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IM799-A
POWER WAVE F355i (CE) January, 2005
For use with machines Code 10997, 11252
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
i
overall safety can be increased by
55
3
EF
proper installation ... and thought-
AV
ful operation on your part. DO
RW
NOT INSTALL, OPERATE OR E
W
PO
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
a. Les circuits à l’électrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
zones où l’on pique le laitier.
v v
SAFETY
ELECTROMAGNETIC COMPATIBILITY (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It
is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are
received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of
electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines,
telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required
when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer s instructions.
If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve constructing an
electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase the risk of injury, e.g., by allowing parallel welding
current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the
surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
3-1-96H
L10093
vi vi
SAFETY
ELECTROMAGNETIC COMPATIBILITY (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other activities
that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer s recommendations.
If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.
Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic
conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be
connected to the welding power source so that good electrical contact is maintained between the conduit and the
welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer s recommendations. All
access and service doors and covers should be closed and properly fastened when the welding equipment is in
operation. The welding equipment should not be modified in any way except for those changes and adjustments
covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should
be adjusted and maintained according to the manufacturer s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close
to the floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,
metallic components bonded to the work piece will increase the risk that the operator could receive a shock by
touching these metallic components and the electrode at the same time. The operator should be insulated from all
such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and
position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk
of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to
earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of
1
interference. Screening of the entire welding installation may be considered for special applications.
1
Portions of the preceding text are contained in EN50199: "Electromagnetic Compatibility (EMC) product standard for
arc welding equipment."
3-1-96H
L10093
vii vii
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found 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 you
have 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 packet
accompanying 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.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
viii viii
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 355 ....................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Stacking ..........................................................................................................A-2
Tilting...............................................................................................................A-2
Input and Grounding Connections ..................................................................A-2
Power Cord Connection ..................................................................................A-2
Undercarriage Mountings................................................................................A-2
Output Cables, Connections and Limitations.........................................................A-3
Negative Electrode Polarity ...................................................................................A-3
Voltage Sensing ............................................................................................A-3, A-4
Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-4
Control Cable Specifications..................................................................................A-4
System Description................................................................................................A-5
System Set-Up.........................................................................................A-6 thru A-8
Welding with Multiple Power Waves......................................................................A-9
I / O Receptacle Specifications............................................................................A-10
Dip Switch Settings and Locations...............................................................A-10
Control Board Dip Switch ..............................................................................A-10
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
General Description ...............................................................................................B-1
Recommended Processes and Equipment ...........................................................B-1
Recommended Processes ..............................................................................B-1
Required Equipment .......................................................................................B-2
Limitations .......................................................................................................B-2
Duty Cycle and Time Period ...........................................................................B-2
Case Front Controls ................................................................................B-2, B-3
Nominal Procedures........................................................................................B-3
Fringe Procedures...........................................................................................B-3
Making a Weld ................................................................................................B-3
Welding Adjustment ........................................................................................B-3
Constant Voltage Welding...............................................................................B-4
Pulse Welding, Pulse on Pulse (GMAW) ........................................................B-4
Power Mode ....................................................................................................B-5
________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Equipment ...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Compatible Lincoln Equipment
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Capacitor Discharge Procedure ............................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance ............................................................................................D-1
Calibration Specification ........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to use Troubleshooting Guide .......................................................................E-1
Using the Status LED to Troubleshoot System Problems .....................................E-2
Troubleshooting Guide.............................................................................E-3 thru E-7
________________________________________________________________________
Wiring Diagram ....................................................................................Section F-1, F-2
Connection Diagram ....................................................................................Section F-3
Dimension Print............................................................................................Section F-4
________________________________________________________________________
Parts Lists ................................................................................................................P432
________________________________________________________________________
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE F355i
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering Input AC Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Cord HxWxD
(continuous)
POWER K2260-1 380-415 350A / 34V / 60% 14.6� x 17.2� x 27.6�*
WAVE K2260-2 AMPS 110.0 lbs. (371 x 437 x 701*)mm
(50.0. kg.)
F355i 60/50 Hz 5-425
3 Phase 300A / 32V /100% * Includes Mounting
Brackets
* Overall Length without Mounting Brackets, 21.06� (535mm)
POWER WAVE F355i INPUT CURRENT
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Voltage Phases 300Amps @ 350Amps @ Fuse size
Line Cord
32Volts(100%) 34Volts(60%)
380 3 23 28 40A
10mm2
400 3 22 27 40A
10mm2
415 3 22 26 40A
10mm2
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Select The output cable size based upon the following chart.*
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
CURRENT
DUTY CYCLE LENGTH UP 200FT.(61m) 200-250 FT. (61-76m)
300
100% 2/0 2/0
350
60% 2/0 2/0
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.
POWER WAVE F355i (CE)
A-2 A-2
INSTALLATION
SAFETY PRECAUTIONS
WARNING CAUTION
ELECTRIC SHOCK can kill.
� Incorrect connection may result in equipment
� Turn the input power off at the dis-
damage.
connect switch before attempting
-----------------------------------------------------------------------
to connect or disconnect input
power lines, output cables or con-
trol cables
POWER CORD CONNECTION
� Only qualified personnel should perform this
A 7ft. (2m) power cord is provided and wired into the
installation.
machine. Follow the power cord connection instruc-
� Connect the green lead of the power cord to
tions.
ground per National Electrical Code.
----------------------------------------------------------------------
SELECT SUITABLE LOCATION i
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The Invertec POWER WAVE F355i will operate in PO
harsh environments. Even so, it is important that sim-
ple preventative measures are followed in order to BLACK
assure long life and reliable operation. GREEN/YELLOW
BLUE
BROWN
� The machine must be located where there is free cir-
culation of clean air such that air movement in the
Three Phase Input
back, out the sides and bottom will not be restricted.
Connect green lead to ground per National Electric
� Dirt and dust that can be drawn into the machine
Code.
should be kept to a minimum. Failure to observe
Connect black, red and white leads to power.
these precautions can result in excessive operating
temperatures and nuisance shutdown.
� Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
� DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
CAUTION
Where there is a combustible surface directly
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .06�(1.6mm) thick, which shall extend not
less than 5.90�(150mm) beyond the equipment on
all sides.
-----------------------------------------------------------------------
STACKING
POWER WAVE F355i can not be stacked.
TILTING
Place the machine directly on a secure, level surface
or on a recommended undercarriage. The machine
may topple over if this procedure is not followed.
INPUT AND GROUNDING CONNECTIONS
� Only a qualified electrician should connect the
Invertec POWER WAVE F355i. Installation should
be made in accordance with the appropriate
National Electrical Code.
POWER WAVE F355i (CE)
A-3 A-3
INSTALLATION
When operating with electrode polarity negative the
OUTPUT CABLES, CONNECTIONS AND
"Electrode Sense Polarity" DIP switch must be set to the
LIMITATIONS
"Negative" position on the Wire Drive Feed Head PC Board.
