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IM10083
®
POWER WAVE R350
October, 2010

For use with machines having Code Numbers: 11745

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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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

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

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
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.

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 iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturerʼs
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. 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 iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où lʼon pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque dʼincendie dû aux étincelles.

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

Thank You
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!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. 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 posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation 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.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi TABLE OF CONTENTS vi
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
________________________________________________________________________________

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 A-1
TECHNICAL SPECIFICATIONS - POWER WAVE® R350
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @
(1 Phase in parenthesis) Rated Output

40% rating 39/35/19/17/14

208/230/380-415/460/575 (60/67*/NA/NA/NA)
K3022-1 50/60 Hz 300 Watts Max. .95
100% rating 31/28/15/14/11 (fan on)
(60/53/NA/NA/NA)

RATED OUTPUT
INPUT GMAW GTAW-DC
VOLTAGE/PHASE/
FREQUENCY 40% 60% 100% 40% 60% 100%

200-208/1/50/60 300 Amps / 29 Volts

230/1/50/60*
200-208/3/50/60
230/3/50/60 350 Amps 320 Amps 300 Amps 350 Amps 325 Amps 300 Amps
380-415/3/50/60 31.5 Volts 30 Volts 29 Volts 24 Volts 23 Volts 22 Volts
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.

RECOMMENDED INPUT WIRE AND FUSE SIZES 1

INPUT MAXIMUM CORD SIZE 3 TIME DELAY FUSE

VOLTAGE / PHASE/ INPUT AMPERE RAT- AWG SIZES OR BREAKER 2
FREQUENCY ING AND DUTY CYCLE (mm2) AMPERAGE

200-208/1/50/60 60A, 100% 6 (13) 80

200-208/3/50/60 39A, 40% 8 (10) 50
230/1/50/60 67A, 30% 4 (16) 80
230/3/50/60 35A, 40% 8 (10) 45
380-415/1/50/60 38A, 40% 8 (10) 50
380-415/3/50/60 19A, 40% 12 (4) 30
460/1/50/60 34A, 40% 8 (10) 45
460/3/50/60 17A, 40% 12 (4) 25
575/1/50/60 27A, 40% 10 (6) 35
575/3/50/60 14A, 40% 14 (2.5) 20
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.

POWER WAVE® R350

A-2 INSTALLATION A-2

WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)
Mean Peak
GMAW
GMAW-Pulse 40-350A 40-70V
FCAW 100V
GTAW-DC 5-350A 24V
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT

K3022-1 20.40 in ( 518 mm) 14.00in ( 356 mm) 24.80in ( 630mm) 85 lbs (39 kg)*

TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20C to 40C) Environmentally Hardened: -40°F to 185°F (-40C to 85C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.

Thermal tests have been performed at ambient tem-

perature. 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 LIFTING

entire installation section before you start installa- Both handles should be used when lifting POWER WAVE®
R350. When using a crane or overhead device a lifting strap
tion.
should be connected to both handles. Do not attempt to lift the
WARNING POWER WAVE® R350 with accessories attached to it.

ELECTRIC SHOCK can kill.

WARNING
• Only qualified personnel should • Lift only with equipment of ade-
perform this installation. quate lifting capacity.
• Turn the input power OFF at the • Be sure machine is stable when
disconnect switch or fuse box before working on lifting.
this equipment. Turn off the input power to any • Do not operate machine while
other equipment connected to the welding system suspended when lifting.
at the disconnect switch or fuse box before work- FALLING
ing on the equipment. EQUIPMENT can
• Do not touch electrically hot parts. cause injury.
• Always connect the POWER WAVE® R350 -------------------------------------------------------------
grounding lug to a proper safety (Earth) ground.
------------------------------------------------------------- STACKING
SELECT SUITABLE LOCATION The POWER WAVE® R350 cannot be stacked.

The POWER WAVE® R350 will operate in harsh envi-

ronments. Even so, it is important that simple preven-
TILTING
Place the machine directly on a secure, level surface or on a
tative measures are followed in order to assure long
recommended undercarriage. The machine may topple over if
life and reliable operation.
this procedure is not followed.

• The machine must be located where there is free

INPUT AND GROUND CONNECTIONS
circulation of clean air such that air movement in Only a qualified electrician should connect the POWER
the back, out the sides and bottom will not be WAVE® R350. Installation should be made in accordance with
restricted. the appropriate National Electrical Code, all local codes and
the information in this manual.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. The use of air filters MACHINE GROUNDING
on the air intake is not recommended because nor- The frame of the welder must be grounded. A ground terminal
mal air flow may be restricted. Failure to observe marked with a ground symbol is located next to the input
these precautions can result in excessive operating power connection block.
temperatures and nuisance shutdown.
See your local and national electrical codes for proper ground-
• Keep machine dry. Shelter from rain and snow. Do ing methods.
not place on wet ground or in puddles.
HIGH FREQUENCY PROTECTION
• Do not mount the POWER WAVE® R350 over
Locate the POWER WAVE® R350 away from radio controlled
combustible surfaces. Where there is a com-
machinery. The normal operation of the POWER WAVE® R350
bustible surface directly under stationary or fixed
may adversely affect the operation of RF controlled equipment,
electrical equipment, that surface shall be covered which may result in bodily injury or damage to the equipment.
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.

