IM755

POWER WAVE F355i April, 2002

For use with machines Code 10916

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 i
3 55
EF
proper installation ... and thought-
V
WA
ful operation on your part. DO
NOT INSTALL, OPERATE OR E R
W
REPAIR THIS EQUIPMENT PO
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

Copyright © 2002 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
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline 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
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
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.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
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
POWER WAVE 355
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
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
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
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
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.g. Never dip the electrode in water for cooling. ucts.

3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

POWER WAVE 355

iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. 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
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.

6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • 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 • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.

6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
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.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
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

POWER WAVE 355

iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.

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

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93

POWER WAVE 355

v v

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

Thank You to take pride in operating this Lincoln Electric Company product
••• 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.
Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

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.
vi TABLE OF CONTENTS vi
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 .................................................................................................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
Connection Diagram ....................................................................................Section F-2
Dimension Print............................................................................................Section F-3
________________________________________________________________________
Parts Lists ................................................................................................................P432
________________________________________________________________________
A-1 INSTALLATION A-1
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 K2156-1 380-400/ 350A / 34V / 60% 14.6” x 17.2” x 27.6”*

WAVE 415-460/ AMPS (100.0 lbs.) (371 x 437 x 701*)mm
F355i 575 5-425 (45.4 kg.)
300A / 32V /100% * Includes Mounting
60/50 Hz Brackets
3 Phase

* 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 @ Line Cord Fuse size
32Volts(100%) 34Volts(60%) AWG
380 3 23 28 10 40A
400 3 22 27 10 40A
415 3 22 26 10 40A
460 3 19 23 10 40A
575 3 16 18 10 30A
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:
DUTY CYCLE CURRENT LENGTH UP 200FT.(61m) 200-250 FT. (61-76m)
100% 300 1/0 1/0
60% 350 1/0 2/0
*Lincoln Electric recommends using a minimum of 2/0 welding cable for pulse welding.

POWER WAVE F355i

A-2 INSTALLATION A-2
SAFETY PRECAUTIONS • Initial 380VAC - 415VAC and 575VAC operation
will require an Input voltage panel setup.
WARNING • Open the front door to access “A” lead.
ELECTRIC SHOCK can kill. • Move the "A" lead to the appropriate terminal.
• Turn the input power off at the dis-
connect switch before attempting CAUTION
to connect or disconnect input
power lines, output cables or con- • Incorrect connection may result in equipment
trol cables damage.
• Only qualified personnel should perform this -----------------------------------------------------------------------
installation.
• Connect the green lead of the power cord to
ground per U.S.National Electrical Code. POWER CORD CONNECTION
---------------------------------------------------------------------- A 7ft. 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- F3
55
i
VE
WA
ple preventative measures are followed in order to PO
WER

assure long life and reliable operation.

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

• 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 Three Phase Input
temperatures and nuisance shutdown. Connect green lead to ground per National Electric
• Keep machine dry. Shelter from rain and snow. Do Code.
not place on wet ground or in puddles. Connect black, red and white leads to power.

• 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, all local codes and the
information detailed below.
• When received directly from the factory, multiple
voltage machines are internally connected for
460VAC. If 460VAC is the desired input, then the
machine may be connected to the power system
without any setup required inside the machine.

POWER WAVE F355i

A-3 INSTALLATION A-3
OUTPUT CABLES, CONNECTIONS AND When operating with electrode polarity negative the
LIMITATIONS "Electrode Sense Polarity" DIP switch must be set to the
"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
to achieve the best possible operation, route all cables WARNING
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.