Connect a work lead of sufficient size and length
The default setting of the switch is positive electrode polari-
between the proper output terminal on the power
ty. Set the Negative Polarity switch on Wire Feed Head PC
source and the work. Be sure the connection to the
board as follows:
work makes tight metal-to-metal electrical contact. To
avoid interference problems with other equipment and
WARNING
to achieve the best possible operation, route all cables
directly to the work or wire feeder. Avoid excessive
ELECTRIC SHOCK can kill
lengths and do not coil excess cable.
� Turn the input power OFF at the dis-
connect switch or fuse box before
CAUTION working on this equipment.
� Do not touch electrically hot parts.
When using an inverter type power source like the
-----------------------------------------------------------
Power Waves, use the largest welding (electrode
1. Turn off power to the power source at the disconnect
and work) cables that are practical. At least 2/0
switch.
copper wire - even if the average output current
2. Remove the front cover from the power source.
would not normally require it. When pulsing, the
3. The feed head PC board is on the left side of the power
pulse current can reach very high levels. Voltage
source. Locate the 8-position DIP switch and look for
drops can become excessive, leading to poor
switch 7 of the DIP switch.(See Figure A.1)
welding characteristics, if undersized welding
4. Using a pencil or other small object, slide the switch to
cables are used.
the OFF position for positive electrode polarity.
------------------------------------------------------------------------
Conversely, slide the switch to the ON position for nega-
Most welding applications run with the electrode being
tive electrode polarity.
positive (+). For those applications, connect the elec-
5. Replace the cover and screws. The PC board will“read�
trode cable between the wire feeder and the positive
the switch at power up, and configure the work voltage
(+) output Twist-Mate terminal on the power source.
sense lead appropriately.
Connect the other end of the electrode cable to the
wire feeder at it’s proper connection point. Be sure the
VOLTAGE SENSING
connection makes tight metal-to-metal electrical con-
tact. The electrode cable should be sized according to The best arc performance occurs when the PowerWaves
the specifications given in the output cable connec- have accurate data about the arc conditions. Depending
tions section. Connect a work lead from the negative upon the process, inductance within the electrode and work
(-) power source output Twist-Mate terminal to the lead cables can influence the voltage apparent at the studs
work piece. The work piece connection must be firm of the welder. Voltage sense leads improve the accuracy of
and secure, especially if pulse welding is planned. the arc conditions and can have a dramatic effect on perfor-
mance. Sense Lead Kits (K940-10, -25 or -50) are available
For additional Safety information regarding the elec- for this purpose.
trode and work cable set-up, See the standard "SAFE-
CAUTION
TY INFORMATION" located in the front of the
Instruction Manuals. If the voltage sensing is enabled but the sense
leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
CAUTION extremely high welding outputs may occur.
------------------------------------------------------------------------
Excessive voltage drops caused by poor work The ELECTRODE sense lead (67) is built into the control
piece connections often result in unsatisfactory cable, and is automatically enabled for all semi-automatic
welding performance. processes. The WORK sense lead (21) connects to the
------------------------------------------------------------------------ Power Wave at the four pin connector. By default the
NEGATIVE ELECTRODE POLARITY WORK voltage is monitored at the output stud in the
POWER WAVE F355i (CE). For more information on the
When negative electrode polarity is required, such as
WORK sense lead (21), see"Work Voltage Sensing� in the
in some Innershield applications, reverse the output
following paragraph.
connections at the power source (electrode cable to
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.
POWER WAVE F355i (CE)
A-4 A-4
INSTALLATION
Enable the voltage sense leads as follows: 5. Replace the wrap around and screws. The PC
TABLE A.1 board will “read� the switch at power up, and config-
Process Electrode Voltage Work Voltage ure the work voltage sense lead appropriately.
Sensing 67 lead * Sensing 21 lead
GMAW 67 lead required 21 lead optional
GMAW-P 67 lead required 21 lead optional ELECTRODE VOLTAGE SENSING
FCAW 67 lead required 21 lead optional Enabling or disabling electrode voltage sensing is
GTAW Voltage sense at studs Voltage sense at studs automatically configured through software. The 67
GMAW Voltage sense at studs Voltage sense at studs electrode sense lead is internal to the cable to the
SAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder
CAC-C Voltage sense at studs Voltage sense at studs is present.
* The electrode voltage 67 sense lead is integral to the
CAUTION
control cable to the wire feeder.
Important: The electrode polarity must be config-
Work Voltage Sensing ured on the feed head PC board. Failure to do so
The standard POWER WAVE F355i (CE)’s default is may result in extremely high welding outputs.
to the work stud (work sense lead disabled). ------------------------------------------------------------------------
POWER WAVE / POWER FEED WIRE
For processes requiring work voltage sensing, con-
FEEDER INTERCONNECTIONS
nect the (21) work voltage sense lead (K940) from the
(See Section F-2 for Connection Diagram)
Power Wave work sense lead receptacle to the work
Connect the control cable between the power source
piece. Attach the sense lead to the work piece as
and wire feeder. The wire feeder connection on the
close to the weld as practical, but not in the return cur-
POWER WAVE F355i (CE) is the 14-pin connector
rent path. Enable the work voltage sensing in the
located on the left side of the machine. The control
Power Wave as follows:
cable is keyed and polarized to prevent improper con-
WARNING nection.
ELECTRIC SHOCK can kill
CONTROL CABLE SPECIFICATIONS
� Turn the input power OFF at the
It is recommended that genuine Lincoln control cables
disconnect switch or fuse box
be used at all times. Lincoln cables are specifically
before working on this equipment.
designed for the communication and power needs of
the Power Wave / Power Feed system.
CAUTION
-----------------------------------------------------------
1. Turn off power to the power source at the dis- The use of non-standard cables, especially in
connect switch. lengths greater than 25 ft.(7.6m), can lead to com-
muni-cation problems (system shutdowns), poor
2. Remove the wrap around cover from the power motor acceleration (poor arc starting) and low
source. wire driving force (wire feeding problems).
------------------------------------------------------------------------
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and HIGH SPEED GEAR BOX
look for switch 8 of the DIP switch (See Figure A.1).
Changing the ratio requires a gear change and a PC
4. Using a pencil or other small object, slide the switch
board switch change. The Power Feed Wire Feeders
to the OFF position if the work sense lead is NOT
are shipped with both high speed and a low speed
connected. Conversely, slide the switch to the ON
gears. As shipped from the factory, the low speed
position if the work sense lead is present.
(high torque) gear is installed on the feeder. To
change Gear ratio see Power Feed 10/R Instruction
Manual.
POWER WAVE F355i (CE)
A-5 A-5
INSTALLATION
switch 8 work sense lead
WARNING off work sense lead not connected*
on work sense lead connected
ELECTRIC SHOCK can kill.
