 100 / 0.7 100 /1.0 80 / 1.5 50 / 0.5

18 ga. 140 / 1.7 140 / 1.5 110 / 1.5 110 / 1.5 100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0

16 ga. 190 / 2.0 190 / 2.0 125 / 2.0 125 / 2.0 125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7

14 ga. 400 / 2.0 400 / 2.5 260 / 3.0 260 / 3.0 160 / 2.3 160 / 2.3 160 / 3.8 160 / 3.5 210 / 3.0 190 / 3.5

12 ga. 330 / 5.0 330 / 4.5 230 / 3.5 230 / 3.5 200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0

10 ga. 500 / 7.0 500 / 7.0 300 / 6.0 300 / 6.0 240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0

3/16 570 / 9.0 600 / 7.8 400 / 7.5 400 / 7.0

1/4 700 / 9.1 700 / 8.5

MA

TE

RIA

L T

HIC

KN

ES

S

WF

S /

PO

WE

R M

OD

E S

ET

TIN

G

COMMENTS

Not Recommended

below 400 WFS

MATERIAL

WIRE

WIRE SIZE

GAS

Not Recommended

below 400 WFS

Recommended Welding Procedures for Power Mode - Table B.3

C-1ACCESSORIESC-1OPTIONAL EQUIPMENT

FACTORY INSTALLED

None Available.

FIELD INSTALLED K940-Work Voltage Sense Lead KitK1764-1-Undercarriage*K1838-1-Valet Style UndercarriageK1796-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 CABLEK852-95 2/0-3/0 CABLE

COMPATIBLE LINCOLN EQUIPMENT

Any Linc-Net compatible wire feeding equipment.Specifically, the semi-automatic Power Feed family (PF-10, PF-10 Dual, PF-11).

POWER WAVE 355

D-1MAINTENANCED-1

POWER WAVE 355

SAFETY PRECAUTIONS

CAPACITOR DISCHARGE PROCEDURE1. Obtain a power resistor (25 ohms, 25 watts).

2. Hold resistor body with electrically insulated glove.DO NOT TOUCH TERMINALS. Connect the resis-tor terminals across the two studs in the positionshown. Hold in each position for 1 second. Repeatfor all four capacitors.

3. Use a DC voltmeter to check that voltage is notpresent across the terminals on all four capacitors.

ROUTINE MAINTENANCERoutine maintenance consists of periodically blowingout the machine, using a low pressure airstream, toremove accumulated dust and dirt from the intake andoutlet louvers, and the cooling channels in themachine.

CAPACITORTERMINALS

RESISTOR

PERIODIC MAINTENANCECalibration of the POWER WAVE 355 is critical to itsoperation. Generally speaking the calibration will notneed adjustment. However, neglected or improperlycalibrated machines may not yield satisfactory weldperformance. To ensure optimal performance, the cal-ibration of output Voltage and Current should bechecked yearly.

CALIBRATION SPECIFICATIONOutput Voltage and Current are calibrated at the fac-tory. Generally speaking the machine calibration willnot need adjustment. However, if the weld perfor-mance changes, or the yearly calibration checkreveals a problem, contact the Lincoln ElectricCompany for the calibration software utility.

The calibration procedure itself requires the use of agrid, and certified actual meters for voltage and cur-rent. The accuracy of the calibration will be directlyaffected by the accuracy of the measuring equipmentyou use. Detailed instructions are available with theutility.

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and

ground• Always wear dry insulating gloves.

------------------------------------------------------------------------EXPLODING PARTS can causeinjury.• Failed parts can explode or cause other

parts to explode when power is applied.

• Always wear a face shield and longsleeves when servicing.

------------------------------------------------------------------------See additional warning informationthroughout this Operator’s Manual -----------------------------------------------------------

WARNING

E-1TROUBLESHOOTINGE-1

POWER WAVE 355

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


POWER WAVE 355

USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMS

The Power Wave / Power Feed are best diagnosed asa system. Each component (power source, user inter-face, and feedhead) has a status light, and when aproblem occurs it is important to note the condition ofeach. In addition, errors displayed on the user inter-face in most cases indicate only that a problem existsin the power source, not what the problem may be.Therefore, prior to cycling power to the system,check the power source status light for errorsequences as noted below. This is especiallyimportant if the user interface displays "Err 006"or "Err 100" .