When using an inverter type power source like the • Do not touch electrically hot parts.
Power Waves, use the largest welding (electrode -----------------------------------------------------------
and work) cables that are practical. At least 2/0 1. Turn off power to the power source at the disconnect
copper wire - even if the average output current switch.
would not normally require it. When pulsing, the 2. Remove the front cover from the power source.
pulse current can reach very high levels. Voltage 3. The feed head PC board is on the left side of the power
drops can become excessive, leading to poor source. Locate the 8-position DIP switch and look for
welding characteristics, if undersized welding switch 7 of the DIP switch.(See Figure A.1)
cables are used. 4. Using a pencil or other small object, slide the switch to
------------------------------------------------------------------------ the OFF position for positive electrode polarity.
Most welding applications run with the electrode being Conversely, slide the switch to the ON position for nega-
positive (+). For those applications, connect the elec- tive electrode polarity.
trode cable between the wire feeder and the positive 5. Replace the cover and screws. The PC board will“read”
(+) output Twist-Mate terminal on the power source. the switch at power up, and configure the work voltage
Connect the other end of the electrode cable to the sense lead appropriately.
wire drive feed plate. The electrode cable lug must be
against the feed plate. Be sure the connection to the VOLTAGE SENSING
feed plate makes tight metal-to-metal electrical con- The best arc performance occurs when the PowerWaves
tact. The electrode cable should be sized according to have accurate data about the arc conditions. Depending
the specifications given in the output cable connec- upon the process, inductance within the electrode and work
tions section. Connect a work lead from the negative lead cables can influence the voltage apparent at the studs
(-) power source output Twist-Mate terminal to the of the welder. Voltage sense leads improve the accuracy of
work piece. The work piece connection must be firm the arc conditions and can have a dramatic effect on perfor-
and secure, especially if pulse welding is planned. 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- CAUTION
TY INFORMATION" located in the front of the If the voltage sensing is enabled but the sense
Instruction Manuals. 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
When negative electrode polarity is required, such as POWER WAVE F355i. For more information on the WORK
in some Innershield applications, reverse the output sense lead (21), see"Work Voltage Sensing” in the follow-
connections at the power source (electrode cable to ing paragraph.
the negative (-) Twist-Mate terminal, and work cable
to the positive (+) Twist-Mate terminal.

POWER WAVE F355i

A-4 INSTALLATION A-4
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
control cable to the wire feeder.
CAUTION
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’s default to the may result in extremely high welding outputs.
work stud (work sense lead disabled) ------------------------------------------------------------------------
POWER WAVE / POWER FEED WIRE
For processes requiring work voltage sensing, con-
nect the (21) work voltage sense lead (K940) from the FEEDER INTERCONNECTIONS
Power Wave work sense lead receptacle to the work (See Section F-2 for Connection Diagram)
piece. Attach the sense lead to the work piece as Connect the control cable between the power source
close to the weld as practical, but not in the return cur- and wire feeder. The wire feeder connection on the
rent path. Enable the work voltage sensing in the Power Wave F355i is the 14-pin connector located on
Power Wave as follows: the left side of the machine. The control cable is
keyed and polarized to prevent improper connection.
WARNING
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
-----------------------------------------------------------
The use of non-standard cables, especially in
1. Turn off power to the power source at the dis- lengths greater than 25 feet, can lead to communi-
connect switch. cation problems (system shutdowns), poor motor
acceleration (poor arc starting) and low wire dri-
2. Remove the wrap around cover from the power ving force (wire feeding problems).
source.
HIGH SPEED GEAR BOX
3. The control board is on the center assembly facing
the case front. Locate the 8-position DIP switch and
Changing the ratio requires a gear change and a PC
look for switch 8 of the DIP switch (See Figure A.1).
board switch change. The Power Feed Wire Feeders
are shipped with both high speed and a low speed
4. Using a pencil or other small object, slide the switch
gears. As shipped from the factory, the low speed
to the OFF position if the work sense lead is NOT
(high torque) gear is installed on the feeder. To
connected. Conversely, slide the switch to the ON
change Gear ratio see Power Feed 10/R Instruction
position if the work sense lead is present.
Manual.

POWER WAVE F355i

A-5 INSTALLATION A-5
switch 8 work sense lead
WARNING off work sense lead not connected*
ELECTRIC SHOCK can kill. on work sense lead connected
• Turn the input power OFF at the
disconnect switch or fuse box
Feed Head Board DIP Switch:
before working on this equipment.
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
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) 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 O
8 7 6 5 4 3 2 1

N
switches:

WARNING E F3
55
i

AV
RW
WE
• Turn off power at the disconnect switch. O
N
1
2
3
4
5
6
7
8
PO

------------------------------------------------------------------------ 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 LEASE SIGNIFICANT BIT
2 MOST SIGNIFICANT BIT
POWER WAVE F355i
A-6 INSTALLATION A-6
WELDING WITH MULTIPLE POWER I / O RECEPTACLE SPECIFICATIONS
WAVES
14-Pin Robotic Wire Feeder Connector
CAUTION Pin Lead Function
A 539 Motor +
Special care must be taken when more than one B 541 Motor -
Power Wave is welding simultaneously on a single C 521 Solenoid +
part. Arc blow and arc interference may occur or D 522 Solenoid common
be magnified. E 845 Tach 2A Differential Signal
----------------------------------------------------------------------- F 847 Single Tach input
G 841 +15V Tach Supply
Each power source requires a work lead from the H 844 Tach common
work stud to the welding fixture. Do not combine all of I Open Reserved for future use
the work leads into one lead. The welding travel direc- J GND Shielding drain
tions should be in the direction moving away from the K 842 Tach 1A Differential Signal
work lead as shown below. Connect all of the work L 843 Tach 1B Differential Signal
sense leads from each power source to the work M 846 Tach 2B Differential Signal
piece at the end of the weld. N 67A Electrode Sense (67)