� Turn the input power OFF at the
Feed Head Board DIP Switch:
disconnect switch or fuse box
switch 1 = Object Instance LSB (see table 1)
before working on this equipment.
switch 2 = Object Instance MSB (see table 1)
switch 3 = Equipment Group 1 Select
switch 4 = Equipment Group 2 Select
----------------------------------------------------------------------
switch 5 = Equipment Group 3 Select
1. Set the High/Low switch code on Feed Head PC
switch 6 = Equipment Group 4 Select
board as follows:
switch 7 = negative polarity switch
2. Turn off power to the power source at the dis-
switch 7 electrode polarity
connect switch.
off positive *
on negative
3. Remove the front cover from the power source.
switch 8 = high speed gear
4. The wire feed head board is on the left side of the
power source. Locate the 8-position DIP switch and
switch 8 wire drive gear
look for position 8 of the DIP switch. (See Figure A.1)
off low speed gear *
on high speed gear
5. Using a pencil or other small object, slide the switch
to the OFF position, when the low speed gear is
TABLE 1
installed. Conversely, slide the switch to the ON
Object Instance
position when the high speed gear is installed.
switch 2 switch 1 Instance
off off 0*
6. Replace the cover and screws. The PC board will
off on 1
“read� the switch at power up, automatically adjust-
on off 2
ing all control parameters for the speed range
on on 3
selected.
*Factory Setting
DIP Switch Settings and Locations
(See Figure A.1)
FIGURE A.1
FEED HEAD BOARD DIP SWITCH
DIP switches on the P.C. Boards allow for custom
configuration of the Power Wave. To access the DIP 3 2 1
8 7 6 5 4
O
N
switches:
WARNING i
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� Turn off power at the disconnect switch. PO
O
N
1
2
3
4
5
6
7
8
------------------------------------------------------------------------ O
N
1
2
3
4
5
6
7
8
� Remove the top four screws securing the front
access panel.
� Adjust the DIP switches as necessary.
� Replace the panel and screws, and restore power.
Control Board DIP Switch:
switch 1 = Object Instance LSB 1 (see table 1) CONTROL BOARD DIP SWITCH
switch 2 = Object Instance MSB 2 (see table 1) O
N
switch 3 = Equipment Group 1 Select 1 2 3 4 5 6 7 8
switch 4 = Equipment Group 2 Select
switch 5 = Equipment Group 3 Select
switch 6 = Equipment Group 4 Select LOCATION OF DIP SWITCHES IN MACHINE
switch 7 = reserved for future use
switch 8 = work sense lead
1 LEAST SIGNIFICANT BIT
2 MOST SIGNIFICANT BIT
POWER WAVE F355i (CE)
A-6 A-6
INSTALLATION
I / O RECEPTACLE SPECIFICATIONS
WELDING WITH MULTIPLE POWER
WAVES
14-Pin Robotic Wire Feeder Connector
CAUTION Pin Lead Function
A 539 Motor +
B 541 Motor -
Special care must be taken when more than one
C 521 Solenoid +
Power Wave is welding simultaneously on a single
D 522 Solenoid common
part. Arc blow and arc interference may occur or
E 845 Tach 2A Differential Signal
be magnified.
F 847 Single Tach input
-----------------------------------------------------------------------
G 841 +15V Tach Supply
H 844 Tach common
Each power source requires a work lead from the
I Open Reserved for future use
work stud to the welding fixture. Do not combine all of
J GND Shielding drain
the work leads into one lead. The welding travel direc-
K 842 Tach 1A Differential Signal
tions should be in the direction moving away from the
L 843 Tach 1B Differential Signal
work lead as shown below. Connect all of the work
M 846 Tach 2B Differential Signal
sense leads from each power source to the work
N 67 Electrode Sense (67)
piece at the end of the weld. (See Figure A.2)
VOLTAGE SENSE RECEPTACLE
For the best results when pulse welding, set the wire
PIN LEAD# FUNCTION
size and wire feed speed the same for all the Power
3 21 Work Voltage Sense
Waves. When these parameters are identical, the
1 67 Electrode Voltage Sense
pulsing frequency will be the same, helping to stabilize
the arcs.
RS232 RECEPTACLE
PIN LEAD# FUNCTION
Every welding gun requires a separate shielding gas
2 253 RS232 Receive
regulator for proper flow rate and shielding gas cover-
3 254 RS232 Transmit
age.
4 # Pin5
5 # Pin4
Do not attempt to supply shielding gas for two or more
6 ## Pin20
guns from only one regulator.
20 ## Pin6
7 251 RS232 Common
If an anti-spatter system is in use then each gun must
have its own anti-spatter system.
WIRE FEEDER RECEPTACLE*
PIN LEAD# FUNCTION
A 153 Communiction Bus L
B 154 Communiction Bus H
C 67 Electrode Voltage Sense
D 52 Ovdc -
E 51 +40vdc +
FIGURE A.2 * Not on Codes 10997
or below.
POWER WAVE F355i
TWO POWER WAVES
POWER WAVE F355i
Travel
Direction
Connect All Work
Sense Leads at the
End of the Joint
Connect All Welding
Work Leads at the
Beginning of the Joint
POWER WAVE F355i (CE)
B-1 B-1
OPERATION
SAFETY PRECAUTIONS GENERAL DESCRIPTION
The Power Wave Robotic power source is designed to
Read this entire section of operating instructions
be a part of a modular, multi-process welding system.
before operating the machine.
Depending on configuration, it can support constant
WARNING current, constant voltage, constant power, pulse on
pulse and pulse welding modes.
ELECTRIC SHOCK can kill.
The Power Wave power source is designed to be
� Unless using cold feed feature, when used with the Robotic family of Power Feed wire feed-
feeding with gun trigger, the elec- ers, operating as a system. Each component in the
trode and drive mechanism are system has special circuitry to "talk with" the other
always electrically energized and system components, so each component (power
could remain energized several sec- source, wire feeder Robotic Controller knows what the
onds after the welding ceases. other is doing at all times. These components commu-
nicate with Arc Link.
� Do not touch electrically live parts or electrodes
with your skin or wet clothing.
The POWER WAVE F355i (CE) is a high perfor-
� Insulate yourself from the work and ground. mance, digitally controlled inverter welding power
source capable of complex, high-speed waveform
� Always wear dry insulating gloves.
control. Properly equipped, it can support the GMAW,
----------------------------------------------------------- GMAW-P and FCAW processes. It carries an output
rating of 350 Amps, 34 Volts at 60% duty cycle and
FUMES AND GASES can be dangerous.
300 Amps, 32 volts at 100% duty cycle.
� Keep your head out of fumes.
� Use ventilation or exhaust to remove
RECOMMENDED PROCESSES AND
fumes from breathing zone.
EQUIPMENT
-----------------------------------------------------------
WELDING SPARKS can cause fire or RECOMMENDED PROCESSES
explosion. The POWER WAVE F355i (CE) can be set up in a
number of configurations, some requiring optional
� Keep flammable material away.
equipment or welding programs. Each machine is fac-
� Do not weld on containers that have tory preprogrammed with multiple welding procedures,
held combustibles. typically including GMAW, GMAW-P and FCAW for a
variety of materials, including mild steel, stainless
steel, cored wires, and aluminum.
-----------------------------------------------------------
ARC RAYS can burn. � The POWER WAVE F355i (CE) is recommended for
Robotic welding with the Fanuc R-J3i.
� Wear eye, ear, and body protection.
� This POWER WAVE F355i (CE) is not recommend-
ed for processes other than those listed.
