Im10294 PDF

Operator’s Manual
POWER WAVE ® R350

For use with machines having Code Numbers:
12482
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Date Purchased no later than the following business day.
For Service outside the USA:

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Serial: (ex: U1060512345)
IM10294 | Issue Date July-16

© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
WARNING PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 5/16/2018
SAFETY
SECTION A: 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
WARNINGS
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
CALIFORNIA PROPOSITION 65 WARNINGS Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
WARNING: Breathing diesel engine exhaust repairing equipment.
exposes you to chemicals known to the State 1.e. In some cases it may be necessary to remove safety guards to
of California to cause cancer and birth defects, perform required maintenance. Remove guards only when
or other reproductive harm. necessary and replace them when the maintenance requiring
• Always start and operate the engine in a their removal is complete. Always use the greatest care when
well-ventilated area. working near moving parts.
• If in an exposed area, vent the exhaust to the outside. 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
• Do not modify or tamper with the exhaust system.
rods while the engine is running.
• Do not idle the engine except as necessary.
1.g. To prevent accidentally starting gasoline engines while turning
For more information go to the engine or welding generator during maintenance work,
www.P65 warnings.ca.gov/diesel disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
WARNING: This product, when used for welding or 1.h. To avoid scalding, do not remove the radiator
cutting, produces fumes or gases which contain pressure cap when the engine is hot.
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm ELECTRIC AND

www.P65warnings.ca.gov MAGNETIC FIELDS MAY
BE DANGEROUS
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 2.a. Electric current flowing through any conductor
INJURY OR DEATH. KEEP CHILDREN AWAY. causes localized Electric and Magnetic Fields (EMF).
PACEMAKER WEARERS SHOULD CONSULT WITH Welding current creates EMF fields around welding cables
THEIR DOCTOR BEFORE OPERATING. and welding machines
Read and understand the following safety highlights. For 2.b. EMF fields may interfere with some pacemakers, and
additional safety information, it is strongly recommended welders having a pacemaker should consult their physician
that you purchase a copy of “Safety in Welding & Cutting - before welding.
ANSI Standard Z49.1” from the American Welding Society,
2.c. Exposure to EMF fields in welding may have other health effects
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
which are now not known.
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. minimize exposure to EMF fields from the welding circuit:
BE SURE THAT ALL INSTALLATION, OPERATION, 2.d.1. Route the electrode and work cables together - Secure
MAINTENANCE AND REPAIR PROCEDURES ARE them with tape when possible.
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 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
FOR ENGINE POWERED work cable should also be on your right side.
EQUIPMENT. 2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
1.a. Turn the engine off before troubleshooting 2.d.5. Do not work next to welding power source.
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 Safety 02 of 04 - 5/16/2018
SAFETY
ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the fume.
• DC Manual (Stick) Welder. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
• AC Welder with Reduced Voltage Control.
hardfacing (see instructions on container or SDS)
3.c. In semiautomatic or automatic wire welding, the electrode, or on lead or cadmium plated steel and other
electrode reel, welding head, nozzle or semiautomatic welding metals or coatings which produce highly toxic
gun are also electrically “hot”. fumes, keep exposure as low as possible and
3.d. Always be sure the work cable makes a good electrical within applicable OSHA PEL and ACGIH TLV limits
connection with the metal being welded. The connection should using local exhaust or mechanical ventilation
be as close as possible to the area being welded. unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
3.e. Ground the work or metal to be welded to a good electrical (earth) outdoors, a respirator may also be required.
ground. Additional precautions are also required when
3.f. Maintain the electrode holder, work clamp, welding cable and welding
welding machine in good, safe operating condition. Replace on galvanized steel.
damaged insulation. 5. b. The operation of welding fume control equipment is affected by
3.g. Never dip the electrode in water for cooling. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between the level should be checked upon installation and periodically
two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8.
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.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 5/16/2018
SAFETY
WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
• Away from areas where they may be struck or subjected
and the operating information for the equipment being used.
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe 7.f. Valve protection caps should always be in place and hand tight
Practices for the Preparation for Welding and Cutting of except when the cylinder is in use or connected for use.
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society 7.g. Read and follow the instructions on compressed gas cylinders,
(see address above). associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
6.e. Vent hollow castings or containers before heating, cutting or the Compressed Gas Association, 14501 George Carter Way
welding. They may explode.
Chantilly, VA 20151.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area. FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
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.
Safety 04 of 04 - 5/16/2018
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 19/17/14

380-415/460/575
K3022-2 50/60 Hz 300 Watts Max. .95
100% rating 15/14/11 (fan on)
RATED OUTPUT
INPUT GMAW GTAW-DC SMAW
VOLTAGE/PHASE/
FREQUENCY 40% 60% 100% 40% 60% 100% 40% 60% 100%
380-415/3/50/60 350 A 320 A 300 A 350 A 325 A 300 A 325 A 275 A 250 A
460/3/50/60 31.5 V 30 V 29 V 24 V 23 V 22 V 33 V 31 V 30 V
575/3/50/60
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
380-415/3/50/60 19A, 40% 12 (4) 30

