Lincoln Electric POWER WAVE IM845-A manual

PO WER W A VE 355M OPERA TOR’S MANUAL For use with machines Code 11141,11489 IM845-A October, 2007 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR R[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...........................................................[...]

A-1 INST ALLA TION POWER WAVE 355M A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE 355M INPUT AC VOL T AGE & DC OUTPUT Product Ordering Input AC Rated DC Output Output Weight Dimensions Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD (continuous) 200 350A / 34V / 60% 14.8” x 13.3” x POWER K2368-1 2 08 - 2 30/ 27.8”* WAVE[...]

A-2 INST ALLA TION POWER WAVE 355M A-2 SELECT SUIT ABLE LOCA TION The Invertec POWER WAVE 355M will operate in harsh environments. Even so, it is important that sim- ple preventative measures are followed in order to assure long life and reliable operation. • The machine must be located where there is free cir- culation of clean air such that air[...]

Output connections on some Power Waves are made via 1/2-13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front. Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode cable between the wire feeder and the positive (+) output Twist-Mate ter[...]

A-4 INST ALLA TION POWER WAVE 355M A-4 VOL T AGE SENSING The best arc performance occurs when the Power Waves have accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influence the apparent voltage at the studs of the welder. Voltage sense leads improve the accuracy of the arc[...]

POWER W A VE TO SEMI-AUTOMA TIC POWER FEED WIRE FEEDER INTERCON- NECTIONS The POWER WAVE 355M and semi-automatic Power Feed family communicate via a 5 conductor control cable (K1543). The control cable consists of two power leads, one twisted pair for digital communica- tion, and one lead for voltage sensing. The cables are designed to be connected[...]

A-6 INST ALLA TION A-6 POWER WAVE 355M CONFIGURING THE SYSTEM The power source will “Auto Map” the system eliminat- ing most of the need to set DIP switches to configure the system. If a system can not be “Auto Mapped” then the status light on the power source will blink green fast and the welder output will be disabled. If a system is not [...]

A-7 INST ALLA TION POWER WAVE 355M A-7 In this case the individual feed heads need to be assigned to the dual head control and the POWER WAVE 355M auto mapping disabled and the Equipment Groups set on (See Figure A-8). (See the Feeder documenta- tion for information on setting the feeder DIP switches) System that is NOT "Auto Mappable" PO[...]

A-8 INST ALLA TION POWER WAVE 355M A-8 Connect All Work Sense Leads at the End of the Joint Connect All Welding Work Leads at the Beginning of the Joint T ravel Direction PO WER WA VE 355M PO WER WA VE 355M TWO POWER W A VES FIGURE A.6 CONTROL CABLE SPECIFICA TIONS It is recommended that genuine Lincoln control cables be used at all times. Lincoln [...]

A-9 INST ALLA TION POWER WAVE 355M A-9 MUL TIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES[...]

A-10 INST ALLA TION POWER WAVE 355M A-10 I / O RECEPT ACLE SPECIFICA TIONS TABLE A.2 WIRE FEEDER RECEPTACLE PIN LEAD# FUNCTION A 53 Communication Bus L B 54 Communication Bus H C 67A Electrode Voltage Sense D 52 0vdc - E 51 +40vdc + TABLE A.3 VOLTAGE SENSE RECEPTACLE PIN LEAD# FUNCTION 3 21A Work Voltage Sense TABLE A.4 RS232 RECEPTACLE PIN LEAD# F[...]

GENERAL DESCRIPTION The Power Wave 355M semi-automatic power source is designed to be a part of a modular, multi-process welding system. Depending on configuration, it can support constant current, constant voltage, constant power and pulse welding modes. The Power Wave 355M power source is designed to be used with the semi automatic family of Powe[...]

5. Internal POWER CIRCUIT BREAKER: Protects 115 volt AC circuit. 6. LEAD CONNECTOR (SENSE LEAD) 7. DIAGNOSTIC CONNECTOR (RS-232) 8. WIRE FEEDER RECEPTACLE (5-PIN) 9. NEGATIVE TWIST- MATE TERMINAL 10. POSITIVE TWIST- MATE TERMINAL FIGURE B.1 10 4 6 1 3 2 5 7 8 9 CASE FRONT LA YOUT POWER W A VE 355M POWER WAVE 355M – Semi-Automatic Operation Power [...]

WELDING ADJUSTMENTS All adjustments are made on the system component known 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 Power Feed wire feeder. Typically, the Control Box is sup- plied as part of the wire feeder. It can be mounted directly on the wir[...]

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 arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. All CV Modes: Arc Control, often referred to as wave control, adjusts the inductan[...]

PULSE-ON-PULSE™ (GMA W -PP) Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin, less than 1/4"(6.4mm) thick aluminum (See Table B.3). It gives weld beads with very consistent uniform ripple. In Pulse on Pulse modes, two distinct pulse types are used, instead of the single pulse type normally used [...]

B-6 OPERA TION B-6 POWER WAVE 355M BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse-on-Pulse. The welds made to obtain the values in the table were fillet [...]

B-7 OPERA TION B-7 POWER WAVE 355M POWER MODE™ The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For alu- minum welding, it provides excellent control and the ability to maintain constant arc length. This results[...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACT OR Y INST ALLED None Available. FIELD INST ALLED K940-Work Voltage Sense Lead Kit K1764-1-Undercarriage* K1838-1-Valet Style Undercarriage K1796-Coaxial Welding Cable- (Requires Adapter K2176-1) K2176-1 Twist-mate to Lug Adapters * Dual Cylinder Kit for K1764-1 is K1702-1 Welding Cable Connectors: K852-7[...]

D-1 MAINTENANCE D-1 POWER WAVE 355M SAFETY PRECAUTIONS CAP ACITOR DISCHARGE PROCEDURE 1. 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 position shown. Hold in each position for 1 second. Repeat for all four ca[...]

E-1 TROUBLESHOOTING E-1 POWER WAVE 355M If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair [...]

E-2 TROUBLESHOOTING E-2 POWER WAVE 355M USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave / Power Feed are best diagnosed as a system. Each component (power source, user inter- face, and feedhead) has a status light, and when a problem occurs it is important to note the condition of each. In addition, errors displayed on the use[...]

E-3 TROUBLESHOOTING E-3 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ERROR C[...]

E-4 TROUBLESHOOTING E-4 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electri[...]

E-5 TROUBLESHOOTING E-5 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electri[...]

E-6 TROUBLESHOOTING E-6 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electri[...]

E-7 TROUBLESHOOTING E-7 POWER WAVE 355M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEM[...]

F-1 WIRING DIAGRAMS F-1 POWER WAVE 355M 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 c[...]

F-2 DIAGRAMS F-2 POWER WAVE 355M 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 num[...]

F-3 CONNECTION DIAGRAM F-3 POWER WAVE 355M Connection Diagram Semi-automatic "Simple System" (Electrode Positive, CV/Pulse Configuration shown) POWER WAVE WIRE FEEDER CONTROL CABLE K1543 TO WORK[...]

F-4 DIMENSION PRINT F-4 POWER WAVE 355M 1 4.7 9 1 2.4 4 3.44 21.60 27.82 5.50 10.0 0 MOUNTING HOLE LOCATIONS M19527 13.1 0 1/4- 20 NUT (4 PLAC ES) NOTE: MOUNTING SCREWS CA 10/01 N NOT PROTR UDE MORE THAN 0.5 IN CHES INSIDE THE MACHINE. 11.8 4 3.50[...]

NOTES POWER WAVE 355M[...]

NOTES POWER WAVE 355M[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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