REQUIRED EQUIPMENT
Observe additional guidelines detailed in the
beginning of this manual. Any Arc Link compatible semi-automatic wire feeding
equipment. Specifically, the Power Feed 10 Robotic
Wire drive.
POWER WAVE F355i (CE)
B-2 B-2
OPERATION
2. HIGH TEMPERATURE LIGHT (thermal overload):
LIMITATIONS
A yellow light that comes on when an over temper-
� Only Arc Link compatible Power Feed automatic wire
ature situation occurs. Output is disabled and the
feeders and users interfaces may be used. Other
fan continues to run, until the machine cools down.
Lincoln wire feeders or non-Lincoln wire feeders can-
When cool, the light goes out and output is
not be used.
enabled.
� POWER WAVE F355i (CE) Output Limitations
The POWER WAVE F355i (CE) will support maxi-
3. CB1 WIRE FEEDER CIRCUIT BREAKER:
mum average output current of 350 Amps @ 60%
Protects 40 volt DC wire feeder power supply.
duty cycle.
DUTY CYCLE AND TIME PERIOD Figure B.1
The duty cycle is based upon a ten minute period. A
3
60% duty cycle represents 6 minutes of welding and 4
minutes of idling in a ten minute period.
2
5
CONNECTOR STATUS LIGHTS (Per Fig B.1)
1. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady green 6
1
light. Error conditions are indicated, per Table B.1.
NOTE: The POWER WAVE F355i (CE) status light
will flash green, and sometimes red and green, for up
4
to one minute when the machine is first turned on.
This is a normal situation as the machine goes
9
through a self test at power up.
TABLE B.1
Meaning
Light
7 8
Condition
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components.
CASE FRONT LAYOUT
POWER WAVE F355i (CE)
Occurs during a reset, and indicates the
Blinking
POWER WAVE F355i (CE) is mapping
Green 4. LEAD CONNECTOR (SENSE LEAD)
(identifying) each component in the system.
Normal for first 1-10 seconds after power is 5. DIAGNOSTIC CONNECTOR (RS-232)
turned on, or if the system configuration is
changed during operation 6. WIRE FEEDER RECEPTACLE (14-PIN)
A l t e r n a t i n g Non-recoverable system fault. If the PS 7. NEGATIVE TWIST- MATE TERMINAL
Green and Status light is flashing any combination of
red and green, errors are present in the
Red 8. POSITIVE TWIST- MATE TERMINAL
POWER WAVE F355i (CE). Read the error
code before the machine is turned off. 9. WIRE FEEDER RECEPTACLE (5 PIN) NOT ON
CODES 10997 OR BELOW.
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with
a long pause between digits. If more than
one 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 Troubleshooting
Section.
Non recoverable hardware fault. Generally
Steady Red
indicates nothing is connected to the
POWER WAVE F355i (CE) wire feeder
receptacle. See Trouble Shooting Section.
Not applicable.
Blinking Red
POWER WAVE F355i (CE)
B-3 B-3
OPERATION
In non-synergic modes, the WFS control behaves
NOMINAL PROCEDURES
more like a conventional CV power source where
The Power Wave is designed to operate with 3/4"
WFS and voltage are independent adjustments.
electrode stick-out for CV and Pulse processes.
Therefore to maintain the arc characteristics, the oper-
ator must adjust the voltage to compensate for any
FRINGE PROCEDURES
changes made to the WFS.
Excessively short or long electrode stick-outs may
function only on a limited basis, if at all.
� VOLTS / TRIM:
MAKING A WELD In constant voltage modes (pulse on pulse GMAW,
standard CV) the control adjusts the welding voltage.
WARNING
In pulse synergic welding modes (pulse GMAW only)
The serviceability of a product or structure utiliz- the user can change the Trim setting to adjust the arc
ing the welding programs is and must be the sole length. It is adjustable from 0.500 to 1.500. A Trim set-
responsibility of the builder/user. Many variables ting of 1.000 is a good starting point for most condi-
beyond the control of The Lincoln Electric tions.
Company affect the results obtained in applying
these programs. These variables include, but are � WELDING MODE
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication Selecting a welding mode determines the output char-
methods and service requirements. The available acteristics of the Power Wave power source. For a
range of a welding program may not be suitable more complete description of the welding modes
for all applications, and the build/user is and must available in the Power Wave and for a complete set of
be solely responsible for welding program selec- weld modes programmed into the Power Wave at the
tion. factory, refer to the weld mode print included with the
------------------------------------------------------------------------ Power Wave.
First, consider the desired welding process and the
part to be welded. Choose an electrode material, � ARC CONTROL
diameter, shielding gas and process (GMAW, GMAW-
P, etc.) Also known as Inductance or Wave Control. Allows
operator to vary the arc characteristics from "soft" to
Second, find the program in the welding software that "harsh" in all weld modes. It is adjustable from -10.0 to
best matches the desired welding process. The stan- +10.0, with a nominal setting of 00.0 (The nominal set-
dard software shipped with the Power Waves encom- ting of 00.0 may be displayed as OFF on some Power
passes a wide range of common processes and will Feed wire feeder control panels). See the Welding
meet most needs. If a special welding program is Mode descriptions, below, for detailed explanations of
desired, contact the local Lincoln Electric sales repre- how the Arc Control affects each mode.
sentative.
To make a weld, the Power Wave needs to know the
desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicat-
ed digitally via the control cable.
� WFS / AMPS:
In synergic welding modes (pulse on pulse GMAW,
pulse GMAW) WFS (wire feed speed) is the dominant
control parameter, controlling all other variables. The
user adjusts WFS according to factors such as weld
size, penetration requirements, heat input, etc. The
Power Wave then uses the WFS setting to adjust its
output characteristics (output voltage, output current)
according to pre-programmed settings contained in
the Power Wave.
POWER WAVE F355i (CE)
B-4 B-4
OPERATION
CONSTANT VOLTAGE WELDING The Power Wave utilizes "adaptive control" to compensate
for changes in electrical stick-out while welding. (Electrical
Non Synergic CV:
stick-out is the distance from the contact tip to the work
This type of CV mode behaves more like a conventional CV
piece.) The Power Wave waveforms are optimized for a
power source. Voltage and WFS are independent adjustments.
0.75" (19mm) stick-out. The adaptive behavior supports a
Therefore to maintain the arc characteristics, the operator must
range of stickouts from 0.50" (13mm) to 1.25" (32mm). At
adjust the voltage to compensate for any changes made to the
very low or high wire feed speeds, the adaptive range may
WFS.
be less due to reaching physical limitations of the welding
process.