460/3/50/60 17A, 40% 12 (4) 25
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

WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)
Mean Peak
GMAW
GMAW-Pulse 40-350A 40-70V 79V
FCAW
GTAW-DC 5-350A 24V 42V
SMAW 55-325A 60V 67V
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3022-2 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
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 should be
tion. connected to both handles. Do not attempt to lift the POWER
WARNING 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
suspended when lifting.
other equipment connected to the welding system
FALLING
at the disconnect switch or fuse box before work-
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
-------------------------------------------------------------
The POWER WAVE® R350 cannot be stacked.
SELECT SUITABLE LOCATION
The POWER WAVE® R350 will operate in harsh environments. Even TILTING
so, it is important that simple preventative measures are followed in
order to assure long life and reliable operation. Place the machine directly on a secure, level surface or on a
recommended undercarriage. The machine may topple over if this
• The machine must be located where there is free circulation of procedure is not followed.
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
INPUT AND GROUND CONNECTIONS
to a minimum. The use of air filters on the air intake is not Only a qualified electrician should connect the POWER WAVE®
recommended because normal air flow may be restricted. Failure R350. Installation should be made in accordance with the
to observe these precautions can result in excessive operating appropriate National Electrical Code, all local codes and the
temperatures and nuisance shutdown. information in this manual.
• Keep machine dry. Shelter from rain and snow. Do not place on
wet ground or in puddles. MACHINE GROUNDING
• Do not mount the POWER WAVE® R350 over combustible The frame of the welder must be grounded. A ground terminal
surfaces. Where there is a combustible surface directly under marked with a ground symbol is located next to the input power
stationary or fixed electrical equipment, that surface shall be connection block.
covered with a steel plate at least .060” (1.6mm) thick, which
shall extend not less than 5.90” (150mm) beyond the equipment
See your local and national electrical codes for proper grounding
on all sides.
methods.
This equipment is for industrial use only and it is not intended for
use in residential locations where the electrical power is provided by HIGH FREQUENCY PROTECTION
the public low-voltage supply system. There can be potential diffi- Locate the POWER WAVE® R350 away from radio controlled
culties in residential locations due to conducted as well as radiated machinery. The normal operation of the POWER WAVE® R350 may
radio-frequency disturbances. The EMC or RF classification of this adversely affect the operation of RF controlled equipment, which
equipment is Class A. may result in bodily injury or damage to the equipment.
POWER WAVE® R350

INPUT CONNECTION WARNING

WARNING The POWER WAVE® R350 ON/OFF
switch is not intended as a service
Only a qualified electrician should disconnect for this equipment. Only
connect the input leads to the a qualified electrician should con-
POWER WAVE® R350. Connections nect the input leads to the POWER
WAVE® R350. Connections should
should be made in accordance with
be made in accordance with all local and national
all local and national electrical electrical codes and the connection diagram locat-
codes and the connection diagrams. Failure to do ed on the inside of the reconnect access door of
so may result in bodily injury or death. the machine. Failure to do so may result in bodily
injury or death.
------------------------------------------------------------------------
------------------------------------------------------------------------
Follow the power cord connection instructions.*
POWER CORD REPLACEMENT
For Three Phase Input
Connect green lead to ground per National Electric WARNING
Code.
Only a qualified electrician should
Connect black, red and white leads to power.
connect the input leads to the
POWER WAVE® R350. Connections
should be made in accordance with
INPUT FUSE AND SUPPLY WIRE all local and national electrical
CONSIDERATIONS codes and the connection dia-
grams. Failure to do so may result in bodily injury
Refer to Specification Section for recommended fuse, or death.
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 If the input power cord is damaged or needs to be
"thermal/magnetic" circuit breakers). Choose input replaced an input power connection block is located
and grounding wire size according to local or national in the back of the machine with the access panel
electrical codes. Using input wire sizes, fuses or cir- removed as shown Figure A.1.
cuit breakers smaller than recommended may result in
"nuisance" shut-offs from welder inrush currents, even ALWAYS CONNECT THE POWER WAVE GROUND-
if the machine is not being used at high currents. 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.
INPUT VOLTAGE SELECTION FIGURE A.1
The POWER WAVE® R350 automatically adjusts to
work with different input voltages. No reconnect
switches settings are required.
*An input cord is not provided with the POWER

WAVE® R350.
POWER WAVE® R350

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
POWER WAVE® R350

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

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
SPECIFICATIONS possible. In extremely sensitive applications it may be
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
WAVE R350 has accurate data about the arc condi- Voltage sense leads requirements are based on the
tions. weld process (See Table A.2)
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® R350