Included in this section is information about the powersource Status LED, and some basic troubleshooting

charts for both machine and weld performance.The STATUS LIGHT is a two color light that indicatessystem errors. Normal operation is a steady greenlight. Error conditions are indicated in the followingchart.

NOTE: The POWER WAVE 355 status light will flashgreen, and sometimes red and green, for up to oneminute when the machine is first turned on. This is anormal situation as the machine goes through a selftest at power up.

LIGHT CONDITIONStatus LED is solid green (no blinking).

Status LED is blinking green.

Status LED is blinking red and green.

Status LED is solid red (no blinking).

Status LED is blinking red.

MEANING1. System OK. Power source communicating normally

with wire feeder and its components.

2. Occurs during a reset, and indicates the POWERWAVE 355 is mapping (identifying) each componentin the system. Normal for first 1-10 seconds afterpower is turned on, or if the system configuration ischanged during operation.

3. Non-recoverable system fault. If the PS Status lightis flashing any combination of red and green, errorsare present in the POWER WAVE 355. Read theerror code before the machine is turned off.

Error Code interpretation through the Status light isdetailed in the Service Manual. Individual code digitsare flashed in red with a long pause between digits. Ifmore than one code is present, the codes will beseparated by a green light.

To clear the error, turn power source off, and backon to reset.

Non recoverable hardware fault. Generally indicatesnothing is connected to the POWER WAVE 355 wirefeeder receptacle. See Trouble Shooting Section.

Not applicable.


POWER WAVE 355

Observe all Safety Guidelines detailed throughout this manual


CAUTION

ERROR CODES FOR THE POWERWAVEThe following is a list of possible error codes that the POWER WAVE 355 can output via the status light (see"Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.

Error Code #11 CAN communication bus off.12 User Interface time out error.

21 Unprogrammed Weld Mode.

22 Empty Weld Table.

23 Weld Table checksum error.

31 Primary overcurrent error.

32 Capacitor "A" under voltage

33 Capacitor "B" under voltage

34 Capacitor "A" over voltage

35 Capacitor "B" over voltage

36 Thermal error

37 Softstart error

41 Secondary overcurrent error

43 Capacitor delta error

Other

IndicationProbably due to excessive number of communication errors.UI is no longer responding to the Power Source. The most likelycause is a fault/bad connection in the communication leads or con-trol cable.

Contact the Service Department for instructions on reloading theWelding Software.Contact the Service Department for instructions on reloading theWelding Software.Contact the Service Department for instructions on reloading theWelding Software.Excessive Primary current present. May be related to a short in themain transformer or output rectifier.Low voltage on the main capacitors. May be caused by improperinput configuration. When accompanied by an overvoltage error on the same side, itindicates no capacitor voltage present on that side, and is usuallythe result of an open or short in the primary side of the machine.Excess voltage on the main capacitors. May be caused by improp-er input configuration.

When accompanied by an under voltage error on the same side, itindicates no capacitor voltage present on that side, and is usuallythe result of an open or short in the primary side of the machine.

Indicates over temperature. Usually accompanied by Thermal LED.Check fan operation. Be sure process does not exceed duty cyclelimit of the machine.

Capacitor precharge failed. Usually accompanied by codes 32-35.The secondary (weld) current limit has been exceeded. When thisoccurs the machine output will phase back to 100 amps, typicallyresulting in a condition referred to as "noodle welding"

NOTE: The secondary limit is 570 amps for the standard stud, and325 amps for all single phase operation.

The maximum voltage difference between the main capacitors hasbeen exceeded. May be accompanied by errors 32-35.

Error codes that contain three or four digits are defined as fatalerrors. These codes generally indicate internal errors on theControl Board. If cycling the input power on the machine does notclear the error, try reloading the operating system. If this fails,replace the control board.


POWER WAVE 355

Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

CAUTIONIf 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.

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

OUTPUT PROBLEMSMajor physical or electrical damageis evident when the sheet metalcovers are removed.

Input fuses keep blowing, or inputbreaker keeps tripping.

Machine will not power up (nolights, no fan, etc.)

1. Contact your local authorizedLincoln Electric Field Servicefacility for technical assis-tance.

1. Make certain that fuses orbreakers are properly sized.See Installation section of thismanual for recommendedfuse and breaker sizes.

2. Welding procedure is drawingtoo much output current, orduty cycle is too high.Reduce output current, dutycycle, or both.

