Lincoln Electric R350 User Manual

IM10083

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POWER WAVE R350

For use with machines having Code Numbers:

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 thoughtful 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.

11745

®

October, 2010

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii

SAFETY

ii

ELECTRIC SHOCK can
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.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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.

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.

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.

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.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
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 within applicable OSHA PEL and
ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. 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.

vapors

to

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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.

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.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

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

6.f.
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.

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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.

7.c. Cylinders should be located:

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

physical damage.

• 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.

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.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

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 suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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.

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

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent 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 nʼimporte quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

Thank You

vv

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications ...............................................................................................A-1, A-2

Safety Precautions ...............................................................................................................A-3

Location, Lifting .............................................................................................................A-3

Stacking ........................................................................................................................A-3

Tilting.............................................................................................................................A-3

Input and Ground Connections .....................................................................................A-3

Machine Grounding.......................................................................................................A-3

High Frequency Protection............................................................................................A-3

Input Connection ..................................................................................................................A-4

Input Fuse and Supply Wire..........................................................................................A-4

Input Voltage Selection .................................................................................................A-4

Power Cord Replacement .............................................................................................A-4

Connection Diagram .....................................................................................................A-5

Recommended Work Cable Sizes ................................................................................A-6

Cable Inductance and its Effects on Welding................................................................A-7

Remote Sense Lead Specifications.......................................................................A-7, A-8

Voltage Sensing Considerations for Multiple Arc Systems..................................A-9, A-10

Control Cable Connections ................................................................................................A-11

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Power-Up Sequence .....................................................................................................B-1

Duty Cycle.....................................................................................................................B-1

Graphic Symbols...........................................................................................................B-1

Product Description ..............................................................................................................B-2

Recommended Processes and Equipment ..........................................................................B-2

Equipment Limitations ..........................................................................................................B-2

Design Features ...................................................................................................................B-3

Case Front Controls .............................................................................................................B-3

Case Back Controls..............................................................................................................B-4

Common Welding Procedures................................................................................B-5 thru B-7

________________________________________________________________________________

vivi

Accessories.....................................................................................................Section C

Kits, Options / Accessories....................................................................................C-1

Field Installed Options...........................................................................................C-1

TIG and MIG Options ...........................................................................................C-1

________________________________________________________________________

Maintenance........................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

Periodic Maintenance...........................................................................................................D-1

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Using Status LED, Error Fault Codes, Input Control Board, Wire Drive Module ..........E-2, E-4

Troubleshooting Guide.............................................................................E-5 thru E-8

________________________________________________________________________________

Wiring Diagram and Dimension Print............................................................Section F

________________________________________________________________________

Parts Pages ...............................................................................................................P-664 Series

_______________________________________________________________________

________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE® R350

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

Duty Cycle

Input Voltage ± 10%

Input Amperes

(1 Phase in parenthesis)

Idle Power

A-1

Power Factor @

Rated Output

K3022-1

40% rating

208/230/380-415/460/575

50/60 Hz

100% rating

39/35/19/17/14

(60/67*/NA/NA/NA)

31/28/15/14/11

(60/53/NA/NA/NA)

300 Watts Max.

(fan on)

RATED OUTPUT

INPUT

VOLTAGE/PHASE/

FREQUENCY

200-208/1/50/60

230/1/50/60*

200-208/3/50/60

230/3/50/60

380-415/3/50/60

460/3/50/60
575/3/50/60

* On 230 Volt / 1 phase inputs the max. rating is at a duty cycle of 30%, except for GTAW processes.

40%

350 Amps

31.5 Volts

RECOMMENDED INPUT WIRE AND FUSE SIZES

GMAW

60%

300 Amps / 29 Volts

320 Amps

30 Volts

300 Amps

29 Volts

100%

40%

350 Amps

24 Volts

GTAW-DC

60%

325 Amps

23 Volts

1

.95

100%

300 Amps

22 Volts

INPUT

VOLTAGE / PHASE/

FREQUENCY

200-208/1/50/60
200-208/3/50/60

230/1/50/60

230/3/50/60
380-415/1/50/60
380-415/3/50/60

460/1/50/60

460/3/50/60

575/1/50/60

575/3/50/60

1. Based on U.S. National electrical Code

2. Also called " inverse time" or "thermal / magnetic" circuit breakers; circuit breakers that have a delay in trip-

ping action that decreases as the magnitude of the current increases

3. Type SO cord or similar in 30° C ambient

4. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.

ING AND DUTY CYCLE

MAXIMUM

INPUT AMPERE RAT-

60A, 100%
39A, 40%

67A, 30%
35A, 40%
38A, 40%
19A, 40%

34A, 40%
17A, 40%
27A, 40%

14A, 40%

CORD SIZE

AWG SIZES

(mm2)

6 (13)
8 (10)

4 (16)
8 (10)

8 (10)

12 (4)
8 (10)

12 (4)
10 (6)

14 (2.5)

3

TIME DELAY FUSE

OR BREAKER

AMPERAGE

80
50
80
45
50
30

45
25
35

20

2

POWER WAVE® R350

A-2

MODEL

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

HEIGHT

INSTALLATION

WELDING PROCESS

OUTPUT RANGE (AMPERES)

40-350A

5-350A

PHYSICAL DIMENSIONS

WIDTH

OCV (Uo)

Mean Peak

40-70V

24V

DEPTH

A-2

100V

WEIGHT

K3022-1

20.40 in ( 518 mm)

14.00in ( 356 mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.

24.80in ( 630mm)

STORAGE TEMPERATURE RANGE

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

85 lbs (39 kg)*

Thermal tests have been performed at ambient tem­perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

POWER WAVE® R350

A-3

INSTALLATION

A-3

SAFETY PRECAUTIONS Read this

entire installation section before you start installa­tion.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding system
at the disconnect switch or fuse box before work­ing on the equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE® R350

grounding lug to a proper safety (Earth) ground.

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

SELECT SUITABLE LOCATION

The POWER WAVE® R350 will operate in harsh envi­ronments. Even so, it is important that simple preven­tative measures are followed in order to assure long
life and reliable operation.

LIFTING

Both handles should be used when lifting POWER WAVE®
R350. When using a crane or overhead device a lifting strap
should be connected to both handles. Do not attempt to lift the
POWER WAVE® R350 with accessories attached to it.