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

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
POWER WAVE® R350

• 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 WAVE® R350

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 coming 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 CD’s 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
R350’s 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-process The POWER WAVE® R350 is a high speed, multi-
power source with high-end functionality capable of process power source capable of regulating the cur-
DC TIG, MIG, Pulsed MIG and Flux-Cored welding. It rent, voltage, or power of the welding arc. With an out-
is ideal for a wide variety of materials including alu- put range of 5 to 350 amperes, it supports a number
minum, stainless, and nickel — where arc perfor- of standard processes including synergic GMAW,
mance is critical. The Power Wave® R350 includes an GMAW-P, FCAW, FCAW-SS, GTAW and GTAW-P
integrated wire drive module and 14-pin MS-Style on various materials especially steel, aluminum and
connection to support the Power Feed 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 Wave’s, 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 compat-

ible 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.
• 380-600 VAC, 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/reliability. WARNING
• 115V/15A duplex receptacle supports rigorous The Power Wave R350 ON/OFF switch is NOT
demands of heavy duty fume extraction and water intended as a Service Disconnect for this
cooling equipment. equipment.
• Enclosure reinforced with heavy duty aluminum ------------------------------------------------------------------------
extrusions for mechanical toughness. 8. OPTIONAL VOLTS/AMPS DISPLAY
• Waveform Control Technology™ for good weld
appearance and low spatter, even when welding
nickel alloys. FIGURE B.1
• 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-
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 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.)
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 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 Pin Function
CIRCUIT BREAKER 1 (10 AMP): Provides protec- 1 Transmit +
tion for the 115V auxiliary. 2 Transmit -
3 Receive +
2. ARCLINK® RECEPTACLE AND CIRCUIT 4 ---
BREAKER 2 (10 AMP): 5 ---
Pin Lead Function 6 Receive -
A 53A / 53B Communication Bus L 7 ---
B 54A / 54B Communication Bus H 8 ---
C 67A / 67B Electrode Voltage Sense
D 52A / 52B +40V DC 6. WIRE FEEDER RECEPTACLE (14-PIN): For con-
E 51A / 51B 0 VDC nection to the Auto Drive 4R100/4R220 and PF10R
series wire feeders.
3. SYNC-TANDEM CONNECTOR (4 PIN – MS Pin Lead Function
STYLE): A 539 Motor +
Pin Lead Function B 541 Motor -
A WHITE “Ready” H C 521 Solenoid +
B BLACK/RED “Ready” L D 522 Solenoid Common
C GREEN “Kill” H E 845 Tach 2A differential signal
D BLACK/GREEN “Kill” L F 847 Single Tach input
G 841 +15V Tach supply
4. OPTIONAL DEVICENET CONNECTOR (5 PIN – H 844 Tach common
SEALED MINI STYLE): I Open Reserved for future use
Pin Lead Function J Open Reserved for future use
2 894 +24 VDC DeviceNet K 842 Tach 1A differential signal
3 893 Common DeviceNet L 843 Tach 1B differential signal
4 892 DeviceNet H M 846 Tach 2B differential signal
5 891 DeviceNet L N 67G Electrode Voltage Sense
7. OPTIONAL EXTERNAL I/O CONNECTOR:
Terminal Strip for making simple input signal connec-
tions. (See Figure B.2a)
The terminal strip is divided into three groups:
FIGURE B.2
Group #1 - TRIGGER
Group #2 - FEED FORWARD/REVERSE
Group #3 - SHUTDOWN INPUTS
When the Power Wave S350(CE) is controlled via
DeviceNet, the “TRIGGER” and “Feed” groups can
interfere with the welding sequence and should not be
used.
All inputs use "normally open" logic except the shut-
down group. The shutdown inputs use "normally
closed" logic, and are always enabled. Unused shut-
downs must be tied to the +15V supply for the shut-
down group. Machines are shipped from the factory
with jumpers installed on both shutdown inputs.
FIGURE B.2a
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
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
POWER WAVE® R350

C-1 ACCESSORIES C-1
KITS, OPTIONS AND ACCESSORIES Welding Fume Extractors

All Kits Options and Accessories are found on the Web site: Lincoln offers a wide range of fume extraction environmental
(www.lincolnelectric.com) system solutions, ranging from portable systems easily
wheeled around a shop to shop-wide central systems ser-
vicing many dedicated welding stations.
FACTORY INSTALLED
Request Lincoln publication E13.40
None Available
(See www.lincolnelectric.com)
FIELD INSTALLED OPTIONS

