Lincoln Electric Welding System F355I User Manual

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IM799-A

January, 2005

POWER WAVE F355i (CE)

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

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

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

• 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

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SAFETY

ARC RAYS can burn.

ELECTRIC SHOCK can

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

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

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

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

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

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

5.e. Also see item 1.b.

Mar ‘95

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iii

SAFETY

WELDING SPARKS can

cause fire or explosion.

CYLINDER may explode

if damaged.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even though they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the Preparation for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil

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.

Always wear safety glasses with side shields when in a

welding area.

FOR ELECTRICALLY

powered equipment.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

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

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

8. S’assurer que la masse est connectée le plus prés possible

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

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

f. Si on utilise la machine à souder comme une source de

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

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

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

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

2. Autant que possible, I’installation et l’entretien du poste seront

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

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

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

place.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

Mar. ‘93

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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

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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

interference. Screening of the entire welding installation may be considered for special applications.

Portions of the preceding text are contained in EN50199: "Electromagnetic Compatibility (EMC) product standard for

arc welding equipment."

3-1-96H

L10093

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vii

for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Thank 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.

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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

________________________________________________________________________

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A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE F355i

INPUT AC VOLTAGE & DC OUTPUT

Product Ordering Input AC

Rated DC Output

Output

Range

(continuous)

Weight

with Cord

Dimensions

HxWxD

Name Information Voltage Amps/Volts/Duty Cycle

POWER K2260-1

380-415

350A / 34V / 60%

300A / 32V /100%

14.6” x 17.2” x 27.6”*

(371 x 437 x 701*)mm

WAVE

F355i

K2260-2

AMPS

5-425

110.0 lbs.

(50.0. kg.)

60/50 Hz

3 Phase

* 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

Line Cord

300Amps @ Fuse size

Voltage

Phases

350Amps @

32Volts(100%)

34Volts(60%)

380

400

415

10mm

40A

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

300

DUTY CYCLE

100%

LENGTH UP 200FT.(61m)

200-250 FT. (61-76m)

2/0

350

60%

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

POWER WAVE F355i (CE)

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A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

CAUTION

ELECTRIC SHOCK can kill.

• Turn the input power off at the dis-

connect switch before attempting

to connect or disconnect input

power lines, output cables or con-

trol cables

• Incorrect connection may result in equipment

damage.

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

POWER CORD CONNECTION

• Only qualified personnel should perform this

installation.

• Connect the green lead of the power cord to

ground per National Electrical Code.

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

A 7ft. (2m) power cord is provided and wired into the

machine. Follow the power cord connection instruc-

tions.

SELECT SUITABLE LOCATION

The Invertec POWER WAVE F355i will operate in

harsh environments. Even so, it is important that sim-

ple preventative measures are followed in order to

assure long life and reliable operation.

BLACK

GREEN/YELLOW

BLUE

BROWN

• The machine must be located where there is free cir-

culation of clean air such that air movement in the

back, out the sides and bottom will not be restricted.

Three Phase Input

Connect green lead to ground per National Electric

Code.

Connect black, red and white leads to power.

• Dirt and dust that can be drawn into the machine

should be kept to a minimum. Failure to observe

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)

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A-3

INSTALLATION

When operating with electrode polarity negative the

"Electrode Sense Polarity" DIP switch must be set to the

"Negative" position on the Wire Drive Feed Head PC Board.

The default setting of the switch is positive electrode polari-

ty. Set the Negative Polarity switch on Wire Feed Head PC

board as follows:

OUTPUT CABLES, CONNECTIONS AND

LIMITATIONS

Connect a work lead of sufficient size and length

between the proper output terminal on the power

source and the work. Be sure the connection to the

work makes tight metal-to-metal electrical contact. To

avoid interference problems with other equipment and

to achieve the best possible operation, route all cables

directly to the work or wire feeder. Avoid excessive

lengths and do not coil excess cable.

WARNING

ELECTRIC SHOCK can kill

• Turn the input power OFF at the dis-

connect switch or fuse box before

working on this equipment.

CAUTION

• Do not touch electrically hot parts.

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

1. Turn off power to the power source at the disconnect

switch.

2. Remove the front cover from the power source.

3. The feed head PC board is on the left side of the power

source. Locate the 8-position DIP switch and look for

switch 7 of the DIP switch.(See Figure A.1)

4. Using a pencil or other small object, slide the switch to

the OFF position for positive electrode polarity.