POWER WAVE® R350

A-4 INSTALLATION A-4

INPUT CONNECTION WARNING

WARNING
Only a qualified electrician should The POWER WAVE® R350 ON/OFF
switch is not intended as a service
connect the input leads to the
disconnect for this equipment. Only
POWER WAVE® R350. Connections a qualified electrician should con-
should be made in accordance with nect the input leads to the POWER WAVE® R350.
all local and national electrical Connections should be made in accordance with
codes and the connection diagrams. Failure to do all local and national electrical codes and the con-
so may result in bodily injury or death. nection diagram located on the inside of the
reconnect access door of the machine. 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. POWER CORD REPLACEMENT
For Single Phase Input WARNING
Connect green lead to ground per National Electrical Only a qualified electrician should
Code. connect the input leads to the
POWER WAVE® R350. Connections
Connect black and white leads to power. should be made in accordance with
Wrap red lead with tape to provide 600V insulation. all local and national electrical
codes and the connection dia-
For Three Phase Input grams. Failure to do so may result in bodily injury
Connect green lead to ground per National Electric or death.
Code. ------------------------------------------------------------------------
Connect black, red and white leads to power. 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
INPUT FUSE AND SUPPLY WIRE removed as shown Figure A.1.
CONSIDERATIONS ALWAYS CONNECT THE POWER WAVE GROUND-
Refer to Specification Section for recommended fuse, ING LUG (LOCATED AS SHOWN IN FIGURE A.1)
wire sizes and type of the copper wires. Fuse the TO A PROPER SAFETY (EARTH) GROUND AND
input circuit with the recommended super lag fuse or ENSURE IT IS APPROXIMATELY 3" LONGER THAN
delay type breakers (also called "inverse time" or PHASE LEADS."
"thermal/magnetic" circuit breakers). Choose input
and grounding wire size according to local or national FIGURE A.1
electrical codes. Using input wire sizes, fuses or cir-
cuit 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.
CONNECTION
BLOCK

INPUT VOLTAGE SELECTION

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

GROUND
LUG INPUT
POWER
CORD

POWER WAVE® R350

A-5 INSTALLATION A-5

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
MIG PROCESS

GAS HOSE

ARCLINK CABLE
K1543-[XX] TO NEGATIVE (-) STUD

WORK CLAMP
TO POSITIVE
(+) STUD
WORK PIECE

PF10-M
WIRE FEEDER

POWER WAVE® R350

A-6 INSTALLATION A-6

RECOMMENDED WORK CABLE General Guidelines

SIZES FOR ARC WELDING • Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive volt-
Connect the electrode and work cables between the age drops caused by undersized welding cables and
appropriate output studs of the POWER WAVE R350 poor connections often result in unsatisfactory weld-
per the following guidelines: ing performance. Always use the largest welding
cables (electrode and work) that are practical, and
• Most welding applications run with the electrode be sure all connections are clean and tight.
being positive (+). For those applications, connect
the electrode cable between the wire drive feed plate Note: Excessive heat in the weld circuit indicates
and the positive (+) output stud on the power source. undersized cables and/or bad connections.
Connect a work lead from the negative (-) power
source output stud to the work piece • Route all cables directly to the work and wire
• When negative electrode polarity is required, such feeder, avoid excessive lengths and do not coil
as in some Innershield applications, reverse the out- excess cable. Route the electrode and work cables
put connections at the power source (electrode cable in close proximity to one another to minimize the
to the negative (-) stud, and work cable to the posi- loop area and therefore the inductance of the weld
tive (+) stud). circuit.

CAUTION • Always weld in a direction away from the work

(ground) connection.
Negative electrode polarity operation WITHOUT
use of a remote work sense lead (21) requires the Table A.1 shows copper cable sizes recommended for
Negative Electrode Polarity attribute to be set. See different currents and duty cycles. Lengths stipulated
the Remote Sense Lead Specification section of are the distance from the welder to work and back to
this document for further details. the welder again. Cable sizes are increased for
----------------------------------------------------------------------- greater lengths primarily for the purpose of minimizing
For additional Safety information regarding the elec- cable drop.
trode and work cable set-up, See the standard
“SAFETY INFORMATION” located in the front of this
Instruction Manual.
OUTPUT CABLE GUIDELINES (Table A.1)
Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
Amperes Cycle CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**
0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.