All CV Modes:
Arc Control, often referred to as wave control, adjusts the induc-
Arc Control, often referred to as wave control, in pulse pro-
tance of the wave shape. The wave control adjustment is similar
grams usually adjusts the focus or shape of the arc. Wave
to the "pinch" function in that it is inversely proportional to induc-
control values greater than 0.0 increase the pulse frequency
tance. Therefore, increasing wave control greater than 0.0
while decreasing the background current, resulting in a tight,
results in a harsher, colder arc while decreasing the wave con-
stiff arc best for high speed sheet metal welding. Wave con-
trol to less than 0.0 provides a softer, hotter arc. (See Figure
trol values less than 0.0 decrease the pulse frequency while
B.2)
increasing the background current, for a soft arc good for
out-of-position welding.See Figure B.3)
FIGURE B.2
FIGURE B.3
CURRENT WAVE FORM (CV)
CURRENT WAVE FORM (PULSE)
Current
Current
Time
Time
PULSE-ON-PULSEâ„? (GMAW-PP)
Pulse on Pulseâ„? is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum. It gives weld beads with very
PULSE WELDING
consistent uniform ripple.
Pulse welding procedures are set by controlling an overall
In Pulse on Pulse modes, two distinct pulse types are
"arc length" variable. When pulse welding, the arc voltage is
used, instead of the single pulse type normally used in
highly dependent upon the waveform. The peak current,
GMAW-P. A number of high energy pulses are used
back ground current, rise time, fall time and pulse frequency
to obtain spray transfer and transfer metal across the
all affect the voltage. The exact voltage for a given wire feed
arc. Such pulses are shown in Figure B.4. After a
speed can only be predicted when all the pulsing waveform
number "N" of such pulses, depending on the wire
parameters are known. Using a preset voltage becomes
feed speed used, an identical number "N" of low ener-
impractical, and instead the arc length is set by adjusting
gy pulses are performed. These low energy pulses,
"trim".
shown in Figure B.4, do not transfer any filler metal
across the arc and help to cool the arc and keep the
Trim adjusts the arc length and ranges from 0.50 to 1.50,
heat input low.
with a nominal value of 1.00. Trim values greater than 1.00
increase the arc length, while values less than 1.00 FIGURE B.4
decrease the arc length.
Current "N" PULSES "N" PULSES
All pulse welding programs are synergic. As the wire feed HIGH HEAT LOW HEAT
speed is adjusted, the Power Wave will automatically recal- PULSES PULSES
PEAK
culate the waveform parameters to maintain similar arc AMPS
properties. BACKGROUND
AMPS
TIME
POWER WAVE F355i (CE)
B-5 B-5
OPERATION
Power Modeâ„? is a method of high speed regulation
The Peak Current, Background Current, and
of the output power whenever an arc is established. It
Frequency are identical for the high energy and low
provides a fast response to changes in the arc. The
energy pulses. In addition to cooling the weld down,
higher the Power Mode Setting, the longer the arc. If a
the major effect of the low energy pulses is that they
welding procedure is not established, the best way to
form a weld ripple. Since they occur at very regular
determine the Power Mode Setting is by experimenta-
time intervals, the weld bead obtained is very uniform
tion until the desired output result is established.
with a very consistent ripple pattern. In fact, the bead
has its best appearance if no oscillation of the welding
In the Power Mode two variables need to be set:
gun ("whipping") is used.(See Figure B.5)
FIGURE B.5 � Wire Feed Speed
� Power Mode Trim
Setting up a Power Mode procedure is similar to set-
ting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
When Arc Control is used in the Pulse on Pulse
modes, it does the same things it does in the other
� For steel, use 75/25 Ar/CO2 shield gas.
pulsed modes: decreasing the Arc Control decreases
the droplet transfer and weld deposition rate. � For stainless, select a Helium blend Tri-Mix.
Increasing the Arc Control increases the droplet trans- � For aluminum, use 100% Ar.
fer and weld deposition rate. Since Arc Control varies
weld droplet transfer rate, the Arc Control can be used Start by setting the wire feed speed based upon mate-
to vary the ripple spacing in the weld bead. rial thickness and appropriate travel speed. Then
adjust the Volts/Trim knob as follows:
POWER MODEâ„?
� For steel, listen for the traditional “frying egg�
The Power Modeâ„? process was developed by
sound of a good short-arc MIG procedure to know
Lincoln to maintain a stable and smooth arc at low
you have the process set correctly.
procedure settings which are needed to weld thin
� For aluminum, simply adjust the Volts/Trim knob
metal without pop-outs or burning-through. For alu-
until the desired arc length is obtained.
minum welding, it provides excellent control and the
ability to maintain constant arc length. This results in
Note the Volts/Trim display is simply a relative number
improved welding performance in two primary types of
and DOES NOT correspond to voltage.
applications.
Some procedure recommendations appear in Table
� Short Arc MIG at low procedure settings.
B.1.
� Aluminum MIG welding.
Recommended Welding Procedures for Power Mode - Table B.1
MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel
WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L
WIRE SIZE 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
GAS
22 ga. 100 / 0.8 90 / 1.0
WFS / POWER MODE SETTING
Not Recommended Not Recommended
20 ga. 120 / 1.0 120 / 1.0 100 / 0.7 100 /1.0 80 / 1.5 50 / 0.5
MATERIAL THICKNESS
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
Not Not
Recommended Recommended
COMMENTS
below 400 below 400
WFS WFS
POWER WAVE F355i (CE)
C-1 C-1
ACCESSORIES
OPTIONAL EQUIPMENT
FACTORY INSTALLED
None Available.
FIELD INSTALLED
K940-[ ] Work Voltage Sense Lead Kit
(Sense Lead Kits,10 Ft.,25 Ft.,50 Ft., or 75 Ft. lengths)
K1796-Coaxial Welding Cable-(Requires Adapter K2176-1)
K2176-1 Twist-mate to Lug Adapters
Welding Cable Connectors:
K852-70 1/0-2/0 CABLE
K852-95 2/0-3/0 CABLE
COMPATIBLE LINCOLN EQUIPMENT
Power Feed 10 Robotic Wire Drive
K1785-[ ] 14 Pin to 14 Pin Fanuc
(Control Cable,12 Ft.,16 Ft. or 25 Ft. lengths)
COMMUNICATION INTERFACE
K2436-1 (Not on Codes 10997 or below)
POWER WAVE F355i (CE)
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS PERIODIC MAINTENANCE
WARNING Calibration of the POWER WAVE F355i (CE) is critical
to its operation. Generally speaking the calibration will
ELECTRIC SHOCK can kill.
not need adjustment. However, neglected or improp-
� Do not touch electrically live parts or
erly calibrated machines may not yield satisfactory
electrode with skin or wet clothing.
� Insulate yourself from work and weld performance. To ensure optimal performance,
ground the calibration of output Voltage and Current should
� Always wear dry insulating gloves.
be checked yearly.
------------------------------------------------------------------------
EXPLODING PARTS can cause
injury.
CALIBRATION SPECIFICATION
� Failed parts can explode or cause other
parts to explode when power is applied. Output Voltage and Current are calibrated at the fac-
tory. Generally speaking the machine calibration will
� Always wear a face shield and long
not need adjustment. However, if the weld perfor-
sleeves when servicing.
mance changes, or the yearly calibration check
------------------------------------------------------------------------ reveals a problem, contact the Lincoln Electric
See additional warning information Company for the calibration software utility.
throughout this Operator’s Manual
-----------------------------------------------------------
The calibration procedure itself requires the use of a
CAPACITOR DISCHARGE PROCEDURE resistance load, and certified actual meters for voltage
and current. The accuracy of the calibration will be
1. Obtain a power resistor (25 ohms, 25 watts).
directly affected by the accuracy of the measuring
equipment you use. Detailed instructions are available
2. Hold resistor body with electrically insulated glove.
with the utility.