Conversely, slide the switch to the ON position for nega-

tive electrode polarity.

5. Replace the cover and screws. The PC board will“read”

the switch at power up, and configure the work voltage

sense lead appropriately.

When using an inverter type power source like the

Power Waves, use the largest welding (electrode

and work) cables that are practical. At least 2/0

copper wire - even if the average output current

would not normally require it. When pulsing, the

pulse current can reach very high levels. Voltage

drops can become excessive, leading to poor

welding characteristics, if undersized welding

cables are used.

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

Most welding applications run with the electrode being

positive (+). For those applications, connect the elec-

trode cable between the wire feeder and the positive

(+) output Twist-Mate terminal on the power source.

Connect the other end of the electrode cable to the

wire feeder at it’s proper connection point. Be sure the

connection makes tight metal-to-metal electrical con-

tact. The electrode cable should be sized according to

the specifications given in the output cable connec-

tions section. Connect a work lead from the negative

(-) power source output Twist-Mate terminal to the

work piece. The work piece connection must be firm

and secure, especially if pulse welding is planned.

VOLTAGE SENSING

The best arc performance occurs when the PowerWaves

have accurate data about the arc conditions. Depending

upon the process, inductance within the electrode and work

lead cables can influence the voltage apparent at the studs

of the welder. Voltage sense leads improve the accuracy of

the arc conditions and can have a dramatic effect on perfor-

mance. Sense Lead Kits (K940-10, -25 or -50) are available

for this purpose.

For additional Safety information regarding the elec-

trode and work cable set-up, See the standard "SAFE-

TY INFORMATION" located in the front of the

Instruction Manuals.

CAUTION

If the voltage sensing is enabled but the sense

leads are missing, improperly connected, or if the

electrode polarity switch is improperly configured,

extremely high welding outputs may occur.

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

The ELECTRODE sense lead (67) is built into the control

cable, and is automatically enabled for all semi-automatic

processes. The WORK sense lead (21) connects to the

Power Wave at the four pin connector. By default the

WORK voltage is monitored at the output stud in the

POWER WAVE F355i (CE). For more information on the

WORK sense lead (21), see"Work Voltage Sensing” in the

following paragraph.

CAUTION

Excessive voltage drops caused by poor work

piece connections often result in unsatisfactory

welding performance.

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

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as

in some Innershield applications, reverse the output

connections at the power source (electrode cable to

the negative (-) Twist-Mate terminal, and work cable

to the positive (+) Twist-Mate terminal.

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A-4

INSTALLATION

Enable the voltage sense leads as follows:

5. Replace the wrap around and screws. The PC

board will “read” the switch at power up, and config-

ure the work voltage sense lead appropriately.

TABLE A.1

Process Electrode Voltage

Sensing 67 lead *

GMAW 67 lead required

GMAW-P 67 lead required

FCAW 67 lead required

GTAW Voltage sense at studs Voltage sense at studs

GMAW Voltage sense at studs Voltage sense at studs

SAW

Work Voltage

Sensing 21 lead

21 lead optional

ELECTRODE VOLTAGE SENSING

Enabling or disabling electrode voltage sensing is

automatically configured through software. The 67

electrode sense lead is internal to the cable to the

wire feeder and always connected when a wire feeder

is present.

67 lead required

21 lead optional

CAC-C Voltage sense at studs Voltage sense at studs

* The electrode voltage 67 sense lead is integral to the

control cable to the wire feeder.

CAUTION

Important: The electrode polarity must be config-

ured on the feed head PC board. Failure to do so

may result in extremely high welding outputs.

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

POWER WAVE / POWER FEED WIRE

Work Voltage Sensing

The standard POWER WAVE F355i (CE)’s default is

to the work stud (work sense lead disabled).

For processes requiring work voltage sensing, con-

nect the (21) work voltage sense lead (K940) from the

Power Wave work sense lead receptacle to the work

piece. Attach the sense lead to the work piece as

close to the weld as practical, but not in the return cur-

rent path. Enable the work voltage sensing in the

Power Wave as follows:

FEEDER INTERCONNECTIONS

(See Section F-2 for Connection Diagram)

Connect the control cable between the power source

and wire feeder. The wire feeder connection on the

POWER WAVE F355i (CE) is the 14-pin connector

located on the left side of the machine. The control

cable is keyed and polarized to prevent improper con-

nection.