TIG OPTIONS
GENERAL OPTIONS
Pro-Torch™ TIG Torches
DeviceNet Kit
A full line of air-cooled and water-cooled
Mounts inside the back of the Power Wave® R350. Allows
torches available.
Devicenet objects to communicate with the Power Wave®
Request Lincoln publication E12.150
R350.
Order K2827-1
Hand Amptrol®
I/O Kit Provides 25 ft. (7.6 m) of remote current control for TIG
Mounts inside the back of the Power Wave® R350. welding.
Allows external access to Feeder Control inputs.
Order K3123-1 Order K963-4 for Hand Amptrol with
12 pin connector
Work Voltage Sense Lead Kit
Required to accurately monitor voltage at the arc. Foot Amptrol®
Order K940-XX Series Provides 25 ft. (7.6 m) of remote current control for TIG
Order K1811-XX Series welding. Order K870-2 for Foot Amptrol with 12 pin connec-
tor.
Deluxe Adjustable Gas Regulator & Hose Kit
Accommodates CO2, Argon, or Argon-blend gas cylinders. Arc Start Switch
Includes a cylinder pressure gauge, dual scale flow gauge May be used in place of the Foot or Hand Amptrol®. Comes
and 4.3 ft. (1.3 m) gas hose. with a 25 ft. (7.6 m) cable. Attaches to the TIG torch for con-
Order K586-1 venient 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. Rated 350 Cam-Lock Torch Adapter
amps, 60% duty cycle. For connecting K1782-1, K1782-3, K1782-12 torches to the
Order K1803-2 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
Coaxial Welding Cable Get everything you need for TIG welding in one complete
Optimum weld cables for minimizing cable inductance and easy-to-order kit packaged in its own portable carrying case.
optimizing welding performance. Includes: PTA-17V torch, parts kit, Harris® flowmeter/regula-
tor, 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 K1796-100 for 100 feet (30.5 m) cable length. Work and Feeder Welding Cables
350 amps, 60% duty cycle with Cam-Lock connectors and
AWG #1 Coaxial Cables: Ground Clamp.
Order K2593-25 for 25 feet (7.6 m) cable length. Order K1803-2
COMPATIBLE LINCOLN EQUIPMENT
Any Arclink compatible wire feeding equipment
POWER WAVE® R350
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING
• 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
• 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

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- LED’s. 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 board’s 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 board’s
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
POWER WAVE® R350
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
POWER WAVE® R350
INPUT CONTROL BOARD

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

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
POWER WAVE® R350
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 won’t weld, can’t 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
POWER WAVE® R350
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
POWER WAVE® R350
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 won’t 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
POWER WAVE® R350
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
POWER WAVE® R350
POWER WAVE R350 WIRING DIAGRAM
F-1
1
1 851
2 GENERAL INFORMATION
2 852 CAVITY NUMBERING SEQUENCE
3 I/O
3 853 ELECTRICAL SYMBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
33
32
33A
4
32A
GND5
LEADS 317A AND 4
CONNECTOR
854
318A PRESENT ON 5 LEAD COLOR CODING
1 415
6
2
5
2 416
3 GND4
4 417
5 418
6
7
8
3
4
EARLIER MODELS 5 855 (OPTIONAL) 1 1 2 1 3
6 B - BLACK J10A1, J2, J5, J11, J9, J13, J16,
6 856 J10B1, J31, J46,
317 7 R - RED J26, J27, J62,
7 857 J811, 2 J51, J111, 3 4 J112, J83, J1 4 6
J63
B5 317A 851 1 +15VDC - GROUP #1
J62
414 7 8 N- BROWN J2 J82, J81
858
xxxxxxx
115 VAC 318 8
413 2 9 852 2 TRIGGER J8, J24, J28, 1 4 1 5
J61 INVERTER PCB B6 318A V - VIOLET J3, J4,
412 6 9 859 J29, J43, J47,
(ASSEMBLY G6571) 10 853 3 DUAL PROCEDURE G - GREEN J45, J61
411 1 10 8510 J63, J84
xxxxxxx
OPTIONAL 5 8 J86 6 10
11 854 4 2 STEP / 4 STEP
DEVICENET 11 8511 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
12 855 5 +15VDC - GROUP #2 1 8
12 8512 ALIGNS WITH WHITE LEAD OF LED SOCKET. 1 6
0 VDC WHEN 'ON' J6, J7,
13 512A 856 6 COLD INCH FORWARD J12, J23,
+15VDC 13 512A J41, J85
16
358
356
361
362
416
363
553
14 J25, J42 9
364
511A
54
53
857 7 COLD INCH REVERSE 6 12 J87
343
344
348
347
342
341
357
349
352
354
345
346
14 511A
892
893
891
894
15 1W STATUS LED 858 8 GAS PURGE
33A STATUS LED 15 1W
33 16 1B 859 9 +15VDC - GROUP #3
16 1B
1
2
3
4
5
6
7
8
9
8510 10 SHUTDOWN 1 INPUT
10
1
2
3
4
5
6
7
8
5
6
9
J85-A
2
3
4
1
10
11
12
1
2
3
4
CB1
2
1
3
4
P85-A 8511 11 SHUTDOWN 2 INPUT
10A
32 8512 12 NOT USED
1
J4
CONTROL BOARD 65
J2
J11
32A
J13
34 2
J12
1
G6682 66 3 J46 LOCATED ON
2
4 L15732 CASE BACK
3
J15
4
5 1 51 S12021-79 (INSERTION SIDE)
GND5
J7
J8
J3
J6
6 2 S2
J5
S3
J9
3 S4 S6
115V 7 4 358 S5
8 J47
RECEPTACLE 356
2
4
3
2
1
5
9
8
7
6
5
4
3
8
3
1
12
9
7
3
8
7
6
5
4
2
15
11
10
6
5
4
2
1
16
14
13
12
4
2
16
15
14
11
3
13
10
5
1
(Neutral Bonded)
6
9 6
7
10
8 52
ETHERNET
CONNECTOR CAPACITOR NOT
67
21
401
402
407
409
410
403
360
404
359
408
373
206
213
406
418
415
372
554
202
417
216
212
211
350
355
371
370
PRESENT ON 67E 67E 1 1 1A
RJ 45 EARLIER MODELS L1 T1
ETHERNET
TYPE CABLE 67C 67D 2
21 3
2A
L2 T2
R
CB2 65A TOROID 4
10A 1J56 353A 353 3 3A
65 361 8 52D
FAN 52C 6 L3 T3
3J56 351A 351 359 7 67C
67D 5 67F
351B 52C
363 6 51C 4 51D
B 206A 54D
67C
360 5 54C 3 THERMAL LED
+
353B 51C
362 4 2 AC
S6 ROBOTIC R
409
410
10 350 54C
364 3 53C 1 53D
INTERFACE 1J55 353C
HEAT B
9 65A 2
RECEPTACLE FAN SINK - AC 373 4
3J55 351C 8 1 P114/J16
372 3 W
200 OHM
100 W
8 7 66 371
A P112 2
539 B 6
7 J45 370 1
5 355 207 NOT USED W B
B R 6
541 B53 4 J51
5
3 353
J29
C 521 1J54 353D B40 4 CONTROL BD STATUS
FAN 3 2 SHEILDED RED/GREEN LED
3J54 351D 1 351 TWISTED
D 522 2 PAIR
B 1
E B/G B52 OUTPUT
8 348 CHOKE
F 847 7 347 BL1 A
553 6 346 216 4
G W GND-B B39 B38 5 345 211 3
BL2 A2 LEM
J28
4 344
R
G
213
W
2
880
541
886
539
521
522
NOT USED
B/R
53D
51D
52D
847
54D
B/G
B/W
H B/W 3 343 212 1 +