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 capacitors.
RESISTOR
CAPACITOR
TERMINALS
3. Use a DC voltmeter to check that voltage is not
present across the terminals on all four capacitors.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.
POWER WAVE F355i (CE)
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
POWER WAVE F355i (CE)
E-2 E-2
TROUBLESHOOTING
USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS
The Power Wave / Power Feed are best diagnosed as
a system. Each component (power source, user inter-
face, and feed head) has a status light, and when a
problem occurs it is important to note the condition of
each.
Included in this section is information about the power
source Status LED, and some basic troubleshooting
charts for both machine and weld performance.
The STATUS LIGHT is a two color light that indicates
system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
chart.
NOTE: The POWER WAVE F355i (CE) status light
will flash green, and sometimes red and green, for up
to one minute when the machine is first turned on.
This is a normal situation as the machine goes
through a self test at power up.
Meaning
Light
Condition
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components.
Occurs during a reset, and indicates the
Blinking
POWER WAVE F355i (CE) is mapping
Green
(identifying) each component in the system.
Normal for first 1-10 seconds after power is
turned on, or if the system configuration is
changed during operation
A l t e r n a t i n g Non-recoverable system fault. If the PS
Green and Status light is flashing any combination of
red and green, errors are present in the
Red
POWER WAVE F355i (CE). Read the error
code before the machine is turned off.
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with
a long pause between digits. If more than
one 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 Troubleshooting
Section.
Non recoverable hardware fault. Generally
Steady Red
indicates nothing is connected to the
POWER WAVE F355i (CE) wire feeder
receptacle. See Trouble Shooting Section.
Not applicable.
Blinking Red
POWER WAVE F355i (CE)
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWER WAVE
The following is a list of possible error codes that the POWER WAVE F355i (CE) can output via the status light
(see "Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11
these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.
Error Code # Indication
11 CAN communication bus off. Probably due to excessive number of communication errors.
UI is no longer responding to the Power Source. The most likely
12 User Interface time out error.
cause is a fault/bad connection in the communication leads or con-
trol cable.
Contact the Service Department for instructions on reloading the
21 Unprogrammed Weld Mode.
Welding Software.
Contact the Service Department for instructions on reloading the
22 Empty Weld Table.
Welding Software.
Contact the Service Department for instructions on reloading the
23 Weld Table checksum error.
Welding Software.
Excessive Primary current present. May be related to a short in the
31 Primary overcurrent error.
main transformer or output rectifier.
Low voltage on the main capacitors. May be caused by improper
32 Capacitor "A" under voltage
input configuration.
When accompanied by an overvoltage error on the same side, it
33 Capacitor "B" under voltage
indicates no capacitor voltage present on that side, and is usually
the result of an open or short in the primary side of the machine.
Excess voltage on the main capacitors. May be caused by improp-
34 Capacitor "A" over voltage
er input configuration.
When accompanied by an under voltage error on the same side, it
35 Capacitor "B" over voltage
indicates no capacitor voltage present on that side, and is usually
the result of an open or short in the primary side of the machine.
Indicates over temperature. Usually accompanied by Thermal LED.
36 Thermal error
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.
37 Soft start error Capacitor precharge failed. Usually accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this
41 Secondary overcurrent error
occurs the machine output will phase back to 100 amps, typically
resulting in a condition referred to as "noodle welding"
NOTE: The secondary limit is 570 amps for the standard stud, and
325 amps for all single phase operation.
The maximum voltage difference between the main capacitors has
43 Capacitor delta error
been exceeded. May be accompanied by errors 32-35.
Error codes that contain three or four digits are defined as fatal
Other
errors. These codes generally indicate internal errors on the
Control Board. If cycling the input power on the machine does not
clear the error, try reloading the operating system. If this fails,
replace the control board.
CAUTION
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.
POWER WAVE F355i (CE)
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal Lincoln Electric Field Service
covers are removed. facility for technical assis-
tance.
Input fuses keep blowing, or input 1. Make certain that fuses or
breaker keeps tripping. breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.
2. Welding procedure is drawing
too much output current, or
duty cycle is too high.
Reduce output current, duty
If all recommended possible areas
cycle, or both.
of misadjustments have been
3. There is internal damage to
checked and the problem persists,
the power source. Contact an
contact your local Lincoln
authorized Lincoln Electric
Authorized Field Service Facility.
Service facility.
Machine will not power up (no 1. Make certain that the Power
lights, no fan, etc.) to the POWER WAVE F355i
(CE) is on.
2. Circuit Breaker CB1 (on Case
Front) may have opened.
Reset. An over load on the
40V Wire Feeder supply may
cause this to trip.
3. Circuit breaker CB3 (in recon-
nect area) may have opened.
Reset.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE F355i (CE)
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Thermal LED is lit. 1. Fan thermostat has opened.
Check for proper fan operation.
(Fan should run whenever out-
put power is on.) Check for
material blocking intake or
exhaust louvers, or for excessive
dirt clogging cooling channels in
machine. Blow air in rear louvers
to remove dirt around the fan.
2. Secondary rectifier or Choke
thermostat has opened. After
machine has cooled, reduce
load, duty cycle, or both. Check
for material blocking intake or
exhaust louvers.
3. DC Bus PC board thermostat
has opened check for excessive
load on 40VDC supply.
Machine won’t weld, can’t get any 1. Input voltage is too low or too
If all recommended possible areas
output. high. Make certain that input
of misadjustments have been
voltage is proper, according to
checked and the problem persists,
the Rating Plate located on the
contact your local Lincoln
rear of the machine.
Authorized Field Service Facility.
2. If the Thermal LED is also lit,
see “Yellow Thermal LED is Lit�
section.
3. Primary current limit has been
exceeded. Possible short in out-
put circuit. Turn machine off.
Remove all loads from the out-
put of the machine. Turn back
on. If condition persists, turn
power off, and contact an autho-
rized Lincoln Electric Field
Service facility.
4. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes by
the status light. See
"Troubleshooting the Power Wave
/ Power Feed System Using the
Status LED" section of this text.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE F355i (CE)
E-6 E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Machine often “noodle welds� (out- 1.Secondary current limit has been
put is limited to approximately 100 exceeded, and the machine has
amps) when running a particular phased back to protect itself.
procedure, especially a procedure 2. Adjust procedure or reduce load
with high WFS. to lower current draw from the
machine.
Machine won’t produce full output. 1. Input voltage may be too low,
limiting output capability of the
power source. Make certain that
the input voltage is proper,
according to the Rating Plate
located on the rear of the
machine.
2. Secondary current or voltage not
be properly calibrated. Check
values displayed on the Power
Feed 10/11 verses readings on
an external meter.
If all recommended possible areas
For no apparent reason, the weld- 1. Check for proper Wire Feed
of misadjustments have been
ing characteristics have changed. Speed setting. In CV MIG and
checked and the problem persists,
FCAW modes, check for proper
contact your local Lincoln
Voltage setting. In the MIG/MAG
Authorized Field Service Facility.
pulse modes, check the Trim
setting. These controls are on
the wire feeder.