200 60 2 2 2 1 1/0

200 100 2 2 2 1 1/0

250 30 3 3 2 1 1/0

250 40 2 2 1 1 1/0

250 60 1 1 1 1 1/0

250 100 1 1 1 1 1/0

300 60 1 1 1 1/0 2/0

300 100 2/0 2/0 2/0 2/0 3/0

350 40 1/0 1/0 2/0 2/0 3/0

** 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).

POWER WAVE® R350

A-7 INSTALLATION A-7

CABLE INDUCTANCE AND ITS Depending upon the process, inductance within the
electrode and work cables can influence the voltage
EFFECTS ON WELDING apparent at the studs of the welder, and have a dra-
matic effect on performance. Remote voltage sense
Excessive cable inductance will cause the welding leads are used to improve the accuracy of the arc volt-
performance to degrade. There are several factors age information supplied to the control pc board.
that contribute to the overall inductance of the cabling Sense Lead Kits (K940-xx) are available for this pur-
pose.
system including cable size, and loop area. The loop
area is defined by the separation distance between The POWER WAVE R350 has the ability to automati-
the electrode and work cables, and the overall welding cally sense when remote sense leads are connected.
loop length. The welding loop length is defined as the With this feature there are no requirements for setting-
total of length of the electrode cable (A) + work cable up the machine to use remote sense leads. This fea-
(B) + work path (C) (See Figure A.6). ture can be disabled through the Diagnostics Utility
(available at www.powerwavesoftware.com).
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
CAUTION
minimize the loop area. Since the most significant fac-
If the auto sense lead feature is disabled and
tor in cable inductance is the welding loop length,
remote voltage sensing is enabled but the sense
avoid excessive lengths and do not coil excess cable. leads are missing, improperly connected extreme-
For long work piece lengths, a sliding ground should ly high welding outputs may occur.
be considered to keep the total welding loop length as ------------------------------------------------------------------------
short as possible. General Guidelines for Voltage Sense Leads
Sense leads should be attached as close to the weld
REMOTE SENSE LEAD as practical, and out of the weld current path when
possible. In extremely sensitive applications it may be
SPECIFICATIONS necessary to route cables that contain the sense
leads away from the electrode and work welding
Voltage Sensing Overview cables.

The best arc performance occurs when the POWER Voltage sense leads requirements are based on the
WAVE R350 has accurate data about the arc condi- weld process (See Table A.2)
tions.

TABLE A.2
Process Electrode Voltage Sensing (1) Work Voltage Sensing (2)
67 lead 21 lead

GMAW 67 lead required 21 lead optional (3)

GMAW-P 67 lead required 21 lead optional (3)
FCAW 67 lead required 21 lead optional (3)
GTAW Voltage sense at studs Voltage sense at studs

(1) The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin arclink control cable (K1543-
xx).
(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.

FIGURE A.6

POWER
WAVE A
R350
C

WORK
B
POWER WAVE® R350
A-8 INSTALLATION 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 automati-
cally configured by the active weld mode.

Work Voltage Sensing

While most applications perform adequately by sens-

ing the work voltage directly at the output stud, the
use of a remote work voltage sense lead is recom-
mended 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."

Negative Electrode Polarity

The POWER WAVE R350 has the ability to automati-
cally 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 If Sense Leads ARE Used:

CONSIDERATIONS FOR MULTIPLE
• Position the sense leads out of the path of the
ARC SYSTEMS weld current. Especially any current paths com-
mon to adjacent arcs. Current from adjacent arcs
Special care must be taken when more than one arc can induce voltage into each others current paths
is welding simultaneously on a single part. Multiple that can be misinterpreted by the power sources,
arc applications do not necessarily dictate the use of and result in arc interference.
remote work voltage sense leads, but they are strong-
ly recommended. • For longitudinal applications, connect all work
leads at one end of the weldment, and all of the
If Sense Leads ARE NOT Used: work voltage sense leads at the opposite end of the
weldment. Perform welding in the direction away
• Avoid common current paths. Current from adja- from the work leads and toward the sense leads.
cent arcs can induce voltage into each others cur- (See Figure A.7)
rent paths that can be misinterpreted by the power
sources, and result in arc interference.

FIGURE A.7
CONNECT ALL SENSE
LEADS AT THE END
DIRECTION OF THE WELD.
OF TRAVEL

CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.