2 342 BL3 A3
I
4
4
4
554
1
1
2
3
5
4
1
6
1
2
3
2
3
5
7
6
8
2
3
1 341 CURRENT
TRANSDUCER
J A4
BL4 INPUT CONTROL J84 J83 J82 J81 1
K R BOARD 2
BL5 A5 3
DIAGRAMS
L B/R G6758 FEEDHEAD PCB 4

309 6 6
M G 3 STAGE INVERTER 5
A6 5 5
POWER WAVE® R350

G4770-1 BL6 G6752 J86 6
303 4 4 321
N 67G J26 J27 7
301 3 3 322 67G 8
2 2 9
INPUT 311 1 1
J85 10
53A CHOKE J87
ARCLINK - A
51A 1 51
53B 52A 2 52 316 12
67A
8
9
7
3
6
5
4
2
8
3 67
1
9
7
3
6
5
4
2
1
54A
16
15
12
11
14
13
10
315
16
15
12
11
B29 11
14
13
10
ARCLINK + B B28 8 338

54B 54A 4 54 B32 7 337 337 10
53A 5 53
ELECTRODE 67A 333 9
B
C 51B 51C 6 336

W
SENSE 67B 6
360
511
512
404
5 335 332 8
52B 7 52C 3A J43
52A 67B 8 67C 4 334 336 7
+40VDC D J23
52B 54B 9 54C 3 333 307 6
51A 53B 10 53C B30 2A 2 332 308 5
0 VDC E B W
51B 1 331 306 4
67F
512
511
67G
J55 305 3
S3 ARCLINK .0047 uF 1A 12 322 313 2
4
317
1
1
2
3
5
6
2
FEEDHEAD STATUS
RECEPTACLE 317A 11 314 1 WHITE LED
318 B31 10 J1 J2
318A 9 206 +
A B37 B41 8 328 901B VOLTAGE SENSE
J24
J25
J41
B LEADS 317A AND 7 SELECT PCB
J42
DIFF_1 HIGH C GRN 318A PRESENT ON 6 326
GRN 1 357 5 M19540-2
9
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
EARLIER MODELS
11
10
12
250 OHM 25 W
DIFF_1 LOW D BLK/GRN BLK/GRN 2 354 4 324
9
8
7
6
5
4
3
2
1
M20305-1
12
11
10
15
14
13
16
DIFF_2 HIGH E RED RED 3 352 3
BLK/RED 4 349 2
250 OHM 25 W
DIFF_2 LOW F BLK/RED