2. Check for proper shielding gas
mix and flow.
3. Check for loose or faulty weld
cables and cable connections.
The Power Wave is triggered to 1. Check for fault signals from the
weld, but there is no output. I/O connector. Possible faults
are lack of water flow/ water flow
turned off.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE F355i (CE)
E-7 E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
General degradation of the weld per- 1.Check for feeding problems, bad
formance connections, excessive loops in
cabling, etc.
2. Verify weld mode is correct for
processes.
3. The power source may require
calibration.
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 displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.
If all recommended possible areas of
Excessively long and erratic arc. 1. Check for proper configuration misadjustments have been checked
and implementation of voltage and the problem persists, contact
sensing circuits. your local Lincoln Authorized
Field Service Facility.
The feeder will not cold inch wire. 1. Check for fault signals from the
I/O connector. Possible faults are
lack of water flow/ water cooler
turned off.
Arc loss fault on robot. 1. Possibly caused by wire feeding
problem.
2. Problem - Conduit leading to the
wire feeder has bends or twists,
which can reduce the wire feed
speed. Solution - Remove bends
and twists from conduit.
3. Problem � Conduit leading up to
the wire feeder from the wire reel
is too long. Solution � Use a short-
er length of conduit.
CAUTION
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.
POWER WAVE F355i (CE)
F-1
WIRING DIAGRAM POWER WAVE F355i FOR CODE 10997
N.D.
RIGHT SIDE OF MACHINE
U A1 N.F.
(U) B
B1
INPUT (B) R V
502
504
C1,C3
W
C1 +
(N)W
3200/300
206 203 xxxxxxx
SWITCH 66C
G
4
2
J20 65C
607
(G/Y) 40VDC BUS
205 208 J46
1
5
615 3
1
65
716 BOARD
1010
6 2
715 153A
L8 66
1020
4 8
611 1002 1020
209 8
4
1103
610 1104
3
7
612 154A
21
3 7 605 52
1010
609 1001 3 7
608
J21
8 4
602 477
2 6 616 J47
1 1
N.C. 6
3 6 1 2
2
1001 903
1 5 1002 475
J9 2
2 5
1
4
3
2 5
J22 51
1 4
901
201
1 2 204
504 J11
67A J10A J10B
3 4 201 L7
8
4
xxxxxxx
804
3200/300
202 207 205 J8
505 3 7
TO ROBOTIC CONTROLLER
2
+ 6
802
T
C2,C4 806
OU 1 5
IN
I- 801
I- B CONTROL
PR PR
2 4
54
886 FEED HEAD P.C. BOARD
16 BOARD
8
2B J81
6 3
1
716 53
J7
P22 (TO SWITCHBOARD) 15
7
2W ~ 154A
715
FAN 1 2 2 4
2
32 C X2
FAN 52
+
SE J82
-
4
3 3
1
153A
880
3 ~
204 7 51
FAN 4
1B 3 6
31 521
T
X3
PW F355i 880
OU 3
1W
I- 5
2
FAN 541 J83
PR
208 X1
J22A P22 886
P22A (TO SWITCHBOARD)
FAN 1 4
J1 539
IN
1 I-
FAN1 FAN
PR 522
CHOKE
1 2 2
31A 632 32 4 8
BLACK
FAN xxxxxxx
3 4 847
8
31 16
3
31B 608
505 J6
C 7
3
BLACK
616
SE 506 15
FAN
4
FAN1 J84
607 7
32A 2 6
RED
CB2 A 615
503 GREEN
14
6
2.5A PW F355i CE 1 5
WHITE
MAIN
13
5
605 BLACK
( 380-575VAC POSI ION )
T X4
TRANSFORMER 610
N.E. 12
4 J85
612 J87
A
CB3 J86
11
3
INPUT
611
A A BRIDGE
REAR OF MACHINE
2 10
602 16 15 14 13 12 11 10 7
6A 9 10 9 8 16 15 14 13 12 11 10 9
6
209 B
+ 9
1
N.B. 6 5 4 1 2 6 5
3 4 1
8 7 3 2 5 4 8 7 3 2
1
TP3 609
A 253
D TP1
H4 J2
380- 2 4
502 1
J5 3 251
_
415V 503
R 3
1 4 2 WIRE FEEDER
B TP2 253 251
J3 254
J4 RECEPTACLE
254
550- 440- _ 8 7
12 11 10 9 10 9 8
7 6 13
207 W
575V 460V 1
67B
H5
H6 2 2
3 3
X2 6 5 4 5 4
1 1
X4
C
F H1 OUTPUT WHITE
RECTIFIER 14 25
406 405 403A 408 407 GREEN
BLACK
412 411 410 402 401A
847
VOLTAGE SENSE
67A
RECEPTACLE
67B
2B H
THERMAL G
H1 H2 H3 H4 H5 H6
20 F
BLACK
40 I
AUXILIARY YELLOW
S L3 N M
N
TRANSFORMER LED 1
GND-A J E
K
U 2W
42V
115V
L
SNB
COM 2
COM 1
B D 2
3
A
41
B B C 21
E 1B 522
539
STATUS
1104
DIAGRAMS
1103 4
R BLACK
65C
66C
5 8 ~ 541
RED/GREEN
401
J52
+
+
-
LED RED
65
66
COM1A
42 ~ 405 R2
POWER WAVE F355i (CE)
401A
407 410
31 1W
401
CB1
32 521
66B 403
C5 402
412 411 408 475 477 403 406
2400/80
~ COLOR CODE:
10Y
41
1 2
3 2 3
2 4 5 6
65B 1 1
15A B = BLACK
403A
4 5 3
42 6 8
4 7 9 10 11 12 G = GREEN
CONTROL _
+
R1 R = RED
RECTIFIER J42 J43 903 903B 901B
J41 POWER W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
J90
CURRENT FRONT VIEW OF MACHINE
1 234
TRANSDUCER 901 LEGEND
802
804
801
806
ALL MACHINES
LEFT SIDE OF MACHINE
OPTION
NOTES:
COMPONENT OUTLINE
N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. J2,J5,J11, J8,
J22, J41,
N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR J20,J21,
J1,J6,J7, J10A,
J46, J81,
550-575V OPERATION. (PW F355i CE HAS 380-415 V CONNECTION) J52, J86 J47, J84
J85, J87 J9, J42, J83 J4, J43 J10B
J82
FAN CASE BASE 1
TOP CENTER 1 8 5 2 4
1 6 1
3 1
1 1
N.C. LEADS A1, B1, C1 ARE PART OF THE INPUT POWER LINE FILTER & IT IS PRESENT ONLY ON PW F355i CE.
SHROUD FRONT
PANEL
N.D. TERMINAL BLOCK PRESENT ONLY ON PW F355i CE.