POWER WAVE® R350

A-10 INSTALLATION A-10
• 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

POWER
SOURCE
#2

POWER
POWER SOURCE
SOURCE #2
#1

POWER
SOURCE
#1

POWER
SOURCE
#2

POWER WAVE® R350

A-11 INSTALLATION A-11

CONTROL CABLE CONNECTIONS Connection Between Power Source and Wire

Feeder (K1785 or K2709 Control Cable)
General Guidelines
The 14-pin wire feeder control cable connects the
Genuine Lincoln control cables should be used at all power source to the wire drive. It contains all of the
times (except where noted otherwise). Lincoln cables necessary signals to drive the motor and monitor the
are specifically designed for the communication and arc, including the motor power, tachometer, and arc
power needs of the Power Wave / Power Feed sys- voltage feedback signals. The wire feeder connection
tems. Most are designed to be connected end to end on the POWER WAVE R350 is located in the upper-
for ease of extension. Generally, it is recommended right corner of the case back. The K2709 series exter-
that the total length not exceed 100ft. (30.5m). The nal dress cable is recommended for severe duty appli-
use of non-standard cables, especially in lengths cations such as hard automation or for robot arms not
greater than 25 feet, can lead to communication prob- equipped with an internal control cable. Best results
lems (system shutdowns), poor motor acceleration will be obtained when control cables are routed sepa-
(poor arc starting), and low wire driving force (wire rate from the weld cables, especially in long distance
feeding problems). Always use the shortest length of applications. Maximum cable length should not
control cable possible, and DO NOT coil excess exceed 25ft (7.6m).
cable.
Connection Between Power Source and Ethernet
Regarding cable placement, best results will be Networks
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility of The POWER WAVE R350 is equipped with an IP67
interference between the high currents flowing rated ODVA compliant RJ-45 Ethernet connector,
through the weld cables, and the low level signals in which is located on the rear panel. All external
the control cables. These recommendations apply to Ethernet equipment (cables, switches, etc.), as
all communication cables including ArcLink® and defined by the connection diagrams, must be supplied
Ethernet connections. by the customer. It is critical that all Ethernet cables
external to either a conduit or an enclosure are solid
Product specific Installation Instructions conductor, shielded cat 5e cable, with a drain. The
drain should be grounded at the source of transmis-
Connection Between Power Source and ArcLink® sion. For best results, route Ethernet cables away
Compatible Wirefeeders (K1543-xx, K2683-xx – from weld cables, wire drive control cables, or any
ArcLink Control Cable) other current carrying device that can create a fluctu-
ating magnetic field. For additional guidelines refer to
The 5-pin ArcLink control cable connects the power ISO/IEC 11801. Failure to follow these recommenda-
source to the wire feeder. The control cable consists tions can result in an Ethernet connection failure dur-
of two power leads, one twisted pair for digital com- ing welding.
munication, and one lead for voltage sensing. The 5-
pin ArcLink connection on the POWER WAVE R350 is Selecting a Wire Drive and Setting the Wire Drive
located on the rear panel above the power cord. The Gear Ratio.
control cable is keyed and polarized to prevent
improper connection. Best results will be obtained The POWER WAVE R350 can accommodate a num-
when control cables are routed separate from the ber of standard wire drives including the AutoDrive
weld cables, especially in long distance applications. 4R100 (default), AutoDrive 4R220, and PF-10R. The
The recommended combined length of the ArcLink feeder control system must be configured for both the
control cable network should not exceed 200ft. wire drive type and gear ratio (high or low speed
(61.0m). 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 GRAPHIC SYMBOLS THAT APPEAR ON

READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL
BEFORE OPERATING MACHINE.

WARNING WARNING OR
• ELECTRIC SHOCK CAN KILL.
CAUTION
• Do not touch electrically live
part or electrode with skin or
DANGEROUS
wet clothing.
• Insulate yourself from work and VOLTAGE
ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards POSITIVE OUTPUT
removed or open.
---------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous. NEGATIVE OUTPUT
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing HIGH TEMPERATURE
zone.
---------------------------------------------------------------------

• WELDING SPARKS can cause

STATUS
fire or explosion.
• Keep flammable material away.

--------------------------------------------------------------------- PROTECTIVE
ARC RAYS can burn. GROUND
• Wear eye, ear and body protec-
tion.

--------------------------------------------------------------------- COOLER
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN-
UAL. OUTPUT
---------------------------------------------------------------------

POWER-UP SEQUENCE OPERATORS

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

DUTY CYCLE

The duty cycle is based on a ten-minute period. A

CIRCUIT BREAKER
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.

POWER WAVE® R350

B-2 OPERATION B-2

PRODUCT DESCRIPTION
RECOMMENDED PROCESSES
PRODUCT SUMMARY
The POWER WAVE® R350 is a portable multi- The POWER WAVE® R350 is a high speed, multi-
process power source with high-end functionality process power source capable of regulating the cur-
capable of DC TIG, MIG, Pulsed MIG and Flux-Cored rent, voltage, or power of the welding arc. With an out-
welding. It is ideal for a wide variety of materials put range of 5 to 350 amperes, it supports a number
including aluminum, stainless, and nickel — where arc of standard processes including synergic GMAW,
performance is critical. The Power Wave® R350 GMAW-P, FCAW, FCAW-SS, GTAW and GTAW-P
includes an integrated wire drive module and 14-pin on various materials especially steel, aluminum and
MS-Style connection to support the PF-10R, and Auto stainless.
Drive 4R100/4R220.
PROCESS LIMITATIONS
The POWER WAVE® R350 is designed to be a flexi-
ble welding system. Like existing Power Waveʼs, the
The software based weld tables of the POWER
software based architecture allows for future
WAVE® R350 limit the process capability within the
upgrades. ArcLink® communication is supported
output range and the safe limits of the machine. In
through the standard 5 pin MS-style interface. The
general the processes will be limited to .030-.052 solid
new ArcLink®XT communication protocol is supported
steel wire, .030-.045 stainless wire, .035-1/16 cored
through an RJ-45 type Ethernet connection, which
wire, and .035 and 1/16 Aluminum wire.
also provides access for the Power Wave Utilities soft-
ware tools. The Ethernet communication also gives
the POWER WAVE® R350 the ability to run EQUIPMENT LIMITATIONS
Production Monitoring™ 2. Also Available is a
Devicenet option to allow the Power Wave® R350 to Only ArcLink compatible robotic wire feeders, semiau-
be used in a wide range of configurations. The tomatic wire feeders and users interfaces may be
POWER WAVE® R350 is being designed to be com- used. If other Lincoln wire feeders or non-Lincoln wire
patible with advanced welding modules like STT. feeders are used there will be limited process capabili-
ty and performance and features will be limited.
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 (elec-
trode only), or at the 5 pin MS-style ArcLink® connec-
tor (electrode only).