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

• Do not operate machine while
suspended when lifting.

FALLING

EQUIPMENT can

cause injury.

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

STACKING

The POWER WAVE® R350 cannot 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.

• The machine must be located where there is free
circulation of clean air such that air movement in
the back, out the sides and bottom will not be
restricted.

• Dirt and dust that can be drawn into the machine
should be kept to a minimum. The use of air filters
on the air intake is not recommended because nor­mal air flow may be restricted. 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 the POWER WAVE® R350 over
combustible surfaces. Where there is a com­bustible surface directly under stationary or fixed
electrical equipment, that surface shall be covered
with a steel plate at least .060” (1.6mm) thick,
which shall extend not less than 5.90” (150mm)
beyond the equipment on all sides.

INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the POWER
WAVE® R350. Installation should be made in accordance with
the appropriate National Electrical Code, all local codes and
the information in this manual.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal
marked with a ground symbol is located next to the input
power connection block.

See your local and national electrical codes for proper ground­ing methods.

HIGH FREQUENCY PROTECTION

Locate the POWER WAVE® R350 away from radio controlled
machinery. The normal operation of the POWER WAVE® R350
may adversely affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the equipment.

POWER WAVE® R350

A-4

CONNECTION
BLOCK

GROUND
LUG

INPUT
POWER
CORD

INSTALLATION

A-4

INPUT CONNECTION

WARNING

Only a qualified electrician should
connect the input leads to the
POWER WAVE® R350. Connections
should be made in accordance with

all local and national electrical
codes and the connection diagrams. Failure to do
so may result in bodily injury or death.

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

A 10 ft. (3.1m) power cord is provided and wired into
the machine. Follow the power cord connection
instructions.

For Single Phase Input

Connect green lead to ground per National Electrical
Code.

Connect black and white leads to power.

Wrap red lead with tape to provide 600V insulation.

For Three Phase Input

Connect green lead to ground per National Electric
Code.

Connect black, red and white leads to power.

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

Refer to Specification Section for recommended fuse,
wire sizes and type of the copper wires. Fuse the
input circuit with the recommended super lag fuse or
delay type breakers (also called "inverse time" or
"thermal/magnetic" circuit breakers). Choose input
and grounding wire size according to local or national
electrical codes. Using input wire sizes, fuses or cir­cuit breakers smaller than recommended may result in
"nuisance" shut-offs from welder inrush currents, even
if the machine is not being used at high currents.

WARNING

The POWER WAVE® R350 ON/OFF
switch is not intended as a service
disconnect for this equipment. Only

a qualified electrician should con­nect the input leads to the POWER WAVE® R350.
Connections should be made in accordance with
all local and national electrical codes and the con­nection diagram located on the inside of the
reconnect access door of the machine. Failure to
do so may result in bodily injury or death.

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

POWER CORD REPLACEMENT

WARNING

Only a qualified electrician should
connect the input leads to the
POWER WAVE® R350. Connections
should be made in accordance with
all local and national electrical

codes and the connection dia­grams. Failure to do so may result in bodily injury
or death.

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

If the input power cord is damaged or needs to be
replaced an input power connection block is located
in the back of the machine with the access panel
removed as shown Figure A.1.

ALWAYS CONNECT THE POWER WAVE GROUND-
ING LUG (LOCATED AS SHOWN IN FIGURE A.1)
TO A PROPER SAFETY (EARTH) GROUND AND
ENSURE IT IS APPROXIMATELY 3" LONGER THAN
PHASE LEADS."

FIGURE A.1

INPUT VOLTAGE SELECTION

The POWER WAVE® R350 automatically adjusts to
work with different input voltages. No reconnect
switches settings are required.

POWER WAVE® R350

A-5

INSTALLATION

CONNECTION DIAGRAM

GMAW (MIG) WELDING

An arclink compatible wire feeder is recommended for
Mig welding. Refer to Figure A.2 for the connection
details.

FIGURE A.2

REGULATOR
FLOWMETER

A-5

MIG PROCESS

PF10-M

WIRE FEEDER

GAS HOSE

ARCLINK CABLE
K1543-[XX]

TO POSITIVE
(+) STUD

TO NEGATIVE (-) STUD

WORK CLAMP

WORK PIECE

POWER WAVE® R350

A-6

INSTALLATION

A-6

RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING

Connect the electrode and work cables between the
appropriate output studs of the POWER WAVE R350
per the following guidelines:

• Most welding applications run with the electrode
being positive (+). For those applications, connect
the electrode cable between the wire drive feed plate
and the positive (+) output stud on the power source.
Connect a work lead from the negative (-) power
source output stud to the work piece

• 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 (-) stud, and work cable to the posi­tive (+) stud).

CAUTION

Negative electrode polarity operation WITHOUT
use of a remote work sense lead (21) requires the
Negative Electrode Polarity attribute to be set. See
the Remote Sense Lead Specification section of
this document for further details.

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

For additional Safety information regarding the elec­trode and work cable set-up, See the standard
“SAFETY INFORMATION” located in the front of this
Instruction Manual.

OUTPUT CABLE GUIDELINES (Table A.1)

General Guidelines

• Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive volt-

age drops caused by undersized welding cables and
poor connections often result in unsatisfactory weld­ing performance. Always use the largest welding
cables (electrode and work) that are practical, and
be sure all connections are clean and tight.

Note: Excessive heat in the weld circuit indicates
undersized cables and/or bad connections.

• Route all cables directly to the work and wire

feeder, avoid excessive lengths and do not coil
excess cable. Route the electrode and work cables

in close proximity to one another to minimize the
loop area and therefore the inductance of the weld
circuit.

• Always weld in a direction away from the work

(ground) connection.

Table A.1 shows copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable drop.

Percent Duty

Amperes

200

200

250

250

250

250

300

300

350

** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may

require cables larger than recommended, or cables rated higher than 167°F (75°C).

Cycle

60

100

30

40

60

100

60

100

40

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**

0 to 50 Ft.

2

2

3

2

1

1

1

2/0

1/0

50 to 100 Ft.

2

2

3

2

1

1

1

2/0

1/0

100 to 150 Ft.

2

2

2

1

1

1

1

2/0

2/0

150 to 200 Ft.

1

1

1

1

1

1

1/0

2/0

2/0

200 to 250 Ft.