PROTECTIV BONDING CIRCUIT
E 8 7
3 5 12
9 16 10 4
6 4 6
N.E. ON PW F355i CE, MOV's ARE IN THE INPUT POWER LINE FILTER. 2
N.F. TOROID ON GROUND LEAD PRESENT ONLY ON PW F355i CE.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONE SIDE OF BOAR
NT D)
ELECTRICAL SYMBOLS PER E1537 B
G4146
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
WIRING DIAGRAM POWER WAVE F355i FOR CODE 11252
N.D.
RIGHT SIDE OF MACHINE
U 52
A1 N.F.
(U) B
B1
INPUT (B) R V 52A
502
504
C1,C3
W
C1 +
(N)W 51
E
3200/300
206 203 xxxxxxx
SWITCH 51A
66C
G
D
A
4
2
J20 65C
607
(G/Y) 40VDC BUS
205 208 J46
1
5
615 3
1
65
716 BOARD
1010 153A
6 2
715 153B
L8 66
1020
4 8
611 1002 1020
209 8
4
1103
610 1104
3
7
612 C
B
153B
154B
21
3 7 605 52
1010
609 1001 3 7
608
J21
8 4
602 477
2 6 616 J47
1 1
N.C. 6
3 6 1 2
2
1001 903 154A ARCLINK
1 5 1002 475
J9 2
2 5
1
4
3
2 5 RECEPTACLE
J22 154B
51
1 4
901
201
1 2 204
504 J11
67A J10A J10B
3 4 201 8
4
xxxxxxx
804
3200/300
202 207 67B
205 J8
505 3 7
TO ROBOTIC CONTROLLER 67C
L7
2
+ 6
802
C2,C4 806
UT
1 5
I-O 801
I-IN B CONTROL
PR PR
2 4
54
886 FEED HEAD P.C. BOARD
16 BOARD
8
2B J81
6 3
1
716 53
J7
P22 (TO SWITCHBOARD) 15
7
2W ~ 154A
715
FAN 1 2 2 4
2
32 C X2
FAN 52A
+
SE J82
-
4
3 3
1
153A
880
3 ~
204 7 51A
FAN 4
1B 3 6
31 521
T
X3
PW F355i 880
OU 3
1W
I- 5
2
FAN 541 J83
PR
208 X1
J22A P22 886
P22A (TO SWITCHBOARD)
FAN 1 4
J1 539
IN
1 I-
FAN1 FAN
PR 522
CHOKE
1 2 2
31A 632 32 4 8
BLACK
FAN xxxxxxx
3 4 847
8
31 16
3
31B 608
505 J6
C 7
3
BLACK
616
SE 506 15
FAN
4
FAN1 J84
607 7
32A 2 6
RED
CB2 A 615
503 GREEN
14
6
2.5A PW F355i CE 1 5
WHITE
MAIN
13
5
605 BLACK
( 380-575VAC POSI ION )
T X4
TRANSFORMER 610
N.E. 12
4 J85
612 J87
A
CB3 J86
11
3
INPUT
611
A A BRIDGE
REAR OF MACHINE
2 10
602 16 15 14 13 12 11 10 7
6A 9 10 9 8 16 15 14 13 12 11 10 9
6
209 B
+ 9
1
N.B. 6 5 4 1 2 6 5
3 4 1
8 7 3 2 5 4 8 7 3 2
1
TP3 609
A 253
D TP1
H4 J2
380- 2 4
502 1
J5 3 251
_
415V 503
R 3
1 4 2 WIRE FEEDER
B TP2 253 251
J3 254
J4 RECEPTACLE
254
550- 440- _ 8 7
12 11 10 9 10 9 8
7 6 13
207 W
575V 460V 1
67B
H5
H6 2 2
3 3
X2 6 5 4 5 4
1 1
X4
C
F H1 OUTPUT WHITE
RECTIFIER 14 25
406 405 403A 408 407 GREEN
BLACK
412 411 410 402 401A
847
67A
67C
2B H
THERMAL VOLTAGE SENSE
G
H1 H2 H3 H4 H5 H6
20 F RECEPTACLE
BLACK
40 I
AUXILIARY YELLOW
S L3 N M
N
TRANSFORMER LED 1
GND-A J E
K
U 2W
42V
115V
L
SNB
COM 2
COM 1
B D 2
3
A
41
B B C 21
E 1B 522
539
DIAGRAMS
STATUS
1104
1103 4
R BLACK
65C
66C
5 8 ~ 541
RED/GREEN
401
J52
+
+
-
LED RED
65
66
COM1A
42 ~ 405 R2
401A
407 410
31 1W
401
CB1
32 521
66B 403
C5 402
412 411 408 475 477 403 406
2400/80
~ COLOR CODE:
10Y
41
1 2
3 2 3
2 4 5 6
65B 1 1
15A B = BLACK
POWER WAVE F355i (CE)
403A
4 5 3
42 6 8
4 7 9 10 11 12 G = GREEN
CONTROL _
+
R1 R = RED
RECTIFIER J42 J43 903 903B 901B
J41 POWER W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
J90
CURRENT FRONT VIEW OF MACHINE
1 234
TRANSDUCER 901 LEGEND
802
804
801
806
ALL MACHINES
LEFT SIDE OF MACHINE
OPTION
NOTES:
COMPONENT OUTLINE
N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. J2,J5,J11, J8,
J22, J41,
N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR J20,J21,
J1,J6,J7, J10A,
FAN J46, J81,
CASE BASE
TOP CENTER
550-575V OPERATION. (PW F355i CE HAS 380-415 V CONNECTION) J52, J86 J47, J84
J85, J87 J9, J42, J83 J4, J43 J10B
SHROUD J82
FRONT
PANEL 1
1 8 5 2 4
1 6 1
3 1
1 1
N.C. LEADS A1, B1, C1 ARE PART OF THE INPUT POWER LINE FILTER & IT IS PRESENT ONLY ON PW F355i CE.
PROTECTIVE BONDING CIRCUIT
N.D. TERMINAL BLOCK PRESENT ONLY ON PW F355i CE.
8 7
3 5 12
9 16 10 4
6 4 6
N.E. ON PW F355i CE, MOV's ARE IN THE INPUT POWER LINE FILTER. 2
N.F. TOROID ON GROUND LEAD PRESENT ONLY ON PW F355i CE.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONE SIDE OF BOAR
NT D)
ELECTRICAL SYMBOLS PER E1537 A.02
G5375
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
F-3 F-3
CONNECTION DIAGRAM
Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, CV / Pulse Configuration shown)
SEE SECTION A-4, Power Wave / Power Feed Wire
Feeder Interconnections
COMMUNICATION INTERFACE
OPTIONAL (K2436-1)
NOT ON CODES 10997 OR BELOW.
POWER WAVE F355i
VOLTAGE SENSE LEADS
(OPTIONAL) K940
WIRE
TO
FEEDER
WORK
CONTROL CABLE K1785
FANUC R-J3i
POWER WAVE F355i (CE)
.40
F-4
10.06
.81
17.20
.51
25.15
27.60
3.37
POWER WAVE F355i (CE)
DIMENSION PRINT
14.64
A
M19982
F-4
NOTES
POWER WAVE F355i (CE)
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES 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 A
ETRE 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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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