RECOMMENDED PROCESSES AND

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

RECOMMENDED EQUIPMENT

The POWER WAVE® R350 is designed to be com-

patible with the current range of Power Feed™ and
Auto Drive systems including future versions of
ArcLink® feeders.

POWER WAVE® R350

B-3 OPERATION B-3

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

light that comes on when an over temperature situ-
ation occurs. Output is disabled and the fan con-
Loaded with Standard Features
tinues to run, until the machine cools down. When
• Multiple process DC output range: 5 - 350 Amps.
cool, the light goes out and output is enabled.
• 200 – 600 VAC, 1 for 208 and 230, 3 phase for all
voltages, 50-60Hz input power.
3. Feeder Status LED - Indicates the status of the
• New and Improved Line Voltage Compensation
feeder control system.
holds the output constant over wide input voltage
fluctuations.
4. NEGATIVE OUTPUT TERMINAL.
• Utilizes next generation microprocessor control,
based on the ArcLink® platform.
5. POSITIVE OUTPUT TERMINAL.
• State of the art power electronics technology yields
superior welding capability. 6. VOLTAGE SENSE CONNECTOR: Allows for sep-
• Electronic over current protection. arate remote electrode and work sense leads.
• Input over voltage protection.
• F.A.N. (fan as needed). Cooling fan runs when the Pin Lead Function
output is energized and for 5 minutes after the out- 3 21 Work Voltage Sense
put has been turned off. 1 67E Electrode Voltage Sense
• Thermostatically protected for safety and reliability.
• Ethernet connectivity via RJ-45 connector. 7. ON/OFF SWITCH: Controls input power to the
• Panel mounted Status, FeedHead Status, and Power Wave R350.
Thermal LED indicators facilitate quick and easy
troubleshooting.
• Potted PC boards for enhanced ruggedness/reliabil- WARNING
ity. The Power Wave R350 ON/OFF switch is NOT
• 115V/15A duplex receptacle supports rigorous intended as a Service Disconnect for this equip-
demands of heavy duty fume extraction and water ment.
cooling equipment. ------------------------------------------------------------------------
• Enclosure reinforced with heavy duty aluminum 8. OPTIONAL VOLTS/AMPS DISPLAY
extrusions for mechanical toughness.
• Waveform Control Technology™ for good weld
appearance and low spatter, even when welding FIGURE B.1
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.

CASE FRONT CONTROLS

(See Figure B.1)
1. STATUS LED - A two color LED that indicates sys- 1
tem errors. The Power Wave R350 is equipped
with two indicators. One is for the inverter power 2
source, while the other indicates the status of the 3
feeder control system. Normal operation is a
steady green light. Basic error conditions are indi-
cated 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.)
4

NOTE: The Power Wave R350 status light will flash 5

8
green, and sometimes red and green, for up to one 6
minute when the machine is first turned on. This is a 7
normal situation as the machine goes through a self
test at power up.
POWER WAVE® R350
B-4 OPERATION B-4

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

(See Figure B.2) ArcLink® XT communication. Also used for diag-
nostics and reprogramming the Power Wave R350.
1. 115V / 15A DUPLEX RECEPTACLE AND
CIRCUIT BREAKER 1 (10 AMP): Provides protec- Pin Function
tion for the 115V auxiliary. 1 Transmit +
2 Transmit -
2. ARCLINK® RECEPTACLE AND CIRCUIT 3 Receive +
BREAKER 2 (10 AMP): 4 ---
Pin Lead Function 5 ---
A 53A / 53B Communication Bus L 6 Receive -
B 54A / 54B Communication Bus H 7 ---
C 67A / 67B Electrode Voltage Sense 8 ---
D 52A / 52B +40V DC
E 51A / 51B 0 VDC
6. WIRE FEEDER RECEPTACLE (14-PIN): For con-
3. SYNC-TANDEM CONNECTOR (4 PIN – MS nection to the Auto Drive 4R100/4R220 and
STYLE): PF10R series wire feeders.
Pin Lead Function
A WHITE “Ready” H Pin Lead Function
B BLACK/RED “Ready” L A 539 Motor +
C GREEN “Kill” H B 541 Motor -
D BLACK/GREEN “Kill” L C 521 Solenoid +
D 522 Solenoid Common
4. OPTIONAL DEVICENET CONNECTOR (5 PIN – E 845 Tach 2A differential signal
SEALED MINI STYLE): F 847 Single Tach input
Pin Lead Function G 841 +15V Tach supply
2 894 +24 VDC DeviceNet H 844 Tach common
3 893 Common DeviceNet I Open Reserved for future use
4 892 DeviceNet H J Open Reserved for future use
5 891 DeviceNet L K 842 Tach 1A differential signal
L 843 Tach 1B differential signal
M 846 Tach 2B differential signal
N 67G Electrode Voltage Sense
FIGURE B.2