J50 1 321
404
403
402
401
408
407
406
334
335
324
338
331
326
328
S5
311
301
303
316
315
314
313
309
308
307
306
305
SYNC/TANDEM 903B
202 - WORK
CONNECTOR
1 GROUND BOND CIRCUIT

G
+24 VDC INPUT 2 894 S4 BASE TO EARTH GROUND PER THE
+24 VDC COMMON 3 893 DEVICENET GND1 VERTICAL PANEL
GND2 CASEBACK
NATIONAL ELECTRIC CODE
DNET CAN_H 4 892 CONNECTOR
GND3 CASEFRONT
DNET CAN_L 5 891 (OPTIONAL) H
G6536-3PRINT
R
CLEVELAND, OHIO U.S.A.
FINAL PRINTED FORM TO

BE ON ONE 8.25 X 11.00
ADHESIVE BACKED LABEL
SHEET PER E3269-1 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICA
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
F-1
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 DIMENSION PRINT F-2
27.44 22.25
13.87
18.81
6.00
18.31
POWER WAVE® R350

Power Wave R350 CCC -
12482
Index of Sub Assemblies - 12482
KEY PART NUMBER DESCRIPTION QTY
P-884-A INDEX OF SUB ASSEMBLIES AR
P-884-B.2 MISCELLANEOUS ITEMS AR
1 P-884-C CASE FRONT ASSEMBLY AR
2 P-884-D BASE & POWER CONVERSION ASSEMBLY AR
3 P-884-E VERTICAL DIVIDER PANEL ASBLY AR
4 P-884-F OUTPUT CHOKE ASSEMBLY AR
5 P-884-G CASE BACK ASSEMBLY AR
6 P-884-H ROOF ASSEMBLY AR
Printed 08/02/2016 at 10:49:51. Produced by Enigma.
Power Wave R350 CCC - 12482 1

Index of Sub Assemblies - 12482
P-884-A.jpg
2 Power Wave R350 CCC - 12482

Miscellaneous Items
9SG6094 PRIMARY CONTROL HARNESS 1
9SM19969-13 ETHERNET PATCH CABLE ASBLY 1

Miscellaneous Items
No Image

Case Front Assembly
9SG6519-6 CASE FRONT ASSEMBLY 1
1 9SG6513-4 CASE FRONT 1
9SM22487-1 LED HARNESS 1
9SS23740-2 LED PANEL MOUNT ASSEMBLY 2
9ST13657-4FA YELLOW LED 1
9ST13657-7H24 LED-T-1 3/4BI-COLORRED/GREEN 1
3 9SS23093-1 LED LENS CLEAR 3
3A 9SS23094-1 RETAINING O RING 3
4A 9SM20305-1 NOISE SUPPRESSOR PC BD ASBLY 1
4B 9SS28402 NOISE SUPPRESSOR BRACKET 1
9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2
5A 9SL13263-1 PCB MOUNTING BRACKET 1
6A 9SL13263-2 PCB MOUNTING BRACKET 1
7A 9SS29541-2 LINE SWITCH 1
15A 9SS16656-4 OUTPUT TERMINAL ASBLY 2
15B 9SCF000371 #10-24X.50HHCS-FULL-GR2-3147 4
16A 9SG6758-1 INPUT CONTROL & POWER SUPPLY PC BD ASBLY 1
18 9SG8554 NAMEPLATE 1
19 9ST3960 FLANGE NUT 2
21 9ST10397-23 PLUG BUTTON 1
22A 9SG6864 OUTPUT STUD COVER 2
9SS9262-184 WASHER 4
9SS9225-100 SELF TAPPING SCREW 4

26A 9SS9262-80 PLAIN WASHER 2
26B 9SE106A-15 LOCKWASHER 2
26C 9SCF000021 1/2-13X1.00HHCS 2
27A 9SS18657 SQUARE FLANGE FEMALE RECEPTACLE 1
28A 9SL15069 COVER PLATE 1
28B 9SS9225-99 SELF TAPPING SCREW 4

Case Front Assembly
28C 9SG6529 UI TRIM 1
9SS23740-1 LED PANEL MOUNT ASBLY 1
9ST13657-7H24 LED-T-1 3/4BI-COLORRED/GREEN 1

