Manual Power Wave 350
Manual Power Wave 350
Manual Power Wave 350
11745
Date Purchased
After hours?
Use Ask the Experts at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
IM10083-A
WARNING
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
SAFETY
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK
CAN KILL.
4.a.
Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
4.b.
4.c.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and cause
Safety 03 of 04 - 06/15/2016
SAFETY
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturers recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Safety 04 of 04 - 06/15/2016
vi
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications ...............................................................................................A-1, A-2
Safety Precautions ...............................................................................................................A-3
Location, Lifting .............................................................................................................A-3
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Input and Ground Connections .....................................................................................A-3
Machine Grounding .......................................................................................................A-3
High Frequency Protection............................................................................................A-3
Input Connection ..................................................................................................................A-4
Input Fuse and Supply Wire..........................................................................................A-4
Input Voltage Selection .................................................................................................A-4
Power Cord Replacement .............................................................................................A-4
Connection Diagram .....................................................................................................A-5
Recommended Work Cable Sizes ................................................................................A-6
Cable Inductance and its Effects on Welding................................................................A-7
Remote Sense Lead Specifications.......................................................................A-7, A-8
Voltage Sensing Considerations for Multiple Arc Systems..................................A-9, A-10
Control Cable Connections ................................................................................................A-11
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Power-Up Sequence .....................................................................................................B-1
Duty Cycle .....................................................................................................................B-1
Graphic Symbols ...........................................................................................................B-1
Product Description ..............................................................................................................B-2
Recommended Processes and Equipment ..........................................................................B-2
Equipment Limitations ..........................................................................................................B-2
Design Features ...................................................................................................................B-3
Case Front Controls .............................................................................................................B-3
Case Back Controls..............................................................................................................B-4
Common Welding Procedures................................................................................B-5 thru B-7
________________________________________________________________________________
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
A-1
A-1
INSTALLATION
Duty Cycle
40% rating
208/230/380-415/460/575
50/60 Hz
K3022-1
Idle Power
Power Factor @
Rated Output
.95
Input Amperes
(1 Phase in parenthesis)
100% rating
39/35/19/17/14
(60/67*/NA/NA/NA)
31/28/15/14/11
(60/53/NA/NA/NA)
RATED OUTPUT
INPUT
VOLTAGE/PHASE/
FREQUENCY
GMAW
60%
40%
GTAW-DC
40%
60%
100%**
350 Amps
24 Volts
325 Amps
23 Volts
300 Amps
22 Volts
100%**
200-208/1/50/60
230/1/50/60*
200-208/3/50/60
230/3/50/60
380-415/3/50/60
460/3/50/60
575/3/50/60
350 Amps
31.5 Volts
320 Amps
30 Volts
300 Amps
29 Volts
* On 230 Volt / 1 phase inputs the max. rating is at a duty cycle of 30%, except for GTAW processes.
** For all rated single phase inputs, the 115 VAC duplex is rated for 5 Amps when welding above 275 Amps at
100% Duty Cycle.
MAXIMUM
INPUT AMPERE RATING AND DUTY CYCLE
CORD SIZE 3
AWG SIZES
(mm2)
200-208/1/50/60
200-208/3/50/60
230/1/50/60
230/3/50/60
380-415/1/50/60
380-415/3/50/60
460/1/50/60
460/3/50/60
575/1/50/60
575/3/50/60
60A, 100%
39A, 40%
67A, 30%
35A, 40%
38A, 40%
19A, 40%
34A, 40%
17A, 40%
27A, 40%
14A, 40%
6 (13)
8 (10)
4 (16)
8 (10)
8 (10)
12 (4)
8 (10)
12 (4)
10 (6)
14 (2.5)
80
50
80
45
50
30
45
25
35
20
A-2
A-2
INSTALLATION
WELDING PROCESS
OCV (Uo)
PROCESS
Mean
GMAW
GMAW-Pulse
FCAW
GTAW-DC
40-350A
40-70V
5-350A
24V
Peak
100V
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
K3022-1
24.80in ( 630mm)
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
Environmentally Hardened: -4F to 104F (-20C to 40C)
IP23
155(F) Insulation Class
* Weight does not include input cord.
Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40C has
been determined by simulation.
POWER WAVE R350
A-3
A-3
INSTALLATION
this
entire installation section before you start installation.
WARNING
LIFTING
Both handles should be used when lifting POWER WAVE
R350. When using a crane or overhead device a lifting strap
should be connected to both handles. Do not attempt to lift the
POWER WAVE R350 with accessories attached to it.
WARNING
Lift only with equipment of adequate lifting capacity.
Be sure machine is stable when
lifting.
Do not operate machine while
suspended when lifting.
FALLING
EQUIPMENT can
cause injury.
-------------------------------------------------------------
STACKING
The POWER WAVE R350 cannot be stacked.
The POWER WAVE R350 will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long
life and reliable operation.
TILTING
MACHINE GROUNDING
The frame of the welder must be grounded. A ground terminal
marked with a ground symbol is located next to the input
power connection block.
See your local and national electrical codes for proper grounding methods.
A-4
A-4
INSTALLATION
INPUT CONNECTION
WARNING
WARNING
------------------------------------------------------------------------
------------------------------------------------------------------------
------------------------------------------------------------------------
ALWAYS CONNECT THE POWER WAVE GROUNDING LUG (LOCATED AS SHOWN IN FIGURE A.1)
TO A PROPER SAFETY (EARTH) GROUND AND
ENSURE IT IS APPROXIMATELY 3" LONGER THAN
PHASE LEADS.
FIGURE A.1
*An
WAVE R350.
A-5
INSTALLATION
CONNECTION DIAGRAM
GMAW (MIG) WELDING
An arclink compatible wire feeder is recommended for
Mig welding. Refer to Figure A.2 for the connection
details.
FIGURE A.2
A-5
A-6
A-6
INSTALLATION
CAUTION
General Guidelines
Select the appropriate size cables per the
Output Cable Guidelines below. Excessive voltage drops caused by undersized welding cables and
poor connections often result in unsatisfactory welding performance. Always use the largest welding
cables (electrode and work) that are practical, and
be sure all connections are clean and tight.
Note: Excessive heat in the weld circuit indicates
undersized cables and/or bad connections.
Route all cables directly to the work and wire
feeder, avoid excessive lengths and do not coil
excess cable. Route the electrode and work cables
in close proximity to one another to minimize the
loop area and therefore the inductance of the weld
circuit.
Always weld in a direction away from the work
(ground) connection.
Percent Duty
Cycle
200
60
1/0
200
100
1/0
250
30
1/0
250
40
1/0
250
60
1/0
250
100
1/0
300
60
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 104F (40C) and below. Applications above 104F (40C) may
require cables larger than recommended, or cables rated higher than 167F (75C).
A-7
A-7
INSTALLATION
CAUTION
If the auto sense lead feature is disabled and
remote voltage sensing is enabled but the sense
leads are missing, improperly connected extremely high welding outputs may occur.
-----------------------------------------------------------------------General Guidelines for Voltage Sense Leads
Sense leads should be attached as close to the weld
as practical, and out of the weld current path when
possible. In extremely sensitive applications it may be
necessary to route cables that contain the sense
leads away from the electrode and work welding
cables.
Voltage sense leads requirements are based on the
weld process (See Table A.2)
TABLE A.2
Process
GMAW
GMAW-P
FCAW
GTAW
67 lead required
67 lead required
67 lead required
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
FIGURE A.6
A-8
INSTALLATION
CAUTION
If the auto sense lead feature is disabled and the
weld polarity attribute is improperly configured
extremely high welding outputs may occur.
------------------------------------------------------------------------
A-8
A-9
INSTALLATION
VOLTAGE SENSING
CONSIDERATIONS FOR MULTIPLE
ARC SYSTEMS
Special care must be taken when more than one arc
is welding simultaneously on a single part. Multiple
arc applications do not necessarily dictate the use of
remote work voltage sense leads, but they are strongly recommended.