1 5

2 6

POWER WAVE® R350

B-5 OPERATION B-5
COMMON WELDING PROCEDURES Basic Welding Controls

WARNING Weld Mode

Selecting a weld mode determines the output charac-
MAKING A WELD teristics of the Power Wave power source. Weld
The serviceability of a product or structure utiliz- modes are developed with a specific electrode materi-
ing the welding programs is and must be the sole al, electrode size, and shielding gas. For a more com-
responsibility of the builder/user. Many variables plete description of the weld modes programmed into
beyond the control of The Lincoln Electric the POWER WAVE® R350 at the factory, refer to the
Company affect the results obtained in applying Weld Set Reference Guide supplied with the machine
these programs. These variables include, but are or available at www.powerwavesoftware.com.
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication Wire Feed Speed (WFS)
methods and service requirements. The available In synergic welding modes (synergic CV, GMAW-P),
range of a welding program may not be suitable WFS is the dominant control parameter. The user
for all applications, and the build/user is and must adjusts WFS according to factors such as wire size,
be solely responsible for welding program selec- penetration requirements, heat input, etc. The
tion. POWER WAVE® R350 then uses the WFS setting to
adjust the voltage and current according to settings
Choose the electrode material, electrode size, shield- contained in the Power Wave.
ing gas, and process (GMAW, GMAW-P etc.) appro-
priate for the material to be welded. In non-synergic modes, the WFS control behaves like
a conventional power source where WFS and voltage
Select the weld mode that best matches the desired are independent adjustments. Therefore, to maintain
welding process. The standard weld set shipped with proper arc characteristics, the operator must adjust
the POWER WAVE® R350 encompasses a wide the voltage to compensate for any changes made to
range of common processes that will meet most the WFS.
needs. If a special weld mode is desired, contact the
local Lincoln Electric sales representative. Amps
In constant current modes, this control adjusts the
All adjustments are made through the user interface. welding amperage.
Because of the different configuration options your
system may not have all of the following adjustments. Volts
See Accessories Section for Kits and Options avali- In constant voltage modes, this control adjusts the
able to use with the POWER WAVE® R350. welding voltage.

Definition of Welding Modes Trim

In pulse synergic welding modes, the Trim setting
NON-SYNERGIC WELDING MODES adjusts the arc length. Trim is adjustable from 0.50 to
• A Non-synergic welding mode requires all welding 1.50. 1.00 is the nominal setting and is a good start-
process variables to be set by the operator. ing point for most conditions.

SYNERGIC WELDING MODES UltimArc™ Control

• A Synergic welding mode offers the simplicity of UltimArc™ Control allows the operator to vary the arc
single knob control. The machine will select the cor- characteristics. UltimArc™ Control is adjustable from
rect voltage and amperage based on the Wire Feed –10.0 to +10.0 with a nominal setting of 0.0.
Speed (WFS) set by the operator.

POWER WAVE® R350

B-6 OPERATION B-6
GTAW (TIG) WELDING PULSE WELDING
The welding current can be set through a PF10M or Pulse welding procedures are set by controlling an
PF25M wire feeder. overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The TIG mode features continuous control from 5 to The peak current, back ground current, rise time, fall
350 amps with the use of an optional foot amptrol time and pulse frequency all affect the voltage. The
(K870). The POWER WAVE® R350 can be run in exact voltage for a given wire feed speed can only be
either a Touch Start TIG mode or Scratch start TIG predicted when all the pulsing waveform parameters
mode. are known. Using a preset voltage becomes impracti-
cal and instead the arc length is set by adjusting
CONSTANT VOLTAGE WELDING “trim”.
Synergic CV
For each wire feed speed, a corresponding voltage is Trim adjusts the arc length and ranges from 0.50 to
preprogrammed into the machine through special soft- 1.50 with a nominal value of 1.00. Trim values greater
ware at the factory. than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length. (See figure B.3)
The nominal preprogrammed voltage is the best aver-
age 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 oper-
ator must adjust the voltage to compensate for any
changes made to the WFS.