WARNING

ELECTRIC SHOCK can kill

CONTROL CABLE SPECIFICATIONS

It is recommended that genuine Lincoln control cables

be used at all times. Lincoln cables are specifically

designed for the communication and power needs of

the Power Wave / Power Feed system.

• Turn the input power OFF at the

disconnect switch or fuse box

before working on this equipment.

CAUTION

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

1. Turn off power to the power source at the dis-

The use of non-standard cables, especially in

lengths greater than 25 ft.(7.6m), can lead to com-

muni-cation problems (system shutdowns), poor

motor acceleration (poor arc starting) and low

wire driving force (wire feeding problems).

connect switch.

2. Remove the wrap around cover from the power

source.

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

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

board switch change. The Power Feed Wire Feeders

are shipped with both high speed and a low speed

gears. As shipped from the factory, the low speed

(high torque) gear is installed on the feeder. To

change Gear ratio see Power Feed 10/R Instruction

Manual.

4. Using a pencil or other small object, slide the switch

to the OFF position if the work sense lead is NOT

connected. Conversely, slide the switch to the ON

position if the work sense lead is present.

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A-5

INSTALLATION

switch 8

off

work sense lead

work sense lead not connected*

work sense lead connected

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the

disconnect switch or fuse box

before working on this equipment.

Feed Head Board DIP Switch:

switch 1 = Object Instance LSB (see table 1)

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

switch 6 = Equipment Group 4 Select

switch 7 = negative polarity switch

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

1. Set the High/Low switch code on Feed Head PC

board as follows:

2. Turn off power to the power source at the dis-

switch 7

off

electrode polarity

positive *

connect switch.

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

look for position 8 of the DIP switch. (See Figure A.1)

switch 8

off

wire drive gear

low speed gear *

high speed gear

5. Using a pencil or other small object, slide the switch

to the OFF position, when the low speed gear is

installed. Conversely, slide the switch to the ON

position when the high speed gear is installed.

TABLE 1

Object Instance

switch 2

switch 1

Instance

off

0 *

6. Replace the cover and screws. The PC board will

“read” the switch at power up, automatically adjust-

ing all control parameters for the speed range

selected.

*Factory Setting

DIP Switch Settings and Locations

(See Figure A.1)

FEED HEAD BOARD DIP SWITCH

FIGURE A.1

DIP switches on the P.C. Boards allow for custom

configuration of the Power Wave. To access the DIP

switches:

WARNING

• Turn off power at the disconnect switch.

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

• 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)

switch 2 = Object Instance MSB 2 (see table 1)

switch 3 = Equipment Group 1 Select

switch 4 = Equipment Group 2 Select

switch 5 = Equipment Group 3 Select

switch 6 = Equipment Group 4 Select

switch 7 = reserved for future use

switch 8 = work sense lead

CONTROL BOARD DIP SWITCH

LOCATION OF DIP SWITCHES IN MACHINE

1 LEAST SIGNIFICANT BIT

2 MOST SIGNIFICANT BIT

POWER WAVE F355i (CE)

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A-6

INSTALLATION

I / O RECEPTACLE SPECIFICATIONS

WELDING WITH MULTIPLE POWER

WAVES

14-Pin Robotic Wire Feeder Connector

Lead

539

541

521

522

845

847

841

844

Open

GND

842

843

846

Function

Motor +

Motor -

Solenoid +

CAUTION

Special care must be taken when more than one

Power Wave is welding simultaneously on a single

part. Arc blow and arc interference may occur or

be magnified.

Solenoid common

Tach 2A Differential Signal

Single Tach input

+15V Tach Supply

Tach common

Reserved for future use

Shielding drain

Tach 1A Differential Signal

Tach 1B Differential Signal

Tach 2B Differential Signal

Electrode Sense (67)

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

Each power source requires a work lead from the

work stud to the welding fixture. Do not combine all of

the work leads into one lead. The welding travel direc-

tions should be in the direction moving away from the

work lead as shown below. Connect all of the work

sense leads from each power source to the work

piece at the end of the weld. (See Figure A.2)

VOLTAGE SENSE RECEPTACLE

For the best results when pulse welding, set the wire

size and wire feed speed the same for all the Power

Waves. When these parameters are identical, the

pulsing frequency will be the same, helping to stabilize

the arcs.