Case Front Assembly
P-884-C.jpg

Base & Power Conversion Assembly
1A 9SL15067-1 BASE 1
2 9SM21251-2 BASE EXTRUSION 2
3A 9SL15091 BRACKET 2
9ST9695-1 LOCKWASHER 2
4A 9SCF000013 1/4-20X.625HHCS 4
4B 9SS28070 QUICK LOCK FOOT 4
9SE106A-2 LOCKWASHER 4
5A 9SM21489-1 INPUT CHOKE 1
5B 9SM21468 INPUT CHOKE BRACKET 1
5C 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 2
10A 9SL13138 CORNER CAP 4
10B 9SS9262-182 PLAIN WASHER 8
10C 9SS9225-100 SELF TAPPING SCREW 8
12A 9SM21469-3 POWERBOARD BOTTOM BRACKET 1
13 9SG6037-1 POWER BOARD ASBLY 1
13A 9ST13359-29 THERMOSTAT 1
13B 9SM21469-2 POWER BOARD UPPER BRACKET 1
9SS9262-27 PLAIN WASHER 6
14 9SM15045-100 ACOUSTICAL FOAM 3
15 9ST13260-4 DECAL-EARTH GROUND CONN 1

16A 9SCF000010 #10-24HN 2
16B 9SE106A-1 LOCKWASHER 1

Base & Power Conversion Assembly
P-884-D.jpg

Vertical Divider Panel Asbly
9SG6589-5 VERTICAL DIVIDER PANEL ASBLY 1
1 9SG6511 CENTER PANEL 1
2A 9SL15732-1 40 V DC BUS BD ASBLY 1
2B 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4
3A 9SS28105 MYLAR INSULATION 1
3B 9SS20763-3 TERMINAL BLOCK 1
3C 9SCF000193 #8-32X1.25RHS 2
4A 9SS28735-5 CONTROL BOARD ASBLY 1
6 9ST12380-1 BUSHING 1
9SS18858-11 SUPPRESSOR ASBLY 1
11A 9SG6571-2 115V SUPPLY PC BD ASBLY 1
9SS19300-7 SUPPORTPCBSNAP-IN0.63 2
11C 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4
12 9SS18491-3 M.O.V. ASBLY 1

Vertical Divider Panel Asbly
P-884-E.jpg

Output Choke Assembly
9SL13270-3 OUTPUT CHOKE ASBLY 1
1 9SM21471-3 TOP CHOKE BRACKET 1
2 9ST11827-3 CARRIAGE BOLT 1
9SS28371 CHOKE INSULATOR 2
4 9SS25781-2 SPACER WASHER 6
5 9SS26801-2 OUTPUT CHOKE COIL 3
6A 9SM21472-3 BOTTOM CHOKE BRACKET 1
6B 9SS18504-10 CURRENT TRANSDUCER 1
9SCF000033 #8-32X.50RHS 1
9ST4291-A LOCKWASHER 1
7A 9ST14605 INSULATOR 1
7C 9SE106A-2 LOCKWASHER 1
7D 9SCF000017 1/4-20HN 1
14A 9SS22168 HEAT SINK HOLDER 2
9SCF000015 1/4-20X1.00HHCS 2
14C 9SS9262-98 PLAIN WASHER 4
14D 9SE106A-2 LOCKWASHER 2
14E 9SCF000017 1/4-20HN 2
15A 9SM22372 BUS BAR 1
15B 9SCF000015 1/4-20X1.00HHCS 2
15D 9SE106A-2 LOCKWASHER 2
15E 9SCF000017 1/4-20HN 2

16A 9SCF000015 1/4-20X1.00HHCS 3
16C 9SE106A-2 LOCKWASHER 3
16D 9SCF000017 1/4-20HN 3
17A 9SS10404-137 RESISTOR-WW100W2005% 1
17B 9ST4479-A INSULATING WASHER 2
17E 9SCF000191 #10-24X7.50RHS 1


P-884-F.jpg

Case Back Assembly
9SG6523-7 CASE BACK ASSEMBLY 1
1A 9SL15066 FAN BRACKET 1
2A 9SM22149 FAN ASBLY 3
2B 9SCF000408 #8-32X2.00HHMS 12
9ST4291-A LOCKWASHER 12
5 9SG6510-3 REAR PANEL 1
6A 9SS19999 CORD GRIP CONNECTOR 1
6B 9ST14370-3 CONDUIT LOCKNUT 1
7A 9SM19969-9 ETHERNET RECEPTACLE BULKHEAD 1
7B 9SS25438-9 ADAPTER PLATE 1
7C 9SM19969-4 ETHERNET RECEPTACLE COVER 1
9SL15109 FAN HARNESS 1
10A 9ST12287-20 CIRCUIT BREAKER-10A250VAC 1
10B 9SS22061-3 SEALING BOOT 1
11A 9SS25438-3 COVER PLATE 1
12A 9SS28546 COVER PLATE 1
9SM21927-1 PLUG AND LEAD ASBLY 1
13A 9SS12021-79 BOX RECEPTACLE SOLID SHELL 1
13B 9SS25438-2 CONNECTOR ADAPTER PLATE 1

14 9SS17062-9 CABLE CONNECTOR CAP 1
15A 9SL15108 LOUVER COVER PLATE 1
20A 9SG6602 RECEPTACLE ASSEMBLY 1
9SCF000010 #10-24HN 2
21 9SS28056-6 RATING PLATE 1