3. There is internal damage tothe power source. Contact anauthorized Lincoln ElectricService facility.

1. Make certain that the PowerSwitch (SW1) is in the “ON”position.

2. Circuit Breaker CB1 (on CaseFront) may have opened.Reset an over load on the 40VWire Feeder supply maycause this to trip.

3. Circuit breaker CB3 (in recon-nect area) may have opened.Reset. Also, check input volt-age selection, below.

4. Input voltage selection madeimproperly. Power down,check input voltage reconnectaccording to diagram onreconnect cover.

If all recommended possible areasof misadjustments have beenchecked and the problem persists,contact your local LincolnAuthorized Field Service Facility.


POWER WAVE 355




PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMSThermal LED is lit.

Machine won’t weld, can’t get anyoutput.

1. Fan thermostat has opened.Check for proper fan operation.(Fan should run whenever out-put power is on.) Check formaterial blocking intake orexhaust louvers, or for excessivedirt clogging cooling channels inmachine. Blow air in rear louversto remove dirt around the fan.

2. Secondary rectifier or Chokethermostat has opened. Aftermachine has cooled, reduceload, duty cycle, or both. Checkfor material blocking intake orexhaust louvers.

3. DC Bus PC board thermostathas opened check for excessiveload on 40VDC supply.

1. Input voltage is too low or toohigh. Make certain that inputvoltage is proper, according tothe Rating Plate located on therear of the machine.

2. If the Thermal LED is also lit,see “Yellow Thermal LED is Lit”section.

3. Primary current limit has beenexceeded. Possible short in out-put circuit. Turn machine off.Remove all loads from the out-put of the machine. Turn backon. If condition persists, turnpower off, and contact an autho-rized Lincoln Electric FieldService facility.

4. This problem will normally beaccompanied by an error code.Error codes are displayed as aseries of red and green flashes bythe status l ight. See"Troubleshooting the Power Wave/ Power Feed System Using theStatus LED" section of this text.



POWER WAVE 355




PROBLEMS(SYMPTOMS)



OUTPUT PROBLEMSMachine often “noodle welds” (out-put is limited to approximately 100amps) when running a particularprocedure, especially a procedurewith high WFS.

Machine won’t produce full output.

1.Secondary current limit has beenexceeded, and the machine hasphased back to protect itself.

2. Adjust procedure or reduce loadto lower current draw from themachine.

1. Input voltage may be too low,limiting output capability of thepower source. Make certain thatthe input voltage is proper,according to the Rating Platelocated on the rear of themachine.

2. Secondary current or voltage notbe properly calibrated. Checkvalues displayed on the PowerFeed 10/11 verses readings onan external meter.



POWER WAVE 355

Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)



General degradation of the weld per-formance

Excessively long and erratic arc.

1.Check for feeding problems, badconnections, excessive loops incabling, etc.

2. Verify weld mode is correct forprocesses.

3. The power source may requirecalibration.

4. Check the actual current dis-played on the Power Feed 10 vs.actual current measured via exter-nal meter.

5. Check the actual voltage dis-played on the Power Feed 10 vs.actual voltage measured via exter-nal meter.

6. Check the actual WFS displayedon the Power Feed 10 vs. actualWFS measured via externalmeter.

1. Check for proper configurationand implementation of voltagesensing circuits.

F-1DIAGRAMSF-1

POWER WAVE 355

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

F-2CONNECTION DIAGRAMF-2

POWER WAVE 355

Connection Diagram Semi-automatic "Simple System"(Electrode Positive, CV/Pulse Configuration shown)

POWER WAVE

WIREFEEDER

CONTROL CABLE K1543

TOWORK

F-3DIMENSION PRINTF-3

POWER WAVE 355

1 4.7

9

12.4

4

3.44

21.6

0

27.8

2

5.50

10.0

0

MO

UN

TIN

G H

OLE

LO

CAT

ION

S

M19

527

13.1

0

1/4-

20 N

UT

(4 P

LACE

S)

NO

TE:

MO

UN

TIN

G S

CR

EWS

CA

10/0

1

N N

OT

PRO

TRU

DE

MO

RE

THAN

0.

5 IN

CH

ES IN

SID

E TH

E M

ACH

INE.

11.8

4

3.50

NOTES

POWER WAVE 355

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

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