LEAD#

FUNCTION

Work Voltage Sense

Electrode Voltage Sense

RS232 RECEPTACLE

LEAD#

253

254

FUNCTION

Every welding gun requires a separate shielding gas

regulator for proper flow rate and shielding gas cover-

age.

RS232 Receive

RS232 Transmit

Pin5

Pin4

Pin20

Pin6

Do not attempt to supply shielding gas for two or more

guns from only one regulator.

# #

251

RS232 Common

If an anti-spatter system is in use then each gun must

have its own anti-spatter system.

WIRE FEEDER RECEPTACLE*

LEAD#

153

154

FUNCTION

Communiction Bus L

Communiction Bus H

Electrode Voltage Sense

Ovdc

+40vdc +

* Not on Codes 10997

or below.

FIGURE A.2

TWO POWER WAVES

POWER WAVE F355i

Travel

Direction

Connect All Work

Sense Leads at the

the

End of

Joint

Connect All Welding

Work Leads at the

Beginning of the Joint

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B-1

OPERATION

SAFETY PRECAUTIONS

GENERAL DESCRIPTION

The Power Wave Robotic power source is designed to

be a part of a modular, multi-process welding system.

Depending on configuration, it can support constant

current, constant voltage, constant power, pulse on

pulse and pulse welding modes.

Read this entire section of operating instructions

before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

The Power Wave power source is designed to be

used with the Robotic family of Power Feed wire feed-

ers, operating as a system. Each component in the

system has special circuitry to "talk with" the other

system components, so each component (power

source, wire feeder Robotic Controller knows what the

other is doing at all times. These components commu-

nicate with Arc Link.

• Unless using cold feed feature, when

feeding with gun trigger, the elec-

trode and drive mechanism are

always electrically energized and

could remain energized several sec-

onds after the welding ceases.

• Do not touch electrically live parts or electrodes

with your skin or wet clothing.

The POWER WAVE F355i (CE) is a high perfor-

mance, digitally controlled inverter welding power

source capable of complex, high-speed waveform

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

300 Amps, 32 volts at 100% duty cycle.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

RECOMMENDED PROCESSES AND

EQUIPMENT

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

WELDING SPARKS can cause fire or

explosion.

RECOMMENDED PROCESSES

The POWER WAVE F355i (CE) can be set up in a

number of configurations, some requiring optional

equipment or welding programs. Each machine is fac-

tory preprogrammed with multiple welding procedures,

typically including GMAW, GMAW-P and FCAW for a

variety of materials, including mild steel, stainless

steel, cored wires, and aluminum.

• Keep flammable material away.

• Do not weld on containers that have

held combustibles.

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

• The POWER WAVE F355i (CE) is recommended for

Robotic welding with the Fanuc R-J3i.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

• This POWER WAVE F355i (CE) is not recommend-

ed for processes other than those listed.

Observe additional guidelines detailed in the

beginning of this manual.

REQUIRED EQUIPMENT

Any Arc Link compatible semi-automatic wire feeding

equipment. Specifically, the Power Feed 10 Robotic

Wire drive.

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B-2

OPERATION

2. HIGH TEMPERATURE LIGHT (thermal overload):

A yellow light that comes on when an over temper-

ature situation occurs. Output is disabled and the

fan continues to run, until the machine cools down.

When cool, the light goes out and output is

enabled.

LIMITATIONS

• Only Arc Link compatible Power Feed automatic wire

feeders and users interfaces may be used. Other

Lincoln wire feeders or non-Lincoln wire feeders can-

not be used.

• POWER WAVE F355i (CE) Output Limitations

The POWER WAVE F355i (CE) will support maxi-

mum average output current of 350 Amps @ 60%

duty cycle.

3. CB1 WIRE FEEDER CIRCUIT BREAKER:

Protects 40 volt DC wire feeder power supply.

DUTY CYCLE AND TIME PERIOD

Figure B.1

The duty cycle is based upon a ten minute period. A

60% duty cycle represents 6 minutes of welding and 4

minutes of idling in a ten minute period.

CONNECTOR STATUS LIGHTS (Per Fig B.1)

1. STATUS LIGHT: A two color light that indicates

system errors. Normal operation is a steady green

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

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.