1/0

1/0

1/0

1/0

1/0

1/0

2/0

3/0

3/0

POWER WAVE® R350

A-7

INSTALLATION

CABLE INDUCTANCE AND ITS
EFFECTS ON WELDING

Excessive cable inductance will cause the welding
performance to degrade. There are several factors
that contribute to the overall inductance of the cabling
system including cable size, and loop area. The loop
area is defined by the separation distance between
the electrode and work cables, and the overall welding
loop length. The welding loop length is defined as the
total of length of the electrode cable (A) + work cable
(B) + work path (C) (See Figure A.6).

To minimize inductance always use the appropriate
size cables, and whenever possible, run the electrode
and work cables in close proximity to one another to
minimize the loop area. Since the most significant fac­tor in cable inductance is the welding loop length,
avoid excessive lengths and do not coil excess cable.
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length as
short as possible.

REMOTE SENSE LEAD
SPECIFICATIONS

Voltage Sensing Overview

A-7

Depending upon the process, inductance within the
electrode and work cables can influence the voltage
apparent at the studs of the welder, and have a dra­matic effect on performance. Remote voltage sense
leads are used to improve the accuracy of the arc volt­age information supplied to the control pc board.
Sense Lead Kits (K940-xx) are available for this pur­pose.

The POWER WAVE R350 has the ability to automati­cally sense when remote sense leads are connected.
With this feature there are no requirements for setting­up the machine to use remote sense leads. This fea­ture can be disabled through the Diagnostics Utility
(available at www.powerwavesoftware.com).

CAUTION

If the auto sense lead feature is disabled and
remote voltage sensing is enabled but the sense
leads are missing, improperly connected extreme­ly high welding outputs may occur.

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

General Guidelines for Voltage Sense Leads

Sense leads should be attached as close to the weld
as practical, and out of the weld current path when
possible. In extremely sensitive applications it may be
necessary to route cables that contain the sense
leads away from the electrode and work welding
cables.

The best arc performance occurs when the POWER
WAVE R350 has accurate data about the arc condi­tions.

Voltage sense leads requirements are based on the
weld process (See Table A.2)

TABLE A.2

Process

Electrode Voltage Sensing

67 lead

GMAW

GMAW-P

FCAW

GTAW

(1)

The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin arclink control cable (K1543­xx).

(2)

When a work voltage sense lead (21) is connected the power source will automatically switch over to using this feedback.

(3)

Negative polarity semi-automatic process operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode
Polarity attribute to be set.

67 lead required
67 lead required
67 lead required

Voltage sense at studs

(1)

Work Voltage Sensing

21 lead

21 lead optional
21 lead optional

21 lead optional

Voltage sense at studs

(2)

(3)
(3)

(3)

FIGURE A.6

POWER
WAVE
R350

A

C

B

POWER WAVE® R350

WORK

A-8

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into
the 5-pin arclink control cable (K1543-xx) and is
always connected to the wire drive feed plate when a
wire feeder is present. Enabling or disabling electrode
voltage sensing is application specific, and automati­cally configured by the active weld mode.

Work Voltage Sensing

While most applications perform adequately by sens­ing the work voltage directly at the output stud, the
use of a remote work voltage sense lead is recom­mended for optimal performance. The remote WORK
sense lead (21) can be accessed through the four-pin
voltage sense connector located on the control panel
by using the K940 Sense Lead Kit. It must be
attached to the work as close to the weld as practical,
but out of the weld current path. For more information
regarding the placement of remote work voltage
sense leads, see the section entitled "Voltage Sensing
Considerations for Multiple Arc Systems."

INSTALLATION

A-8

Negative Electrode Polarity

The POWER WAVE R350 has the ability to automati­cally sense the polarity of the sense leads. With this
feature there are no set-up requirements for welding
with negative electrode polarity. This feature can be
disabled through the Diagnostics Utility (available at

www.powerwavesoftware.com).

CAUTION

If the auto sense lead feature is disabled and the
weld polarity attribute is improperly configured
extremely high welding outputs may occur.

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

POWER WAVE® R350

A-9

INSTALLATION

A-9

VOLTAGE SENSING
CONSIDERATIONS FOR MULTIPLE
ARC SYSTEMS

Special care must be taken when more than one arc
is welding simultaneously on a single part. Multiple
arc applications do not necessarily dictate the use of
remote work voltage sense leads, but they are strong­ly recommended.

If Sense Leads ARE NOT Used:

• Avoid common current paths. Current from adja­cent arcs can induce voltage into each others cur­rent paths that can be misinterpreted by the power
sources, and result in arc interference.

FIGURE A.7

DIRECTION
OF TRAVEL

If Sense Leads ARE Used:

• Position the sense leads out of the path of the
weld current. Especially any current paths com-

mon to adjacent arcs. Current from adjacent arcs
can induce voltage into each others current paths
that can be misinterpreted by the power sources,
and result in arc interference.

• For longitudinal applications, connect all work
leads at one end of the weldment, and all of the
work voltage sense leads at the opposite end of the
weldment. Perform welding in the direction away
from the work leads and toward the sense leads.

(See Figure A.7)

CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD.

CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.

POWER WAVE® R350

A-10

INSTALLATION

• For circumferential applications, connect all work

leads on one side of the weld joint, and all of the
work voltage sense leads on the opposite side,
such that they are out of the current path.

(See Figure 8.A)

FIGURE A.8

POWER

SOURCE

#1

WER

PO
SOURCE

#2

A-10

POWER
SOURCE
#1

WER

PO
SOURCE

#1

POWER
SOURCE

#2

WER

PO

SOURCE

#2

POWER WAVE® R350

A-11

INSTALLATION

A-11

CONTROL CABLE CONNECTIONS

General Guidelines

Genuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
are specifically designed for the communication and
power needs of the Power Wave / Power Feed sys­tems. Most are designed to be connected end to end
for ease of extension. Generally, it is recommended
that the total length not exceed 100ft. (30.5m). The
use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication prob­lems (system shutdowns), poor motor acceleration
(poor arc starting), and low wire driving force (wire
feeding problems). Always use the shortest length of
control cable possible, and DO NOT coil excess
cable.

Regarding cable placement, best results will be
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility of
interference between the high currents flowing
through the weld cables, and the low level signals in
the control cables. These recommendations apply to
all communication cables including ArcLink® and
Ethernet connections.