For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power VOLTAGE SENSE RECEPTACLE
Waves. When these parameters are identical, the PIN LEAD# FUNCTION
pulsing frequency will be the same, helping to stabilize 3 21A Work Voltage Sense
the arcs. 1 678 Electrode Voltage Sense

Every welding gun requires a separate shielding gas

regulator for proper flow rate and shielding gas cover- RS232 RECEPTACLE
age. PIN LEAD# FUNCTION
2 253 RS232 Receive
Do not attempt to supply shielding gas for two or more 3 254 RS232 Transmit
guns from only one regulator. 4 # Pin5
5 # Pin4
If an anti-spatter system is in use then each gun must 6 ## Pin20
have its own anti-spatter system. (See Figure A.2 20 ## Pin6
7 251 RS232 Common

FIGURE A.2 POWER WAVE F355i

POWER WAVE F355i

TWO POWER WAVES

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

B-1 OPERATION B-1

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, and pulse welding modes.

ELECTRIC SHOCK can kill. The Power Wave power source is designed to be
used with the Robotic family of Power Feed wire feed-
• Unless using cold feed feature, when ers, operating as a system. Each component in the
feeding with gun trigger, the elec- system has special circuitry to "talk with" the other
trode and drive mechanism are system components, so each component (power
always electrically energized and source, wire feeder Robotic Controller knows what the
could remain energized several sec- other is doing at all times. These components commu-
onds after the welding ceases. nicate with Arc Link.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing. The POWER WAVE F355i is a high performance, dig-
itally controlled inverter welding power source capable
• Insulate yourself from the work and ground. of complex, high-speed waveform control. Properly
• Always wear dry insulating gloves. 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.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove RECOMMENDED PROCESSES AND
fumes from breathing zone. EQUIPMENT
-----------------------------------------------------------
RECOMMENDED PROCESSES
WELDING SPARKS can cause fire or The POWER WAVE F355i can be set up in a number
explosion. of configurations, some requiring optional equipment
• Keep flammable material away. or welding programs. Each machine is factory prepro-
grammed with multiple welding procedures, typically
• Do not weld on containers that have including GMAW, GMAW-P and FCAW for a variety of
held combustibles. materials, including mild steel, stainless steel, cored
wires, and aluminum.

----------------------------------------------------------- The POWER WAVE F355i is recommended for

ARC RAYS can burn. Robotic welding with the Fanuc R-J3i.
• Wear eye, ear, and body protection. • This Power Wave F355i is not recommended for
processes other than those listed.

REQUIRED EQUIPMENT
Observe additional guidelines detailed in the Any Arc Link compatible semi-automatic wire feeding
beginning of this manual. equipment. Specifically, the Power Feed 10 Robotic
Wire drive.

POWER WAVE F355i

B-2 OPERATION B-2
LIMITATIONS 2. HIGH TEMPERATURE LIGHT (thermal overload):
• Only Arc Link compatible Power Feed automatic wire A yellow light that comes on when an over temper-
feeders and users interfaces may be used. Other ature situation occurs. Output is disabled and the
Lincoln wire feeders or non-Lincoln wire feeders can- fan continues to run, until the machine cools down.
not be used. When cool, the light goes out and output is
• POWER WAVE F355i Output Limitations enabled.
The POWER WAVE F355i will support maximum
average output current of 350 Amps @ 60% duty 3. CB1 WIRE FEEDER CIRCUIT BREAKER:
cycle. 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 3
minutes of idling in a ten minute period.
2
CONNECTOR STATUS LIGHTS (Per Fig B.1) 5
1. STATUS LIGHT: A two color light that indicates
system errors. Normal operation is a steady green 1 6
light. Error conditions are indicated, per Table B.1.
NOTE: The POWER WAVE F355i status light will
flash green, and sometimes red and green, for up to
one minute when the machine is first turned on. This 4
is a normal situation as the machine goes through a
self test at power up.
TABLE B.1
Light Meaning
Condition 7 8
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components.
CASE FRONT LAYOUT
Blinking Occurs during a reset, and indicates the POWER WAVE F355i
Green POWER WAVE F355i is mapping (identify- 4. LEAD CONNECTOR (SENSE LEAD)
ing) each component in the system. Normal
for first 1-10 seconds after power is turned 5. DIAGNOSTIC CONNECTOR (RS-232)
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 red and green, errors are present in the 8. POSITIVE TWIST- MATE TERMINAL
POWER WAVE F355i. 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.