TABLE B.1

Light

Condition

Meaning

Steady Green System OK. Power source communicating normal-

ly with wire feeder and its components.

CASE FRONT LAYOUT

POWER WAVE F355i (CE)

Blinking

Green

Occurs during a reset, and indicates the

POWER WAVE F355i (CE) is mapping

(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

4. LEAD CONNECTOR (SENSE LEAD)

5. DIAGNOSTIC CONNECTOR (RS-232)

6. WIRE FEEDER RECEPTACLE (14-PIN)

7. NEGATIVE TWIST- MATE TERMINAL

8. POSITIVE TWIST- MATE TERMINAL

Alternating Non-recoverable system fault. If the PS

Green and Status light is flashing any combination of

Red

red and green, errors are present in the

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

indicates nothing is connected to the

POWER WAVE F355i (CE) wire feeder

receptacle. See Trouble Shooting Section.

Steady Red

Blinking Red

Not applicable.

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B-3

OPERATION

In non-synergic modes, the WFS control behaves

more like a conventional CV power source where

WFS and voltage are independent adjustments.

Therefore to maintain the arc characteristics, the oper-

ator must adjust the voltage to compensate for any

changes made to the WFS.

NOMINAL PROCEDURES

The Power Wave is designed to operate with 3/4"

electrode stick-out for CV and Pulse processes.

FRINGE PROCEDURES

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 user can change the Trim setting to adjust the arc

length. It is adjustable from 0.500 to 1.500. A Trim set-

ting of 1.000 is a good starting point for most condi-

tions.

The serviceability of a product or structure utiliz-

ing the welding programs is and must be the sole

responsibility of the builder/user. Many variables

beyond the control of The Lincoln Electric

Company affect the results obtained in applying

these programs. These variables include, but are

not limited to, welding procedure, plate chemistry

and temperature, weldment design, fabrication

methods and service requirements. The available

range of a welding program may not be suitable

for all applications, and the build/user is and must

be solely responsible for welding program selec-

tion.

• WELDING MODE

Selecting a welding mode determines the output char-

acteristics of the Power Wave power source. For a

more complete description of the welding modes

available in the Power Wave and for a complete set of

weld modes programmed into the Power Wave at the

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,

diameter, shielding gas and process (GMAW, GMAW-

P, etc.)

• ARC CONTROL

Also known as Inductance or Wave Control. Allows

operator to vary the arc characteristics from "soft" to

"harsh" in all weld modes. It is adjustable from -10.0 to

+10.0, with a nominal setting of 00.0 (The nominal set-

ting of 00.0 may be displayed as OFF on some Power

Feed wire feeder control panels). See the Welding

Mode descriptions, below, for detailed explanations of

how the Arc Control affects each mode.

Second, find the program in the welding software that

best matches the desired welding process. The stan-

dard software shipped with the Power Waves encom-

passes a wide range of common processes and will

meet most needs. If a special welding program is

desired, contact the local Lincoln Electric sales repre-

sentative.

To make a weld, the Power Wave needs to know the

desired welding parameters. 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.

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B-4

OPERATION

The Power Wave utilizes "adaptive control" to compensate

for changes in electrical stick-out while welding. (Electrical

stick-out is the distance from the contact tip to the work

piece.) The Power Wave waveforms are optimized for a

0.75" (19mm) stick-out. The adaptive behavior supports a

range of stickouts from 0.50" (13mm) to 1.25" (32mm). At

very low or high wire feed speeds, the adaptive range may

be less due to reaching physical limitations of the welding

process.

CONSTANT VOLTAGE WELDING

Non Synergic CV:

This type of CV mode behaves more like a conventional CV

power source. Voltage and WFS are independent adjustments.

Therefore to maintain the arc characteristics, the operator must

adjust the voltage to compensate for any changes made to the

WFS.