Product specific Installation Instructions

Connection Between Power Source and ArcLink®
Compatible Wirefeeders (K1543-xx, K2683-xx –
ArcLink Control Cable)

The 5-pin ArcLink control cable connects the power
source to the wire feeder. The control cable consists
of two power leads, one twisted pair for digital com­munication, and one lead for voltage sensing. The 5­pin ArcLink connection on the POWER WAVE R350 is
located on the rear panel above the power cord. The
control cable is keyed and polarized to prevent
improper connection. Best results will be obtained
when control cables are routed separate from the
weld cables, especially in long distance applications.
The recommended combined length of the ArcLink
control cable network should not exceed 200ft.
(61.0m).

Connection Between Power Source and Wire
Feeder (K1785 or K2709 Control Cable)

The 14-pin wire feeder control cable connects the
power source to the wire drive. It contains all of the
necessary signals to drive the motor and monitor the
arc, including the motor power, tachometer, and arc
voltage feedback signals. The wire feeder connection
on the POWER WAVE R350 is located in the upper­right corner of the case back. The K2709 series exter­nal dress cable is recommended for severe duty appli­cations such as hard automation or for robot arms not
equipped with an internal control cable. Best results
will be obtained when control cables are routed sepa­rate from the weld cables, especially in long distance
applications. Maximum cable length should not
exceed 25ft (7.6m).

Connection Between Power Source and Ethernet
Networks

The POWER WAVE R350 is equipped with an IP67
rated ODVA compliant RJ-45 Ethernet connector,
which is located on the rear panel. All external
Ethernet equipment (cables, switches, etc.), as
defined by the connection diagrams, must be supplied
by the customer. It is critical that all Ethernet cables
external to either a conduit or an enclosure are solid
conductor, shielded cat 5e cable, with a drain. The
drain should be grounded at the source of transmis­sion. For best results, route Ethernet cables away
from weld cables, wire drive control cables, or any
other current carrying device that can create a fluctu­ating magnetic field. For additional guidelines refer to
ISO/IEC 11801. Failure to follow these recommenda­tions can result in an Ethernet connection failure dur­ing welding.

Selecting a Wire Drive and Setting the Wire Drive
Gear Ratio.

The POWER WAVE R350 can accommodate a num­ber of standard wire drives including the AutoDrive
4R100 (default), AutoDrive 4R220, and PF-10R. The
feeder control system must be configured for both the
wire drive type and gear ratio (high or low speed
range). This can be accomplished with the Weld

Manager Utility (included on the Power Wave
Utilities and Service Navigator CDʼs or available at
www.powerwavesoftware.com).

Additional information is also available in the “How To”
section at www.powerwavesoftware.com.

POWER WAVE® R350

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.

• Do not touch electrically live
part or electrode with skin or
wet clothing.

• Insulate yourself from work and
ground.

• Always wear dry insulating gloves.

• Do not operate with covers, panels or guards
removed or open.

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

• FUMES AND GASSES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

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

• WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WARNING OR
CAUTION

DANGEROUS
VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

HIGH TEMPERATURE

STATUS

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

ARC RAYS can burn.

Wear eye, ear and body protec-

•
tion.

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

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN­UAL.

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

POWER-UP SEQUENCE

When the POWER WAVE® R350 is powered up, it
can take as long as 30 seconds for the machine to be

ready to weld.

DUTY CYCLE

The duty cycle is based on a ten-minute period. A
40% duty cycle represents 4 minutes of welding and 6
minutes of idling in a ten-minute period. Refer to the
technical specification section for the Power Wave

R350ʼs duty cycle ratings.

PROTECTIVE
GROUND

COOLER

OUTPUT

OPERATORS
MANUAL

WORK

CIRCUIT BREAKER

POWER WAVE® R350

B-2

OPERATION

PRODUCT DESCRIPTION

PRODUCT SUMMARY

The POWER WAVE® R350 is a portable multi­process power source with high-end functionality
capable of DC TIG, MIG, Pulsed MIG and Flux-Cored
welding. It is ideal for a wide variety of materials
including aluminum, stainless, and nickel — where arc
performance is critical. The Power Wave® R350
includes an integrated wire drive module and 14-pin
MS-Style connection to support the PF-10R, and Auto
Drive 4R100/4R220.

B-2

RECOMMENDED PROCESSES

The POWER WAVE® R350 is a high speed, multi­process power source capable of regulating the cur­rent, voltage, or power of the welding arc. With an out­put range of 5 to 350 amperes, it supports a number
of standard processes including synergic GMAW,
GMAW-P, FCAW, FCAW-SS, GTAW and GTAW-P
on various materials especially steel, aluminum and

stainless.

The POWER WAVE® R350 is designed to be a flexi­ble welding system. Like existing Power Waveʼs, the
software based architecture allows for future
upgrades. ArcLink® communication is supported
through the standard 5 pin MS-style interface. The
new ArcLink®XT communication protocol is supported
through an RJ-45 type Ethernet connection, which
also provides access for the Power Wave Utilities soft­ware tools. The Ethernet communication also gives
the POWER WAVE® R350 the ability to run
Production Monitoring™ 2. Also Available is a
Devicenet option to allow the Power Wave® R350 to
be used in a wide range of configurations. The
POWER WAVE® R350 is being designed to be com­patible with advanced welding modules like STT.

Access to remote voltage sensing is available through
the 4 pin sense lead connector (work and electrode),
at the feeder via the 14 pin MS-style connector (elec­trode only), or at the 5 pin MS-style ArcLink® connec­tor (electrode only).

RECOMMENDED PROCESSES AND
EQUIPMENT

PROCESS LIMITATIONS

The software based weld tables of the POWER
WAVE® R350 limit the process capability within the
output range and the safe limits of the machine. In
general the processes will be limited to .030-.052 solid
steel wire, .030-.045 stainless wire, .035-1/16 cored
wire, and .035 and 1/16 Aluminum wire.

EQUIPMENT LIMITATIONS

Only ArcLink compatible robotic wire feeders, semiau­tomatic wire feeders and users interfaces may be
used. If other Lincoln wire feeders or non-Lincoln wire
feeders are used there will be limited process capabili­ty and performance and features will be limited.