Case Back Assembly
22A 9SL15123 AIR BAFFLE 1
9SM22519 CONNECTOR & LEAD ASBLY 1
9SG6539 WIRE DRIVE HARNESS 1
28B 9SS25438-4 ADAPTER PLATE 1

Case Back Assembly
P-884-G.jpg

Roof Assembly
9SM22129-7 ROOF ASSEMBLY 1
1A 9SL12763-1 ROOF 1
1B 9SG8554 NAMEPLATE 1
1C 9SL8064-1 WARNING DECAL (INTERNATIONAL) 1
9SM22375 TOP EXTRUSION ASSEMBLY 1
2A 9SL15068-1 HORIZONTAL DIVIDER PANEL 1
2B 9SM21251-1 TOP EXTRUSION 2
3A 9SL15070 HANDLE MOUNTING BRACKET 2
5A 9SL13138 CORNER CAP 4
6A 9SG6525-3 HANDLE 2
6B 9SCF000410 1/4-20x.75HHCS-FULL-GR2-4554 8
6C 9SE106A-27 LOCK WASHER 8
9SM22191-1 LEFT CASE SIDE 1
7A 9SL13232-3 LEFT CASE SIDE 1
7B 9SS27368-4 DECAL LE LOGO 1
7C 9SS27468 POWERWAVE LOGO 1
9SM22192-1 RIGHT CASE SIDE 1
8A 9SL13232-2 RIGHT CASE SIDE 1
8B 9SS27368-4 DECAL LE LOGO 1

8C 9SS27468 POWERWAVE LOGO 1
8D 9SS28039-2 DECAL GREEN INITIATIVE 1
9SM22119 WIRE DRIVE INTERFACE ASSEMBLY 1
10A 9SM22120 WIRE DRIVE PCB BRACKET 1
10B 9SS28626-5 FEEDHEAD PC BD ASBLY 1

Roof Assembly
10D 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 1
9SCF000010 #10-24HN 1
10H 9SM19540-3 VOLTAGE SENSE SELECT PC BD ASBLY 1
9SG6536-5 WIRING DIAGRAM 1

Roof Assembly
P-884-H.jpg

WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
electrode with skin or wet clothing.
l Insulate yourself from work and
AVISO DE
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
PRECAuCION
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
l Aislese del trabajo y de la tierra.
French
ATTENTION
l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
German
WARNuNG
l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
ATENÇÃO
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l 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.
WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
AVISO DE
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o
PRECAuCION
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French
ATTENTION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
de travail.
German
WARNuNG
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
ATENÇÃO
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos
l 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.
CUSTOMER ASSISTANCE POLICY
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
customer’s 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.
TABLE OF CONTENTS
INSTALLATION
OPERATION
ACCESSORIES
MAINTENANCE
TROUBLESHOOTING
DIAGRAMS

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Operator’s Manual

POWER WAVE ® R350

Register your machine: Need Help? Call 1.888.935.3877

For Service outside the USA:

Serial: (ex: U1060512345)

IM10294 | Issue Date July-16

WARNING: Cancer and Reproductive Harm ELECTRIC AND

ELECTRIC SHOCK ARC RAYS CAN BURN.

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

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

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

40% rating 19/17/14

RECOMMENDED INPUT WIRE AND FUSE SIZES 1

INPUT MAXIMUM CORD SIZE 3 TIME DELAY FUSE

380-415/3/50/60 19A, 40% 12 (4) 30

1. Based on U.S. National electrical Code

POWER WAVE® R350

IP23 155º(F) Insulation Class

Thermal tests have been performed at ambient tem-

SAFETY PRECAUTIONS Read this LIFTING

ELECTRIC SHOCK can kill.

POWER WAVE® R350

INPUT CONNECTION WARNING

*An input cord is not provided with the POWER

POWER WAVE® R350

An arclink compatible wire feeder is recommended for

POWER WAVE® R350

RECOMMENDED WORK CABLE General Guidelines

CAUTION • Always weld in a direction away from the work

200 100 2 2 2 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

POWER WAVE® R350

GMAW 67 lead required 21 lead optional (3)

POWER WAVE® R350

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into

Work Voltage Sensing

While most applications perform adequately by sens-

Negative Electrode Polarity

If the auto sense lead feature is disabled and the

POWER WAVE® R350

VOLTAGE SENSING If Sense Leads ARE Used:

POWER WAVE® R350

POWER WAVE® R350

CONTROL CABLE CONNECTIONS Connection Between Power Source and Wire

Additional information is also available in the “How To”

POWER WAVE® R350

SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

• WELDING SPARKS can cause

POWER-UP SEQUENCE OPERATORS

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

POWER WAVE® R350

RECOMMENDED PROCESSES AND

The POWER WAVE® R350 is designed to be compat-

POWER WAVE® R350

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