All CV Modes:

Arc Control, often referred to as wave control, adjusts the induc-

tance of the wave shape. The wave control adjustment is similar

to the "pinch" function in that it is inversely proportional to induc-

tance. Therefore, increasing wave control greater than 0.0

results in a harsher, colder arc while decreasing the wave con-

trol to less than 0.0 provides a softer, hotter arc. (See Figure

B.2)

Arc Control, often referred to as wave control, in pulse pro-

grams usually adjusts the focus or shape of the arc. Wave

control values greater than 0.0 increase the pulse frequency

while decreasing the background current, resulting in a tight,

stiff arc best for high speed sheet metal welding. Wave con-

trol values less than 0.0 decrease the pulse frequency while

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

Time

PULSE-ON-PULSE™ (GMAW-PP)

Pulse on Pulse™ is a Lincoln process specifically

designed for use in welding relatively thin (less than

1/4" thick) aluminum. It gives weld beads with very

consistent uniform ripple.

PULSE WELDING

Pulse welding procedures are set by controlling an overall

"arc length" variable. When pulse welding, the arc voltage is

highly dependent upon the waveform. The peak current,

back ground current, rise time, fall time and pulse frequency

all affect the voltage. The exact voltage for a given wire feed

speed can only be predicted when all the pulsing waveform

parameters are known. Using a preset voltage becomes

impractical, and instead the arc length is set by adjusting

"trim".

In Pulse on Pulse modes, two distinct pulse types are

used, instead of the single pulse type normally used in

GMAW-P. A number of high energy pulses are used

to obtain spray transfer and transfer metal across the

arc. Such pulses are shown in Figure B.4. After a

number "N" of such pulses, depending on the wire

feed speed used, an identical number "N" of low ener-

gy pulses are performed. These low energy pulses,

shown in Figure B.4, do not transfer any filler metal

across the arc and help to cool the arc and keep the

heat input low.

Trim adjusts the arc length and ranges from 0.50 to 1.50,

with a nominal value of 1.00. Trim values greater than 1.00

increase the arc length, while values less than 1.00

decrease the arc length.

FIGURE B.4

Current

"N" PULSES

All pulse welding programs are synergic. As the wire feed

speed is adjusted, the Power Wave will automatically recal-

culate the waveform parameters to maintain similar arc

properties.

HIGH HEAT

PULSES

LOW HEAT

PULSES

PEAK

AMPS

BACKGROUND

AMPS

TIME

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B-5

OPERATION

Power Mode™ is a method of high speed regulation

of the output power whenever an arc is established. It

provides a fast response to changes in the arc. The

higher the Power Mode Setting, the longer the arc. If a

welding procedure is not established, the best way to

determine the Power Mode Setting is by experimenta-

tion until the desired output result is established.

The Peak Current, Background Current, and

Frequency are identical for the high energy and low

energy pulses. In addition to cooling the weld down,

the major effect of the low energy pulses is that they

form a weld ripple. Since they occur at very regular

time intervals, the weld bead obtained is very uniform

with a very consistent ripple pattern. In fact, the bead

has its best appearance if no oscillation of the welding

gun ("whipping") is used.(See Figure B.5)

In the Power Mode two variables need to be set:

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

pulsed modes: decreasing the Arc Control decreases

the droplet transfer and weld deposition rate.

Increasing the Arc Control increases the droplet trans-

fer and weld deposition rate. Since Arc Control varies

weld droplet transfer rate, the Arc Control can be used

to vary the ripple spacing in the weld bead.

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

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

• For aluminum, use 100% Ar.

Start by setting the wire feed speed based upon mate-

rial thickness and appropriate travel speed. Then

adjust the Volts/Trim knob as follows:

POWER MODE™

• For steel, listen for the traditional “frying egg”

sound of a good short-arc MIG procedure to know

you have the process set correctly.

• For aluminum, simply adjust the Volts/Trim knob

until the desired arc length is obtained.

The Power Mode™ process was developed by

Lincoln to maintain a stable and smooth arc at low

procedure settings which are needed to weld thin

metal without pop-outs or burning-through. For alu-

minum welding, it provides excellent control and the

ability to maintain constant arc length. This results in

improved welding performance in two primary types of

applications.

Note the Volts/Trim display is simply a relative number

and DOES NOT correspond to voltage.

Some procedure recommendations appear in Table

B.1.

• Short Arc MIG at low procedure settings.

• Aluminum MIG welding.

Recommended Welding Procedures for Power Mode - Table B.1

MATERIAL

WIRE

Aluminum 4043 Aluminum 5356

Mild Steel

L56

Mild Steel

L56

Mild Steel

L56

Mild Steel

L56

Mild Steel

L56

Mild Steel

L56

Stainless Steel Stainless Steel

E4043

0.035

E5356

0.035

E308L

0.030

E308L

0.035

WIRE SIZE

GAS

0.025

0.030

0.035

100% Ar.