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 Trim 1.00 Trim 1.50

Arc Length Short Arc Length Medium Arc L ength Long

POWER WAVE® R350

B-7 OPERATION B-7
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 cur-
rent. 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 cur-
rent. This results in a soft arc good for out of position
welding. (See Figure B.4)

FIGURE B.4

UltimArc™ Control -10.0 UltimArc™ Control OFF UltimArc™ Control +10.0

Low Frequency, Wi de Med ium Fr equency and Wi dth Hi gh Frequency , Fo cu sed

POWER WAVE® R350

C-1 ACCESSORIES C-1
Request Lincoln publication E13.40
KITS, OPTIONS AND ACCESSORIES (See www.lincolnelectric.com)
All Kits Options and Accessories are found on the
Web site: (www.lincolnelectric.com) TIG OPTIONS
FACTORY INSTALLED Pro-Torch™ TIG Torches
None Available A full line of air-cooled and water-cooled torches available.
Request Lincoln publication E12.150
FIELD INSTALLED OPTIONS (See www.lincolnelectric.com)

GENERAL OPTIONS Hand Amptrol®

DeviceNet Kit Provides 25 ft. (7.6 m) of remote cur-
Mounts inside the back of the Power Wave R350. rent control for TIG welding.
Allows Devicenet objects to communicate with the
Power Wave R350. Order K963-4 for Hand Amptrol with
Order K2827-1 12 pin connector

Work Voltage Sense Lead Kit Foot Amptrol®

Required to accurately monitor voltage at the arc. Provides 25 ft. (7.6 m) of remote
Order K940-XX Series current control for TIG welding.
Order K1811-XX Series Order K870-2 for Foot Amptrol
with 12 pin connector.
Deluxe Adjustable Gas Regulator & Hose Kit
Accommodates CO2, Argon, or Argon-blend gas cylin- Arc Start Switch
ders. Includes a cylinder pressure gauge, dual scale May be used in place of the Foot or Hand Amptrol®.
flow gauge and 4.3 ft. (1.3 m) gas hose. Comes with a 25 ft. (7.6 m) cable. Attaches to the TIG
Order K586-1 torch for convenient finger control to start and stop the
weld cycle at the current set on the machine.
Work and Wire Feeder 2/0 Weld Cable Package Order K814
Includes Cam-Lock connectors, work clamps, 15 ft.
(4.5 m) work cable and 10 ft. (3.0 m) electrode cable. Cam-Lock Torch Adapter
Rated 350 amps, 60% duty cycle. For connecting K1782-1, K1782-3, K1782-12 torches
Order K1803-2 to the S350.
Order K960-3
Cam-Lock cable plug for 2/0 (50mm2)cable. Order
K2946-1 TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack
Get everything you need for TIG welding in one com-
Coaxial Welding Cable plete easy-to-order kit packaged in its own portable
Optimum weld cables for minimizing cable inductance carrying case. Includes: PTA-17V torch, parts kit,
and optimizing welding performance. Harris® flowmeter/regulator, 10 ft. (3.0 m) gas hose,
and work clamp and cable.
AWG 1/0 Coaxial Cables: Order K2265-1
Order K1796-25 for 25 feet (7.6 m) cable length.
Order K1796-50 for 50 feet (15.2 m) cable length. MIG OPTIONS
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length. Work and Feeder Welding Cables
350 amps, 60% duty cycle with Cam-Lock connectors
AWG #1 Coaxial Cables: and Ground Clamp.
Order K2593-25 for 25 feet (7.6 m) cable length. Order K1803-2
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length. COMPATIBLE LINCOLN EQUIPMENT
Welding Fume Extractors Any Arclink compatible wire feeding equipment
Lincoln offers a wide range of fume extraction environ- (See www.lincolnelectric.com)
mental system solutions, ranging from portable sys-
tems easily wheeled around a shop to shop-wide cen-
tral systems servicing many dedicated welding sta-
tions.
POWER WAVE® R350
D-1 MAINTENANCE D-1
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.

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

CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the fac-
tory. 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 adjust-
ments.

The calibration procedure itself requires the use of a

grid, and certified actual meters for voltage and cur-
rent. 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 E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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 E-2
USING THE STATUS LED TO
Included in this section is information about the Status
TROUBLESHOOT SYSTEM PROBLEMS Lights and some basic troubleshooting charts for both
machine and weld performance.
There are two status lights that display error codes. If a
problem occurs it is important to note the condition of the The status lights for the main control board is a dual-color
status lights. Therefore, prior to cycling power to the sys- LEDʼs. Normal operation for each is steady green. Where
tem, check the power source status light for error as the status light on the input control board is one color.
sequences as noted below. Normal operation is for the status light to be off ( and the
buzzer to be off).
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 Error conditions are indicated in the following Table E.1.
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 Meaning
Condition Main control board status light Input control board

Steady Green System OK. Power source is operational, and is communicating normally with all Not applicable.
healthy peripheral equipment connected to its ArcLink network.

Blinking Green Occurs during power up or a system reset, and indicates the POWER Not applicable.
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.

Fast Blinking Green Indicates Auto-mapping has failed Not applicable.

Alternating Green and Red Non-recoverable system fault. If the Status lights are flashing any com- Not applicable.
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.

Steady Red Not applicable. Not applicable.

Blinking Red 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 E-3
Observe all Safety Guidelines detailed throughout this manual

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 Indicates over temperature. Usually accompanied by Thermal LED.