The

POWER WAVE® R350
and semiautomatic welding. The
can be set up in a number of configurations, some requiring
optional equipment or welding programs.

is recommended for robotic

POWER WAVE® R350

RECOMMENDED EQUIPMENT

The POWER WAVE® R350 is designed to be com­patible with the current range of Power Feed™ and
Auto Drive systems including future versions of

ArcLink® feeders.

POWER WAVE® R350

B-3

8

1

2

4

7

5

6

3

OPERATION

B-3

DESIGN FEATURES

Loaded with Standard Features

• Multiple process DC output range: 5 - 350 Amps.

• 200 – 600 VAC, 1 for 208 and 230, 3 phase for all
voltages, 50-60Hz input power.

• New and Improved Line Voltage Compensation
holds the output constant over wide input voltage
fluctuations.

• Utilizes next generation microprocessor control,
based on the ArcLink® platform.

• State of the art power electronics technology yields
superior welding capability.

• Electronic over current protection.

• Input over voltage protection.

• F.A.N. (fan as needed). Cooling fan runs when the
output is energized and for 5 minutes after the out­put has been turned off.

• Thermostatically protected for safety and reliability.

• Ethernet connectivity via RJ-45 connector.

• Panel mounted Status, FeedHead Status, and
Thermal LED indicators facilitate quick and easy
troubleshooting.

• Potted PC boards for enhanced ruggedness/reliabil­ity.

• 115V/15A duplex receptacle supports rigorous
demands of heavy duty fume extraction and water
cooling equipment.

• Enclosure reinforced with heavy duty aluminum
extrusions for mechanical toughness.

• Waveform Control Technology™ for good weld
appearance and low spatter, even when welding
nickel alloys.

• Sync Tandem installed.

• Auto Drive 4R9100, 4R200 and PF-10R feeders
supported via standard 14 pin MS style connector.

• Cam Lock type connectors.

2. THERMAL LED - (Thermal overload): A yellow

light that comes on when an over temperature 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.

3. Feeder Status LED - Indicates the status of the

feeder control system.

4. NEGATIVE OUTPUT TERMINAL.

5. POSITIVE OUTPUT TERMINAL.

6. VOLTAGE SENSE CONNECTOR: Allows for sep-

arate remote electrode and work sense leads.

Pin Lead Function

3 21 Work Voltage Sense
1 67E Electrode Voltage Sense

7. ON/OFF SWITCH: Controls input power to the

Power Wave R350.

WARNING

The Power Wave R350 ON/OFF switch is NOT
intended as a Service Disconnect for this equip­ment.

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

8. OPTIONAL VOLTS/AMPS DISPLAY

FIGURE B.1

CASE FRONT CONTROLS

(See Figure B.1)

1. STATUS LED - A two color LED that indicates sys-

tem errors. The Power Wave R350 is equipped
with two indicators. One is for the inverter power
source, while the other indicates the status of the
feeder control system. Normal operation is a
steady green light. Basic error conditions are indi­cated in the table below. For more information and
a detailed listing, see the troubleshooting section of
this document or the Service Manual for this
machine. (See Troubleshooting Section for

operational functions.)

NOTE: The Power Wave R350 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.

POWER WAVE® R350

B-4

1

2

3

4

5

6

OPERATION

B-4

CASE BACK CONTROLS

(See Figure B.2)

1. 115V / 15A DUPLEX RECEPTACLE AND
CIRCUIT BREAKER 1 (10 AMP): Provides protec-

tion for the 115V auxiliary.

2. ARCLINK® RECEPTACLE AND CIRCUIT
BREAKER 2 (10 AMP):

Pin Lead Function

A 53A / 53B Communication Bus L
B 54A / 54B Communication Bus H
C 67A / 67B Electrode Voltage Sense
D 52A / 52B +40V DC
E 51A / 51B 0 VDC

3. SYNC-TANDEM CONNECTOR (4 PIN – MS
STYLE):

Pin Lead Function

A WHITE “Ready” H
B BLACK/RED “Ready” L
C GREEN “Kill” H
D BLACK/GREEN “Kill” L

4. OPTIONAL DEVICENET CONNECTOR (5 PIN –
SEALED MINI STYLE):

Pin Lead Function

2 894 +24 VDC DeviceNet
3 893 Common DeviceNet
4 892 DeviceNet H
5 891 DeviceNet L

FIGURE B.2

5. ETHERNET CONNECTOR (RJ-45): Used for

ArcLink® XT communication. Also used for diag­nostics and reprogramming the Power Wave R350.

Pin Function

1 Transmit +
2 Transmit ­3 Receive +
4 --­5 --­6 Receive ­7 --­8 ---

6. WIRE FEEDER RECEPTACLE (14-PIN): For con-

nection to the Auto Drive 4R100/4R220 and
PF10R series wire feeders.

Pin Lead Function

A 539 Motor +
B 541 Motor ­C 521 Solenoid +
D 522 Solenoid Common
E 845 Tach 2A differential signal
F 847 Single Tach input
G 841 +15V Tach supply
H 844 Tach common
I Open Reserved for future use
J Open Reserved for future use
K 842 Tach 1A differential signal
L 843 Tach 1B differential signal
M 846 Tach 2B differential signal
N 67G Electrode Voltage Sense

POWER WAVE® R350

B-5

OPERATION

B-5

COMMON WELDING PROCEDURES

WARNING

MAKING A WELD
The serviceability of a product or structure utiliz­ing 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 selec­tion.

Choose the electrode material, electrode size, shield­ing gas, and process (GMAW, GMAW-P etc.) appro­priate for the material to be welded.

Select the weld mode that best matches the desired
welding process. The standard weld set shipped with
the POWER WAVE® R350 encompasses a wide
range of common processes that will meet most
needs. If a special weld mode is desired, contact the
local Lincoln Electric sales representative.

All adjustments are made through the user interface.
Because of the different configuration options your
system may not have all of the following adjustments.
See Accessories Section for Kits and Options avali­able to use with the POWER WAVE® R350.

Basic Welding Controls

Weld Mode

Selecting a weld mode determines the output charac­teristics of the Power Wave power source. Weld
modes are developed with a specific electrode materi­al, electrode size, and shielding gas. For a more com­plete description of the weld modes programmed into
the POWER WAVE® R350 at the factory, refer to the
Weld Set Reference Guide supplied with the machine
or available at www.powerwavesoftware.com.