100% CO₂

75/25 Ar/CO₂

100 / 0.8

120 / 1.0

140 / 1.5

190 / 2.0

260 / 3.0

330 / 4.5

100% CO₂

75/25 Ar/CO₂

90 / 1.0

100% CO₂

75/25 Ar/CO₂

Tri-mix

22 ga.

Not Recommended

120 / 1.0

140 / 1.7

190 / 2.0

260 / 3.0

330 / 5.0

Not Recommended

100 / 0.7

110 / 1.5

125 / 2.0

160 / 2.3

230 / 3.5

300 / 6.0

400 / 7.5

20 ga.

18 ga.

16 ga.

14 ga.

12 ga.

10 ga.

3/16

100 /1.0

110 / 1.5

125 / 2.0

160 / 2.3

230 / 3.5

300 / 6.0

400 / 7.0

80 / 1.5

110 / 2.0

140 / 2.5

210 / 3.0

270 / 5.0

325 / 6.5

50 / 0.5

110 / 2.0

130 / 2.7

190 / 3.5

230 / 6.0

300 / 7.0

100 / 2.5

125 / 3.0

160 / 3.8

200 / 5.0

240 / 6.5

100 / 2.5

125 / 3.0

160 / 3.5

200 / 4.5

240 / 7.0

400 / 2.0

400 / 2.5

500 / 7.0

570 / 9.0

500 / 7.0

600 / 7.8

1/4

700 / 9.1

Not

700 / 8.5

Not

Recommended Recommended

COMMENTS

below 400

WFS

below 400

WFS

POWER WAVE F355i (CE)

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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)

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D-1

MAINTENANCE

SAFETY PRECAUTIONS

PERIODIC MAINTENANCE

Calibration of the POWER WAVE F355i (CE) is critical

to its operation. Generally speaking the calibration will

not need adjustment. However, neglected or improp-

erly calibrated machines may not yield satisfactory

weld performance. To ensure optimal performance,

the calibration of output Voltage and Current should

be checked yearly.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

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

EXPLODING PARTS can 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

not need adjustment. However, if the weld perfor-

mance changes, or the yearly calibration check

reveals a problem, contact the Lincoln Electric

Company for the calibration software utility.

•

Always wear a face shield and long

sleeves when servicing.

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

See additional warning information

throughout this Operator’s Manual

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

The calibration procedure itself requires the use of a

resistance load, and certified actual meters for voltage

and current. The accuracy of the calibration will be

directly affected by the accuracy of the measuring

equipment you use. Detailed instructions are available

with the utility.

CAPACITOR DISCHARGE PROCEDURE

1. Obtain a power resistor (25 ohms, 25 watts).

2. Hold resistor body with electrically insulated glove.

DO NOT TOUCH TERMINALS. Connect the resis-

tor terminals across the two studs in the position

shown. Hold in each position for 1 second. Repeat

for all four 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)

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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

locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the

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-

TOMS)”. This column describes possible symptoms

that the machine may exhibit. Find the listing that

best describes the symptom that the machine is

exhibiting.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your

local Lincoln Authorized Field Service Facility.

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)

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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.

Light

Meaning

Condition

Steady Green System OK. Power source communicating normal-

ly with wire feeder and its components.

Blinking

Green

Occurs during a reset, and indicates the

POWER WAVE F355i (CE) is mapping

(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

Alternating Non-recoverable system fault. If the PS

Green and Status light is flashing any combination of

Red

red and green, errors are present in the

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

indicates nothing is connected to the

POWER WAVE F355i (CE) wire feeder

receptacle. See Trouble Shooting Section.

Steady Red

Blinking Red

Not applicable.

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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 #

CAN communication bus off.

User Interface time out error.

Indication

Probably due to excessive number of communication errors.

UI is no longer responding to the Power Source. The most likely

cause is a fault/bad connection in the communication leads or con-

trol cable.

Contact the Service Department for instructions on reloading the

Welding Software.

Contact the Service Department for instructions on reloading the

Welding Software.

Contact the Service Department for instructions on reloading the

Welding Software.

Unprogrammed Weld Mode.

Empty Weld Table.

Weld Table checksum error.