Check fan operation. Be sure process does not exceed duty cycle
limit of the machine

54 Secondary (Output) over current error The long term average secondary (weld) current limit has been
exceeded. NOTE: The long term average secondary current limit is
325 amps.

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

58 Primary Fault error 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.

Other 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 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual

INPUT CONTROL BOARD

Error Code # Indication

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

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

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

337 Pre-charge timeout Problem with start-up sequence. If problem persists contact Service
Department.

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

Other Contact the Service Department.

WIRE DRIVE MODULE

Error Code # Indication

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

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

83 Shutdown #1 The Shutdown inputs on the Power Wave R350 have been dis-
abled. The presence of these errors indicates the Feed Head
84 Shutdown #2 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 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Basic Machine Problems

Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly
sized. See installation section of
this manual for recommended
sizes.

2. Improper Weld Procedure requir- 2. Reduce output current, duty

ing output levels in excess of cycle, or both.
machine rating.

3. Major physical or electrical dam- 3. Contact your local authorized

age is evident when the covers Lincoln Electric Field Service
are removed. facility for technical assistance.

Machine will not power up (no lights) 1. No Input Power 1. Make sure input supply discon-
nect has been turned ON. Check
input fuses. Make certain that the
Power Switch (SW1) on the
power source is in the “ON” posi-
tion.

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

Machine wonʼt weld, canʼt get any 1. Input voltage is too low or too high. 1. Make certain that input voltage is
output. correct, according to the Rating
Plate located on the rear of the
machine.

2. Thermal Error. 2. See “Thermal LED is ON” sec-

This problem will normally be tion.
accompanied by an error code. See
“Status Light” section of this docu- 3. Secondary current limit has been 3. Possible short in output circuit. If
ment for additional information. exceeded. (see error 54) condition persists, contact an
3a. Input control board fault (see authorized Lincoln Electric Field
input control board error status). 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 TROUBLESHOOTING E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Thermal LED is ON Improper
Basic fan operation
Machine Problems (Continued)

Thermal LED is ON 1. Improper fan operation. 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. Open thermostat circuit. 2. Check for broken wires, open

connections or faulty thermostats
in the thermostat circuit.

“Real Time Clock” no longer func- 1. Control PC Board Battery. 1. Replace the battery (Type:
tioning BS2032)
Weld and Arc Quality Problems
General degradation of weld perfor- 1. Wire feed problem. 1. Check for feeding problems. Make
mance sure proper gear ratio has been
selected.

2. Cabling problems. 2. Check for bad connections,

excessive loops in cable, etc.

NOTE: The presence of heat in the

external welding circuit indicates
poor connections or undersized
cables.

3. Loss of, or improper Shielding 3. Verify gas flow and type are cor-
Gas. rect.

4. Verify weld mode is correct for 4.Select the correct weld mode for
process. the application.

5. Machine calibration. 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 TROUBLESHOOTING E-7
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Weld and Arc Quality Problems (Continued)
Wire burns back to tip at the end of 1. Burnback Time 1. Reduce burnback time and/or
the weld. work point.

Machine output shuts down during a 1. Secondary current limit has been 1. Adjust procedure or reduce load
weld. exceeded, and the machine shuts to lower current draw from the
down to protect itself. machine.

2. System Fault 2. A non-recoverable fault will inter-

rupt welding. This condition will
also result in a status light blink-
ing. See the Status Light section
for more information.

Machine wonʼt produce full output. 1. Input voltage may be too low, lim- 1. Make certain that the input voltage
iting output capability of the power is proper, according to the Rating
source. Plate located on the rear of the
machine.

2. Single Phase Operation 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. Machine calibration. 3. Calibrate secondary current and

voltage.

Excessively long and erratic arc. 1. Wire feed problem. 1. Check for feeding problems. Make
sure proper gear ratio has been
selected.

2. Loss of, or improper Shielding 2. Verify gas flow and type are cor-
Gas rect

3. Machine calibration. 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 TROUBLESHOOTING E-8
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Ethernet

Cannot Connect 1. Physical connection. 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. IP address information. 2. Use the appropriate PC utility to

verify the correct IP address infor-
mation has been entered.

2a. Verify no duplicate the IP

addresses exist on the network.

3. Ethernet Speed 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 locat-
ed next to current carrying con-
ductors. 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

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-1
F-2 DIMENSION PRINT F-2

27.44 22.25

13.87

18.81

6.00
18.31

POWER WAVE® R350

 NOTES

POWER WAVE® R350

 NOTES

POWER WAVE® R350

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

WARNING electrode with skin or wet clothing.

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

PRECAUCION G Aislese del trabajo y de la tierra.

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

German G Berühren Sie keine stromführenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
G Los humos fuera de la zona de res- Spanish
G Desconectar el cable de ali- G No operar con panel abierto o
piración.
G Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
G Gardez la tête à l’écart des fumées. G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux French
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
G Vermeiden Sie das Einatmen von G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
G Mantenha seu rosto da fumaça. G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Use ventilação e exhaustão para G Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. G Não opere com os paineis abertos ATENÇÃO
G Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 • World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com