Wire Feed Speed (WFS)

In synergic welding modes (synergic CV, GMAW-P),
WFS is the dominant control parameter. The user
adjusts WFS according to factors such as wire size,
penetration requirements, heat input, etc. The
POWER WAVE® R350 then uses the WFS setting to
adjust the voltage and current according to settings
contained in the Power Wave.

In non-synergic modes, the WFS control behaves like
a conventional power source where WFS and voltage
are independent adjustments. Therefore, to maintain
proper arc characteristics, the operator must adjust
the voltage to compensate for any changes made to
the WFS.

Amps

In constant current modes, this control adjusts the
welding amperage.

Volts

In constant voltage modes, this control adjusts the
welding voltage.

Definition of Welding Modes

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

single knob control. The machine will select the cor­rect voltage and amperage based on the Wire Feed
Speed (WFS) set by the operator.

POWER WAVE® R350

Trim

In pulse synergic welding modes, the Trim setting
adjusts the arc length. Trim is adjustable from 0.50 to

1.50. 1.00 is the nominal setting and is a good start­ing point for most conditions.

UltimArc™ Control

UltimArc™ Control allows the operator to vary the arc
characteristics. UltimArc™ Control is adjustable from
–10.0 to +10.0 with a nominal setting of 0.0.

B-6

OPERATION

B-6

GTAW (TIG) WELDING

The welding current can be set through a PF10M or
PF25M wire feeder.

The TIG mode features continuous control from 5 to
350 amps with the use of an optional foot amptrol
(K870). The POWER WAVE® R350 can be run in
either a Touch Start TIG mode or Scratch start TIG
mode.

CONSTANT VOLTAGE WELDING
Synergic CV

For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft­ware at the factory.

The nominal preprogrammed voltage is the best aver­age voltage for a given wire feed speed, but may be
adjusted to preference. When the wire feed speed
changes, the Power Wave automatically adjusts the
voltage level correspondingly to maintain similar arc
characteristics throughout the WFS range.

Non Synergic CV

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 oper­ator must adjust the voltage to compensate for any
changes made to the WFS.

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”.

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. (See figure B.3)

All CV Modes

Pinch adjusts the apparent inductance of the wave
shape. The “pinch” function is inversely proportional
to inductance. Therefore, increasing Pinch Control
greater than 0.0 results in a crisper arc (more spatter)
while decreasing the Pinch Control to less than 0.0
provides a softer arc (less spatter).

FIGURE B.3

Trim .50

Arc Length Short

Arc Length Medium

Trim 1.00

Trim 1.50

Arc Length Long

POWER WAVE® R350

B-7

OPERATION

Most pulse welding programs are synergic. As the
wire feed speed is adjusted, the POWER WAVE®
R350 will automatically recalculate the waveform
parameters to maintain similar arc properties.

The POWER WAVE® R350 utilizes “adaptive control”
to compensate for changes in the electrical stick-out
while welding. (Electrical stick-out is the distance
from the contact tip to the work piece.) The POWER
WAVE® R350 waveforms are optimized for a 0.75”
stick-out. The adaptive behavior supports a range of
stick-outs from 0.50 to 1.25”. At very low or high wire
feed speeds, the adaptive range may be less due to
reaching physical limitations of the welding process.

UltimArc™ Control adjusts the focus or shape of the
arc. UltimArc™ Control is adjustable from -10.0 to
+10.0 with a nominal setting of 0.0. Increasing the
UltimArc™ Control increases the pulse frequency and
background current while decreasing the peak cur­rent. This results in a tight, stiff arc used for high
speed sheet metal welding. Decreasing the
UltimArc™ Control decreases the pulse frequency
and background current while increasing the peak cur­rent. This results in a soft arc good for out of position
welding. (See Figure B.4)

B-7

UltimArc™ Control -10.0

Low F requency, Wide

FIGURE B.4

UltimArc™ Control

Med ium Frequency and Width

OF F

POWER WAVE® R350

UltimArc™ Control

Hi gh F requency , Fo cu sed

+10.0

C-1

ACCESSORIES

KITS, OPTIONS AND ACCESSORIES

All Kits Options and Accessories are found on the
Web site: (www.lincolnelectric.com)

C-1

Request Lincoln publication E13.40
(See www.lincolnelectric.com)

TIG OPTIONS

FACTORY INSTALLED

None Available

FIELD INSTALLED OPTIONS

GENERAL OPTIONS
DeviceNet Kit

Mounts inside the back of the Power Wave R350.
Allows Devicenet objects to communicate with the
Power Wave R350.

Order K2827-1

Work Voltage Sense Lead Kit

Required to accurately monitor voltage at the arc.

Order K940-XX Series
Order K1811-XX Series

Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO
ders. Includes a cylinder pressure gauge, dual scale

flow gauge and 4.3 ft. (1.3 m) gas hose.

Order K586-1

Work and Wire Feeder 2/0 Weld Cable Package

Includes Cam-Lock connectors, work clamps, 15 ft.
(4.5 m) work cable and 10 ft. (3.0 m) electrode cable.
Rated 350 amps, 60% duty cycle.

Order K1803-2

Cam-Lock cable plug for 2/0 (50mm2)cable. Order
K2946-1

Coaxial Welding Cable

Optimum weld cables for minimizing cable inductance
and optimizing welding performance.

AWG 1/0 Coaxial Cables:
Order K1796-25 for 25 feet (7.6 m) cable length.
Order K1796-50 for 50 feet (15.2 m) cable length.
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length.

AWG #1 Coaxial Cables:
Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length.

, Argon, or Argon-blend gas cylin-

2

Pro-Torch™ TIG Torches

A full line of air-cooled and water-cooled torches available.

Request Lincoln publication E12.150
(See www.lincolnelectric.com)

Hand Amptrol®

Provides 25 ft. (7.6 m) of remote cur­rent control for TIG welding.

Order K963-4 for Hand Amptrol with
12 pin connector

Foot Amptrol®

Provides 25 ft. (7.6 m) of remote
current control for TIG welding.
Order K870-2 for Foot Amptrol
with 12 pin connector.

Arc Start Switch

May be used in place of the Foot or Hand Amptrol®.
Comes with a 25 ft. (7.6 m) cable. Attaches to the TIG
torch for convenient finger control to start and stop the
weld cycle at the current set on the machine.

Order K814

Cam-Lock Torch Adapter

For connecting K1782-1, K1782-3, K1782-12 torches
to the S350.

