Lincoln Electric Power Wave K4352 User manual

Operator’s Manual
Power Wave ® Communication Kit
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10460-A te Jun - 22aDeussI|
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
K4352
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

Page
POWER WAVE R450...................................................................................................................................1
POWER WAVE R500.................................................................................................................................11
POWER WAVE R350.................................................................................................................................21
POWER WAVE S500 ................................................................................................................................27
POWER WAVE S350 CODES 11694, 11753, 11782, 12371 & 12394....................................................... 37
POWER WAVE S350 CODES 11589, 11625 & 11783............................................................................... 47
LIMITED WARRANT ...............................................................................................................................61
Content/details may be changed or updated without notice. For most current Instruction Manuals, go
to parts.lincolnelectric.com.
DIGITAL DISPLAY.....................................................................................................................................57

1
INSTALLATION INSTRUCTIONS:
WARNING
CAN KILL
ELECTRIC SHOCK
Disconnect input power before servicing.
Do not operate with covers removed.
Do not touch electrically live parts.
Only qualified persons should install, use
or service this equipment.
OVERVIEW:
This kit provides all necessary hardware to install a K4352 Power Wave
Communication Kit for use on a Power Wave R450.
INSTRUCTIONS FOR INSTALLING K4352
POWER WAVE COMMUNICATION KIT ON
A POWER WAVE R450 (ALL CODES)
Parts List Required for Installation on Power Wave R450:
Parts List Required for Installation on other machines:
Item Part Number Description Qty
1 G9015 Power Wave Communication Module Asbly 1
Item Part Number Description Qty
2 S18250-1107 Plug & Lead Assembly (4-pin plug / 4-pin plug) 1
3 S18250-1112 Plug & Lead Assembly (4-pin plug / 6-pin receptacle) 1
4 S18250-1117 Plug & Lead Assembly (4-pin plug / 6-pin plug) 1

Power Wave Communication Kit Installation Instructions
Recommended Tools:
•5/16” nut driver or other suitable tools
CAUTION : PC BOARD CAN BE DAMAGED BY STATIC ELECTRICITY
Before making any connections to a PC board, remove your body’s static charge by touching unpainted
grounded frame of equipment.
INSTALLATION:
1. Turn off input power to the Power Wave at the disconnect switch or fuse box before working
on the Power Wave.
2. Remove the weld cables from the output studs, and disconnect all control cables including the
Ethernet connection from the Power Wave.
3. Remove the UI cover plate by removing the four screws fastening the cover plate to the power
source using a 5/16” nut driver or other suitable tool (Figure 1). Retain the mounting hardware
removed for installing the Power Wave Communication Kit.
4. Remove the two top left Corner Caps by removing the screws and washers mounting them,
using a 5/16” nut driver or other suitable tool (Figure 2). Retain all mounting hardware for
reinstalling the Corner Caps.
5. Remove the bottom left Corner Cap fasteners, two places, using a 5/16” nut driver or other
suitable tool (Figure 2). Retain all mounting hardware for reinstalling the Corner Caps.
6. Remove the left case side by removing the four screws mounting them, using a 5/16” nut driver
or other suitable tool (Figure 3). Retain all mounting hardware for case side.
7. Obtain Item 1 Power Wave Communication Module provided with the kit. Route the 4-pin
connector P30 of the Power Wave R450 harness thru the case front, and to J30 of Item 1Power
Wave Communication Module (Figure 4).
8. Install the Power Wave Communication Module to the Case Front using the hardware removed
from cover plate in Step 3, using a 5/16” nut driver or other suitable tool (Figure 5).
9. Install the left case side using the hardware removed from mounting the left case side in Step 6
using a 5/16” nut driver or other suitable tool (Figure 6).
10. Install the bottom left Corner Caps using the hardware removed from mounting the corner caps
in Step 5, using a 5/16” nut driver or other suitable tool (Figure 7).
11. Install the top left Corner Caps by using the hardware removed from mounting the Corner Caps
in step 5, using a 5/16” nut driver or other suitable tool (Figure 8).
12. Replace the weld cables from the output studs, and reconnect all control cables including the
Ethernet connection from the Power Wave.
13. The WiFi and Bluetooth are disabled as shipped from the factory.
14. After installing the K4352 Power Wave Communication Kit, the Power Wave firmware
may need to be updated. Visit www.powerwavesoftware.com for firmware updates and
the Power Wave Utilities. Included with Power Wave Utilities are the Power Wave
Manager PC tool for setting up the wireless or Bluetooth connection, and the Help Me
Connect guide for setup instructions.
2
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