Steady Red Non recoverable hardware fault. Generally

indicates nothing is connected to the
POWER WAVE F355i wire feeder recepta-
cle. See Trouble Shooting Section.

Blinking Red Not applicable.

POWER WAVE F355i

B-3 OPERATION B-3

NOMINAL PROCEDURES In non-synergic modes, the WFS control behaves

The Power Wave is designed to operate with 3/4" more like a conventional CV power source where
electrode stick-out for CV and Pulse processes. WFS and voltage are independent adjustments.
Therefore to maintain the arc characteristics, the oper-
FRINGE PROCEDURES ator must adjust the voltage to compensate for any
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 (synergic CV, 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.
CONSTANT VOLTAGE WELDING
To make a weld, the Power Wave needs to know the
Synergic CV:
desired welding parameters. The Power Feed (PF)
For each wire feed speed, a corresponding voltage is
family of feeders communicate settings to the Power
preprogrammed into the machine through special soft-
Wave through control cable connection. Arc length,
ware at the factory. The nominal preprogrammed volt-
wire feed speed, arc control, etc. are all communicat-
age is the best average voltage for a given wire feed
ed digitally via the control cable.
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automati-
• WFS / AMPS:
cally adjusts the voltage level correspondingly to
In synergic welding modes (synergic CV, pulse
maintain similar arc characteristics throughout the
GMAW) WFS (wire feed speed) is the dominant con-
WFS range.
trol 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) accord-
ing to pre-programmed settings contained in the
Power Wave.

POWER WAVE F355i

B-4 OPERATION B-4
Non Synergic CV:
This type of CV mode behaves more like a conven- The Power Wave utilizes "adaptive control" to com-
tional CV power source. Voltage and WFS are inde- pensate for changes in electrical stick-out while weld-
pendent adjustments. Therefore to maintain the arc ing. (Electrical stick-out is the distance from the con-
characteristics, the operator must adjust the voltage to tact tip to the work piece.) The Power Wave wave-
compensate for any changes made to the WFS. forms are optimized for a 0.75" (19mm) stick-out. The
adaptive behavior supports a range of stickouts from
All CV Modes: 0.50" (13mm) to 1.25" (32mm). At very low or high
Arc Control, often referred to as wave control, adjusts wire feed speeds, the adaptive range may be less due
the inductance of the wave shape. The wave control to reaching physical limitations of the welding process.
adjustment is similar to the "pinch" function in that it is
inversely proportional to inductance. Therefore, Arc Control, often referred to as wave control, in pulse
increasing wave control greater than 0.0 results in a programs usually adjusts the focus or shape of the
harsher, colder arc while decreasing the wave control arc. Wave control values greater than 0.0 increase the
to less than 0.0 provides a softer, hotter arc. pulse frequency while decreasing the background cur-
(See Figure B.2) rent, resulting in a tight, stiff arc best for high speed
sheet metal welding. Wave control values less than
FIGURE B.2 0.0 decrease the pulse frequency while increasing the
CURRENT WAVE FORM (CV) background current, for a soft arc good for out-of-posi-
tion welding.
(See Figure B.3)

FIGURE B.3
CURRENT WAVE FORM (PULSE)

Current Current

Time
PULSE WELDING Time
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 impracti-
cal, and instead the arc length is set by adjusting
"trim".

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.

Most pulse welding programs are synergic. As the

wire feed speed is adjusted, the Power Wave will
automatically recalculate the waveform parameters to
maintain similar arc properties.

POWER WAVE F355i

C-1 ACCESSORIES C-1
OPTIONAL EQUIPMENT

FACTORY INSTALLED
None Available.