Order K960-3

TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack

Get everything you need for TIG welding in one com­plete easy-to-order kit packaged in its own portable
carrying case. Includes: PTA-17V torch, parts kit,
Harris® flowmeter/regulator, 10 ft. (3.0 m) gas hose,
and work clamp and cable.

Order K2265-1

MIG OPTIONS

Work and Feeder Welding Cables
350 amps, 60% duty cycle with Cam-Lock connectors
and Ground Clamp.

Order K1803-2

COMPATIBLE LINCOLN EQUIPMENT

Welding Fume Extractors

Lincoln offers a wide range of fume extraction environ­mental system solutions, ranging from portable sys­tems easily wheeled around a shop to shop-wide cen­tral systems servicing many dedicated welding sta­tions.

POWER WAVE® R350

Any Arclink compatible wire feeding equipment
(See www.lincolnelectric.com)

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not operate with covers
removed.

•Turn off power source before
installing or servicing.

•Do not touch electrically hot
parts.

• Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.

• Only qualified personnel should install, use or
service this equipment.

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

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing
out the machine, using a low-pressure air stream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.

D-1

PERIODIC MAINTENANCE

Calibration of the POWER WAVE® R350 is critical to
its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improp­erly calibrated machines may not yield satisfactory
weld performance. To ensure optimal performance,
the calibration of output Voltage and Current should
be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the fac­tory. Generally the machine calibration will not need
adjustment. However, if the weld performance
changes, or the yearly calibration check reveals a
problem, use the calibration section of the
Diagnostics Utility to make the appropriate adjust­ments.

The calibration procedure itself requires the use of a
grid, 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. The Diagnostics Utility includes detailed
instructions, and is available on the Service

Navigator CD or at www.powerwavesoftware.com.

POWER WAVE® R350

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
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.

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.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any
applicable local codes.

• Only qualified personnel should perform maintenance work.

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

Observe all additional Safety Guidelines detailed throughout this manual.

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® R350

E-2

TROUBLESHOOTING

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

There are two status lights that display error codes. If a
problem occurs it is important to note the condition of the
status lights. Therefore, prior to cycling power to the sys-

tem, check the power source status light for error
sequences as noted below.

There is one externally mounted status light located on the
case front of the machine. This status light corresponds to
the main control boardʼs status. A second status light is
internal and is located on the input control board and can be
seen by looking through the left case side louvers. There is
an audible beeper associated with this input control boardʼs
status light. So the error codes on the input board can be
detected through either the status light or the status beeper.

TABLE E.1

Light

Condition

Main control board status light

E-2

Included in this section is information about the Status
Lights and some basic troubleshooting charts for both
machine and weld performance.

The status lights for the main control board is a dual-color
LEDʼs. Normal operation for each is steady green. Where
as the status light on the input control board is one color.
Normal operation is for the status light to be off ( and the
buzzer to be off).

Error conditions are indicated in the following Table E.1.

Meaning

Input control board

Steady Green

Blinking Green

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

System OK. Power source is operational, and is communicating normally with all

healthy peripheral equipment connected to its ArcLink network.

Occurs during power up or a system reset, and indicates the POWER
WAVE® R350 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.

Indicates Auto-mapping has failed

Non-recoverable system fault. If the Status lights are flashing any com-

bination of red and green, errors are present. Read the error code(s)

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 separated by a green light. Only active error conditions will be

accessible through the Status Light.

Error codes can also be retrieved with the Diagnostics Utility (includ-

ed on the Service Navigator CD or available at www.power-

wavesoftware.com). This is the preferred method, since it can access

historical information contained in the error logs.

To clear the active error(s), turn power source off, and back on to

reset.

Not applicable.

Not applicable.

Not applicable.

Not applicable.

Not applicable.

Not applicable.

Not applicable.

Error Code interpretation -

Individual code digits are flashed
in red with a long pause between
digits. These error codes are three
digit codes that all start with a
number three.

Status LED off

Not applicable.

System OK

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® R350

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWER WAVE® R350

The following is a partial list of possible error codes for the POWER WAVE® R350. For a complete listing consult
the Service Manual for this machine.

MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code #

Indication

36 Thermal error

54 Secondary (Output) over current error

56 Chopper communication error

58 Primary Fault error

Other

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine

The long term average secondary (weld) current limit has been
exceeded. NOTE: The long term average secondary current limit is
325 amps.

Indicates communication link between main control board and chop­per has errors. If cycling the input power on the machine does not
clear the error, contact the Service Department.

Review error code from input board status light or status beeper.
Most likely caused by an over power condition which caused an
under voltage on the primary bus. If cycling the input power on the
machine does not clear the error, contact the Service Department.

Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the Power
Source Control Board. If cycling the input power on the machine
does not clear the error, contact the Service Department.

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® R350

E-4

Error Code #

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

INPUT CONTROL BOARD

Indication

E-4

331 Peak input current limit

333 Under-voltage lockout

336 Thermal Fault

337 Pre-charge timeout

346 Transformer primary over current

Other

Input current limit has been exceeded. Typically indicates short
term power overload. If problem persists contact Service
Department.

+15 VDC supply on Input control board too low. Verify input voltage
is within the acceptable range. If problem persists contact service
department.

Thermostat on primary module tripped. Typically caused by bottom
fan not working.

Problem with start-up sequence. If problem persists contact Service
Department.

Transformer current too high. Typically indicates short term power
overload. If problem persists contact service department.

Contact the Service Department.

Error Code #

81 Motor Overload

82 Motor Overcurrent

83 Shutdown #1

84 Shutdown #2

WIRE DRIVE MODULE

Indication

Long term average motor current limit has been exceeded.
Typically indicates mechanical overload of system. If problem con­tinues consider higher torque gear ratio (lower speed range).

Absolute maximum motor current level has been exceeded. This is
a short term average to protect drive circuitry.

The Shutdown inputs on the Power Wave R350 have been dis­abled. The presence of these errors indicates the Feed Head
Control PCB may contain the wrong operating software.