Excessive Primary current present. May be related to a short in the

main transformer or output rectifier.

Low voltage on the main capacitors. May be caused by improper

input configuration.

When accompanied by an overvoltage error on the same side, it

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-

er input configuration.

Primary overcurrent error.

Capacitor "A" under voltage

Capacitor "B" under voltage

Capacitor "A" over voltage

Capacitor "B" over voltage

When accompanied by an under voltage error on the same side, it

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.

Check fan operation. Be sure process does not exceed duty cycle

limit of the machine.

Thermal error

Soft start error

Capacitor precharge failed. Usually accompanied by codes 32-35.

The secondary (weld) current limit has been exceeded. When this

occurs the machine output will phase back to 100 amps, typically

resulting in a condition referred to as "noodle welding"

Secondary overcurrent error

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

been exceeded. May be accompanied by errors 32-35.

Capacitor delta error

Error codes that contain three or four digits are defined as fatal

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.

Other

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)

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E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical damage 1. Contact your local authorized

is evident when the sheet metal

covers are removed.

Lincoln Electric Field Service

facility for technical assis-

tance.

Input fuses keep blowing, or input

breaker keeps tripping.

1. Make certain that fuses or

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

cycle, or both.

3. There is internal damage to

the power source. Contact an

authorized Lincoln Electric

Service facility.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

Authorized Field Service Facility.

Machine will not power up (no

lights, no fan, etc.)

1. Make certain that the Power

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)

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E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

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

output.

1. Input voltage is too low or too

high. Make certain that input

voltage is proper, according to

the Rating Plate located on the

rear of the machine.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

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.

. 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)

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E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Machine often “noodle welds” (out- 1.Secondary current limit has been

put is limited to approximately 100

amps) when running a particular

procedure, especially a procedure

with high WFS.

exceeded, and the machine has

phased back to protect itself.

2. Adjust procedure or reduce load

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

of misadjustments have been

checked and the problem persists,

contact your local Lincoln

For no apparent reason, the weld-

ing characteristics have changed.

1. Check for proper Wire Feed

Speed setting. In CV MIG and

FCAW modes, check for proper

Voltage setting. In the MIG/MAG

pulse modes, check the Trim

setting. These controls are on

the wire feeder.

Authorized Field Service Facility.

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)

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E-7

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

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.

The feeder will not cold inch wire.

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.

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)

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F-1

DIAGRAMS

B L A C

A 1 0 4

6 0 8

1 0 8

4 0 8

2 0 8

xxxxxxx

1 M C O

4 2 V

2 M C O

1 1 5

E N I H C A M F O R A E R

POWER WAVE F355i (CE)

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F-2

DIAGRAMS

B L A C

A 1 0 4

6 0 8

1 0 8

4 0 8

2 0 8

xxxxxxx

1 M C O

4 2 V

2 M C O

1 1 5

E N I H C A M F O R A E R

POWER WAVE F355i (CE)

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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

FEEDER

WORK

CONTROL CABLE K1785

FANUC R-J3i

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F-4

DIMENSION PRINT

POWER WAVE F355i (CE)

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NOTES

POWER WAVE F355i (CE)

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● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● Keep flammable materials away.

● Wear eye, ear and body protection.

WARNING

^SpanisA^hVISO DE

PRECAUCION

French

● No toque las partes o los electrodos ● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

bajo carga con la piel o ropa moja-

da.

● Aislese del trabajo y de la tierra.

fuera del área de trabajo.

cuerpo.

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact

avec des pièces sous tension.

● Gardez à l’écart de tout matériel

inflammable.

● Protégez vos yeux, vos oreilles et

votre corps.

ATTENTION

● Isolez-vous du travail et de la terre.

German

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem

Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

WARNUNG

Elektroden und dem Erdboden!

Portuguese

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha-

da.

● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e

dos.

corpo.

ATENÇÃO

● 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

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● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

Spanish

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o

aspiración para gases.

● Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

● No operar con panel abierto o

guardas quitadas.

AVISO DE

PRECAUCION

French

● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux

tien.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones

de travail.

ouverts ou avec les dispositifs de

protection enlevés.

ATTENTION

German

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in

Betrieb setzen!

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

WARNUNG

Portuguese

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

ATENÇÃO

● Não toque as partes elétricas nuas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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• 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

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