FIELD INSTALLED
K940-Work Voltage Sense Lead Kit
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)

POWER WAVE F355i

D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS PERIODIC MAINTENANCE
WARNING Calibration of the POWER WAVE F355i is critical to
ELECTRIC SHOCK can kill. its operation. Generally speaking the calibration will
• Do not touch electrically live parts or not need adjustment. However, neglected or improp-
electrode with skin or wet clothing. erly calibrated machines may not yield satisfactory
• 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.
• Failed parts can explode or cause other
CALIBRATION SPECIFICATION
parts to explode when power is applied. Output Voltage and Current are calibrated at the fac-
• Always wear a face shield and long tory. Generally speaking the machine calibration will
sleeves when servicing. not need adjustment. However, if the weld perfor-
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

E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
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

E-2 TROUBLESHOOTING E-2

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 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 Occurs during a reset, and indicates the

Green POWER WAVE F355i is mapping (identify-
ing) 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 red and green, errors are present in the
POWER WAVE F355i. 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.

Steady Red Non recoverable hardware fault. Generally

indicates nothing is connected to the
POWER WAVE F355i wire feeder recepta-
cle. See Trouble Shooting Section.

Blinking Red Not applicable.

POWER WAVE F355i

E-3 TROUBLESHOOTING E-3
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 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.
12 User Interface time out error. 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.

21 Unprogrammed Weld Mode. Contact the Service Department for instructions on reloading the
Welding Software.
22 Empty Weld Table. Contact the Service Department for instructions on reloading the
Welding Software.
23 Weld Table checksum error. Contact the Service Department for instructions on reloading the
Welding Software.
31 Primary overcurrent error. Excessive Primary current present. May be related to a short in the
main transformer or output rectifier.
32 Capacitor "A" under voltage Low voltage on the main capacitors. May be caused by improper
input configuration.
33 Capacitor "B" under voltage 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.
34 Capacitor "A" over voltage Excess voltage on the main capacitors. May be caused by improp-
er input configuration.

35 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.

36 Thermal error Indicates over temperature. Usually accompanied by Thermal LED.

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.

43 Capacitor delta error The maximum voltage difference between the main capacitors has
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
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) 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
cycle, or both.
3. There is internal damage to
the power source. Contact an If all recommended possible areas
authorized Lincoln Electric of misadjustments have been
Service facility. checked and the problem persists,
contact your local Lincoln
Machine will not power up (no 1. Make certain that the Power Authorized Field Service Facility.
lights, no fan, etc.) to the Power Wave F355i 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. Also, check input volt-
age selection, below.
4. Input voltage selection made
improperly. Power down,
check input voltage reconnect
according to diagram on
reconnect cover.

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

E-5 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) 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
output. high. Make certain that input If all recommended possible areas
voltage is proper, according to of misadjustments have been
the Rating Plate located on the checked and the problem persists,
rear of the machine. contact your local Lincoln
2. If the Thermal LED is also lit, Authorized Field Service Facility.
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

E-6 TROUBLESHOOTING E-6
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) 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.

For no apparent reason, the weld- 1. Check for proper Wire Feed If all recommended possible areas
ing characteristics have changed. Speed setting. In CV MIG and of misadjustments have been
FCAW modes, check for proper checked and the problem persists,
Voltage setting. In the MIG/MAG contact your local Lincoln
pulse modes, check the Trim Authorized Field Service Facility.
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

E-7 TROUBLESHOOTING E-7
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) 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
 F-1

WIRING DIAGRAM POWER WAVE F355i

RIGHT SIDE OF MACHINE
B
INPUT R
C1,C3 504 502
W +
G 206 3200/300 203
SWITCH xxxxxxx
66C
607 J20 65C 2 4 40VDC BUS
205 208 J46
615 5 1 1 3
716 65 BOARD
715 6 2 1010
4 8 1020 153 66
611 209 1002 1020
612 7 3 610 1105 1104 4 8
609 3 7 605 21 1001 1010 154 52
602 8 4 J21 608 3 7
2 6 616 477 J47
1001 903 3 6 1 1 1 2 2 6
1 5 1002 J9 475
2 5 2 2 3 4 1 5
J22 51
1 2 204 201 901 1 4
504 67A J10A J10B J11
3 4 201 8 L7
4

xxxxxxx
202 3200/300 804
207 205 J8
505 3 7
FAN FAN L6 TO ROBOTIC CONTROLLER
31 32 +C2,C4 802 2 6

UT
806
1 5

I-O
I-IN
Pin 3 lead 31B or 31C B 801 CONTROL

PR
PR
Pin 4 lead 32A or 532A 886 54 2 4
6 2B 8 16 BOARD J81 FEED HEAD P.C. BOARD
716 J7 53 1 3
2W 7 15 ~
2 715 154 2 4
C X2 52