REMOVE COVER PLATE
10-24 X .50 SCREWS, (QTY 4)
FIGURE 1
3
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 2
REMOVE TOP LEFT CORNER CAPS (2)
10-24 X .75 SCREWS (QTY 6)
#10 WASHERS (QTY 6)
REMOVE BOTTOM LEFT CORNER CAP FASTENERS
10-24 X .75 SCREWS (QTY 2)
#10 WASHERS (QTY 2)
4
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 3
REMOVE LEFT CASE SIDE
10-24 X .50 SCREWS (QTY 4)
5
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 4
PC BOARD
J30
1
2
3
4
358A 356A
53E54E
ROUTE THE 4-PIN CONNECTOR
P30 OF THE POWER WAVE
R450 HARNESS THRU THE
CASE FRONT, AND INSTALL
TO J30 OF ITEM 1 COMMUNICATION
MODULE ASSEMBLY PC BOARD
P30
ITEM 1 COMMUNICATION
MODULE ASSEMBLY
REMOVE
INSTRUCTION TAG
6
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 5
INSTALL THE COMMUNICATION
MODULE ASSEMBLY TO THE CASE
FRONT USING THE HARDWARE
REMOVED FROM COVER PLATE
10-24 X .50 SCREWS (QTY 4)
7
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 6
INSTALL LEFT CASE SIDE
10-24 X .50 SCREWS (QTY 4)
8
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 7
INSTALL BOTTOM LEFT CORNER CAP FASTENERS
10-24 X .75 SCREWS (QTY 2)
#10 WASHERS (QTY 2)
9
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

FIGURE 8
INSTALL TOP LEFT CORNER CAPS (2)
10-24 X .75 SCREWS (QTY 6)
#10 WASHERS (QTY 6)
10
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R450 (ALL CODES)

INSTALLATION INSTRUCTIONS:
WARNING
CAN KILL
ELECTRIC SHOCK
Disconnect input power before servicing.
Do not operate with covers removed.
Do not touch electrically live parts.
Only qualified persons should install, use
or service this equipment.
OVERVIEW:
This kit provides all necessary hardware to install a K4352 Power Wave
Communication Kit for use on a Power Wave R500.
INSTRUCTIONS FOR INSTALLING K4352
POWER WAVE COMMUNICATION KIT
ON A POWER WAVE R500
Parts List Required for Installation on Power Wave R500:
Parts List Required for Installation on other machines:
Item Part Number Description Qty
1 G9015 Power Wave Communication Module Asbly 1
2 S18250-1107 Plug & Lead Assembly (4-pin plug / 4-pin plug) 1
Item Part Number Description Qty
3 S18250-1112 Plug & Lead Assembly (4-pin plug / 6-pin receptacle) 1
4 S18250-1117 Plug & Lead Assembly (4-pin plug / 6-pin plug) 1
11