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® R350

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

Basic Machine Problems

E-5

RECOMMENDED

COURSE OF ACTION

Input fuses keep blowing

Machine will not power up (no lights)

1. Improperly sized input fuses.

2. Improper Weld Procedure requir­ing output levels in excess of
machine rating.

3. Major physical or electrical dam­age is evident when the covers
are removed.

1. No Input Power

2. Input voltage is too low or too
high.

1. Make sure fuses are properly
sized. See installation section of
this manual for recommended
sizes.

2. Reduce output current, duty
cycle, or both.

3. Contact your local authorized
Lincoln Electric Field Service
facility for technical assistance.

1. Make sure input supply discon­nect has been turned ON. Check
input fuses. Make certain that the
Power Switch (SW1) on the
power source is in the “ON” posi­tion.

2. Make certain that input voltage is
correct, according to the Rating
Plate located on the rear of the
machine.

Machine wonʼt weld, canʼt get any
output.

This problem will normally be
accompanied by an error code. See
“Status Light” section of this docu­ment for additional information.

Input voltage is too low or too high.

1.

2. Thermal Error.

3. Secondary current limit has been
exceeded. (see error 54)

3a. Input control board fault (see

input control board error status).

1. Make certain that input voltage is
correct, according to the Rating
Plate located on the rear of the
machine.

2. See “Thermal LED is ON” sec-
tion.

3. Possible short in output circuit. If
condition persists, contact an
authorized Lincoln Electric Field
Service facility.

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® R350

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

Thermal LED is ON

Thermal LED is ON

“Real Time Clock” no longer func­tioning

General degradation of weld perfor­mance

Improper fan operation

Basic Machine Problems (Continued)

1. Improper fan operation.

2. Open thermostat circuit.

1. Control PC Board Battery.

Weld and Arc Quality Problems

1. Wire feed problem.

2. Cabling problems.

1. Check for proper fan operation.
Fan should run in a low speed
setting when the machine is idle
and in a high speed when the
output is triggered. Check for
material blocking intake or
exhaust louvers, or for excessive
dirt clogging cooling channels in
machine.

2. Check for broken wires, open
connections or faulty thermostats
in the thermostat circuit.

1. Replace the battery (Type:
BS2032)

1. Check for feeding problems. Make
sure proper gear ratio has been
selected.

2. Check for bad connections,
excessive loops in cable, etc.

3. Loss of, or improper Shielding
Gas.

4. Verify weld mode is correct for
process.

5. Machine calibration.

NOTE: The presence of heat in the
external welding circuit indicates
poor connections or undersized
cables.

3. Verify gas flow and type are cor­rect.

4.Select the correct weld mode for

the application.

5. The power source may require
calibration. (current, voltage,
WFS).

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® R350

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Weld and Arc Quality Problems (Continued)

Wire burns back to tip at the end of
the weld.

TROUBLESHOOTING

POSSIBLE

CAUSE

1. Burnback Time

E-7

RECOMMENDED

COURSE OF ACTION

1. Reduce burnback time and/or
work point.

Machine output shuts down during a
weld.

Machine wonʼt produce full output.

Excessively long and erratic arc.

1. Secondary current limit has been
exceeded, and the machine shuts
down to protect itself.

2. System Fault

1. Input voltage may be too low, lim­iting output capability of the power
source.

2. Single Phase Operation

3. Machine calibration.

1. Wire feed problem.

1. Adjust procedure or reduce load
to lower current draw from the
machine.

2. A non-recoverable fault will inter­rupt welding. This condition will
also result in a status light blink­ing. See the Status Light section
for more information.

1. Make certain that the input voltage
is proper, according to the Rating
Plate located on the rear of the
machine.

2. Maximum output is reduced if

there is a loss of phase on 460 or
575 VAC. Check for the presence of
all phases.

3. Calibrate secondary current and
voltage.

1. Check for feeding problems. Make
sure proper gear ratio has been
selected.

2. Loss of, or improper Shielding
Gas

3. Machine calibration.

2. Verify gas flow and type are cor­rect

3. Calibrate secondary current and
voltage.

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® R350

E-8

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Ethernet

RECOMMENDED

COURSE OF ACTION

E-8

Cannot Connect

1. Physical connection.

2. IP address information.

3. Ethernet Speed

1. Verify that the correct patch cable
or cross over cable is being used
(refer to local IT department for
assistance).

1a. Verify the cables are fully insert-

ed into the bulk head connector.

1b. The LED under the PC board

ethernet connector will be lit
when the machine is connected
to another network device.

2. Use the appropriate PC utility to
verify the correct IP address infor­mation has been entered.

2a. Verify no duplicate the IP

addresses exist on the network.

3. Verify that the network device
connected to the Power Wave is
either a 10-baseT device or a
10/100-baseT device.

Connection Drops while welding

1. Cable Location

1. Verify Network cable is not locat­ed next to current carrying con­ductors. This would include input
power cables and welding output
cables.

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® R350

F-1

DIAGRAMS

F-1

POWER WAVE® R350

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

13.87

18.81

6.00

18.31

22.2527.44

DIMENSION PRINT

F-2

POWER WAVE® R350

NOTES

POWER WAVE® R350

NOTES

POWER WAVE® R350

WARNING

Spanish

AVISO DE

PRECAUCION

G Do not touch electrically live parts or

electrode with skin or wet clothing.

G Insulate yourself from work and

ground.

G No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

G Aislese del trabajo y de la tierra.

G Keep flammable materials away.

G Mantenga el material combustible

fuera del área de trabajo.

G Wear eye, ear and body protection.

G Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

G Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

G Isolez-vous du travail et de la terre.

G Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

G Isolieren Sie sich von den

Elektroden und dem Erdboden!

G Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

G Isole-se da peça e terra.

G Gardez à l’écart de tout matériel

inflammable.

G Entfernen Sie brennbarres Material!

G Mantenha inflamáveis bem guarda-

dos.

G Protégez vos yeux, vos oreilles et

votre corps.

G Tragen Sie Augen-, Ohren- und Kör-

perschutz!

G Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

G Keep your head out of fumes.
G Use ventilation or exhaust to

remove fumes from breathing zone.

G Turn power off before servicing.

G Do not operate with panel open or

guards off.

WARNING

G Los humos fuera de la zona de res-

piración.

G Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

G Vermeiden Sie das Einatmen von

Schweibrauch!

G Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para

remover fumo da zona respiratória.

G Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

G Débranchez le courant avant l’entre-

tien.

G Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer

serviço.

G Não toque as partes elétricas nuas.

G No operar con panel abierto o

guardas quitadas.

G N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

G Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

G Mantenha-se afastado das partes

moventes.

G Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com