+
SE
-
880 153 1 3 J82
204 3 ~
FANFAN 7 51
1B 4 521 3 6

UT
X3 886

I-O
1W 3 541 2 5

PR
208 X1 880
J83
FAN J1 539 1 4

I-IN
PR
CHOKE 522
xxxxxxx 844 4 8
C 505 608 8 16 J6 847
616 843 3 7
SE 506 607 7 15 J84
A 615 842 2 6
503 6 14 846
MAIN 841 1 5
( 380-575VAC POSITION ) X4 605 5 13 845
TRANSFORMER 610
4 12 J85
A 612 J87
CB3 INPUT 3 11 J86
A A BRIDGE 611

REAR OF MACHINE
602 2 10 16 15 14 13 12 11 10 9 7 16 15 14 13 12 11 10 9
10 9 8 6
209 + B
N.B. 1 9 8 7 6 5 4 3 2 1 3 2 6 5 4 1
A TP3 609 5 4 1 8 7 3 2
D TP1 253
H4 J2
380- _ 502 2 4 J5 3 1 251
415V R 503
1 3 4 2
B TP2 J4 J3 254 253 251
254
WIRE FEEDER
550- 440- _ 12 11 10 9 8 7 10 9 8 7 6 RECEPTACLE
575V 460V 207 W 1 13
H6 H5 F C H1 X4 X2 OUTPUT 6 5 4 3 2 1 5 4 3 2 1

RECTIFIER 67B
406 405 14 25
403A 408 407
412 411 410 402 401A 844 841
67A 846 VOLTAGE SENSE
2B 67B RECEPTACLE
H1 H2 H3 H4 H5 H6
THERMAL 842 H 847
40 20 G
AUXILIARY S L3 YELLOW F
TRANSFORMER N LED
I N 1
U 2W M

42V
845

115V
GND-A J

COM2
COM1
SNB B K E
B 41
L D 3 2
DIAGRAMS

E 1B STATUS
A B 21
1104
R 1103 539 C 522 4

POWER WAVE F355i

5 8 ~ 66C 65C
401 RED/GREEN
J52 541 843

+
-
66 65
LED 521
42 COM1A ~ 405 R2

401A
32 31 CB1 407 410 401 1W
66B C5 402 403
2400/80
412 411 408 475 477 403 406
41
~ 10 COLOR CODE:
65B 1 2 3 1 2 1 2 3 4 5 6 B = BLACK
42 CONTROL 4 5 6 3 4 7 8 9 10 11 12 403A _ G = GREEN
+

R1 R = RED
RECTIFIER J42 J41 J43 POWER 903 903B 901B
W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
CURRENT J90
1 234 FRONT VIEW OF MACHINE
TRANSDUCER 901 LEGEND

802
804
801
806
LEFT SIDE OF MACHINE ALL MACHINES
NOTES: OPTION
N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING COMPONENT OUTLINE
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.B. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. J2,J5,J11, J8,
CONNECTION SHOWN IS FOR 550-575V OPERATION. J22, J41, J20,J21,
J1,J6,J7, J10A,
J52, J86 J46, J81, J47, J84
J85, J87 J9, J42, J83 J43 J10B
TOP CENTER FAN CASE BASE 1 8 1 5
J82
1 2 1 3 1 4 1 6 1
PANEL SHROUD FRONT
PROTECTIVE BONDING CIRCUIT 9 16 10 3 4 5 8 7 12
6 4 6 2

CONNECTOR CAVITY NUMBERING SEQUENCE

ELECTRICAL SYMBOLS PER E1537 (VIEWED FROM COMPONENT SIDE OF BOARD)
A

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 CONNECTION DIAGRAM F-2
Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, CV / Pulse Configuration shown)
SEE SECTION A-4, Power Wave / Power Feed Wire
Feeder Interconnections

POWER WAVE F355i

VOLTAGE SENSE LEADS

(OPTIONAL) K940

TO WIRE
WORK FEEDER

CONTROL CABLE K1785

FANUC R-J3i

POWER WAVE F355i

 .40
F-3

10.06

.81

17.20

.51

25.15
27.60
3.37

POWER WAVE F355i

DIMENSION PRINT

14.64

A
M19982
F-3
 NOTES

POWER WAVE F355i

Now Available...12th Edition New Lessons in Arc Welding
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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The book contains the latest information and application
“hands on”
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and For details write: Lincoln Welding School
draftsmen use the “short-cut” language of symbols to pass 22801 St. Clair Ave.
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.

Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear Welding School Registrar.
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Lincoln Welding School Titles: Price Code Quantity Cost

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 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION ● Aislese del trabajo y de la tierra.

French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.

German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● 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.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● 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
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 • 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