Power Wave Communication Kit Installation Instructions
Recommended Tools:
•5/16” nut driver or other suitable tools
•7/16” nut driver or other suitable tools
CAUTION : PC BOARD CAN BE DAMAGED BY STATIC ELECTRICITY
Before making any connections to a PC board, remove your body’s static charge by touching unpainted
grounded frame of equipment.
INSTALLATION:
1. Turn off input power to the Power Wave at the disconnect switch or fuse box before working
on the Power Wave.
2. Remove the weld cables from the output studs, and disconnect all control cables including the
Ethernet connection from the Power Wave.
3. Remove the UI cover plate by removing the four screws fastening the cover plate to the power
source using a 5/16
”
nut driver or other suitable tool (Figure 1). Retain the mounting hardware
removed for installing the Power Wave Communication Kit.
4. Remove the four top Corner Caps by removing the screws and washers mounting them, using
a 5/16” nut driver or other suitable tool (Figure 2). Retain all mounting hardware for
reinstalling the Corner Caps.
5. Remove the two handles by removing the screws and lock washers mounting them, using a
7/16” nut driver or other suitable tool (Figure 3). Retain all mounting hardware for
reinstalling the handles.
6. Remove the roof by removing the two screws, using a 5/16” nut driver or other suitable tool
(Figure 4). Retain all hardware for reinstalling the roof.
7. Position roof as shown in Figure 5. Obtain Item 2 plug & lead assembly (S18250-1107, 4 pin
plug / 4 pin plug) provided with the kit. Install the 4 pin connector of the plug & lead assembly
to J81 of the Feedhead PC Board located on the roof. Route the other end of the plug & lead
assembly thru the case front as shown.
8. Obtain Item 1 Power Wave Communication Module provided with the kit. Connect Item 2
plug & lead assembly to J30 of Item 1 Power Wave Communication Module (Figure 6).
9. Install the Power Wave Communication Module to the Case Front using the hardware removed
from cover plate in Step 3, using a 5/16” nut driver or other suitable tool (Figure 7).
10. Install the roof using the hardware removed from roof in Step 6, using a 5/16” nut driver or
other suitable tool (Figure 8).
11. Install the top four Corner Caps using the hardware removed from mounting the corner caps in
Step 4, using a 5/16” nut driver or other suitable tool (Figure 9).
12. Install the two handles using the hardware removed from mounting the handles in step 5, using
a 7/16” nut driver or other suitable tool (Figure 10).
13. Replace the weld cables from the output studs, and reconnect all control cables including the
Ethernet connection from the Power Wave.
14. The WiFi and Bluetooth are disabled as shipped from the factory.
15. After installing the K4352 Power Wave Communication Kit, the Power Wave firmware
may need to be updated. Visit www.powerwavesoftware.com for firmware updates and
the Power Wave Utilities. Included with Power Wave Utilities are the Power Wave
Manager PC tool for setting up the wireless or Bluetooth connection, and the Help Me
Connect guide for setup instructions.
12
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

FIGURE 1
REMOVE COVER PLATE
10-24 X .50 SCREWS, (QTY 4)
13
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

REMOVE CORNER CAPS
10-24 X .75 SCREWS (QTY 12)
#10 WASHERS (QTY 12)
FIGURE 2
14
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

FIGURE 3
REMOVE HANDLES
1/4-20 x .75 SCREWS (QTY 8)
1/4" LOCKWASHERS (QTY 8)
15
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

FIGURE 4
REMOVE ROOF
10-24 X .50 SCREWS (QTY 2)
16
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

FIGURE 5
INSTALL THE 4-PIN CONNECTOR
OF ITEM 2 PLUG & LEAD ASSEMBLY
INTO J81 OF FEEDHEAD PC BOARD
FEEDHEAD PC BOARD
J81
ROOF
ROUTE THE OTHER END OF
THE 4-PIN CONNECTOR OF
ITEM 2 PLUG & LEAD ASSEMBLY
THRU CASE FRONT AS SHOWN
17
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500

FIGURE 6
INSTALL THE OTHER END OF
THE 4-PIN CONNECTOR OF
ITEM 2 PLUG & LEAD ASSEMBLY
INTO J30 OF ITEM 1
COMMUNICATION MODULE
ASSEMBLY PC BOARD
J30
PC BOARD
ITEM 1 COMMUNICATION
MODULE ASSEMBLY
REMOVE
INSTRUCTION TAG
18
K4352 POWER WAVE COMMUNICATION KIT
POWER WAVE R500
P30
54E
21
S24017-4 (INSERTION SIDE)
3
4
52E 51E
53E