If Sense Leads ARE NOT Used:
Avoid common current paths. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power
sources, and result in arc interference.
A-9
FIGURE A.7
A-10
INSTALLATION
For circumferential applications, connect all work
leads on one side of the weld joint, and all of the
work voltage sense leads on the opposite side,
such that they are out of the current path.
(See Figure 8.A)
FIGURE A.8
A-10
A-11
INSTALLATION
A-11
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
WARNING
ELECTRIC SHOCK CAN KILL.
Do not touch electrically live
part or electrode with skin or
wet clothing.
Insulate yourself from work and
ground.
Always wear dry insulating gloves.
Do not operate with covers, panels or guards
removed or open.
-------------------------------------------------------------------- FUMES AND GASSES can be
dangerous.
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing
zone.
-------------------------------------------------------------------- WELDING SPARKS can cause
fire or explosion.
Keep flammable material away.
WARNING OR
CAUTION
DANGEROUS
VOLTAGE
POSITIVE OUTPUT
NEGATIVE OUTPUT
HIGH TEMPERATURE
STATUS
PROTECTIVE
GROUND
COOLER
OUTPUT
OPERATORS
MANUAL
POWER-UP SEQUENCE
When the POWER WAVE R350 is powered up, it can
take as long as 30 seconds for the machine to be
ready to weld.
WORK
DUTY CYCLE
The duty cycle is based on a ten-minute period. A
40% duty cycle represents 4 minutes of welding and 6
minutes of idling in a ten-minute period. Refer to the
technical specification section for the Power Wave
R350s duty cycle ratings.
CIRCUIT BREAKER
B-2
OPERATION
PRODUCT DESCRIPTION
B-2
RECOMMENDED PROCESSES
PRODUCT SUMMARY
The POWER WAVE R350 is a portable multi-process
power source with high-end functionality capable of
DC TIG, MIG, Pulsed MIG and Flux-Cored welding. It
is ideal for a wide variety of materials including aluminum, stainless, and nickel where arc performance is critical. The Power Wave R350 includes an
integrated wire drive module and 14-pin MS-Style
connection to support the Power Feed 10R, and Auto
Drive 4R100/4R220.
The POWER WAVE R350 is designed to be a flexible welding system. Like existing Power Waves, the
software based architecture allows for future
upgrades. ArcLink communication is supported
through the standard 5 pin MS-style interface. The
new ArcLinkXT communication protocol is supported
through an RJ-45 type Ethernet connection, which
also provides access for the Power Wave Utilities software tools. The Ethernet communication also gives
the POWER WAVE R350 the ability to run
Production Monitoring 2. Also Available is a
Devicenet option to allow the Power Wave R350 to
be used in a wide range of configurations. The
POWER WAVE R350 is being designed to be compatible with advanced welding modules like STT.
The POWER WAVE R350 is a high speed, multiprocess power source capable of regulating the current, voltage, or power of the welding arc. With an output range of 5 to 350 amperes, it supports a number
of standard processes including synergic GMAW,
GMAW-P, FCAW, FCAW-SS, GTAW and GTAW-P
on various materials especially steel, aluminum and
stainless.
PROCESS LIMITATIONS
The software based weld tables of the POWER
WAVE R350 limit the process capability within the
output range and the safe limits of the machine. In
general the processes will be limited to .030-.052 solid
steel wire, .030-.045 stainless wire, .035-1/16 cored
wire, and .035 and 1/16 Aluminum wire.
EQUIPMENT LIMITATIONS
Only ArcLink compatible robotic wire feeders, semiautomatic wire feeders and users interfaces may be
used. If other Lincoln wire feeders or non-Lincoln wire
feeders are used there will be limited process capability and performance and features will be limited.
RECOMMENDED EQUIPMENT
The POWER WAVE R350 is designed to be compatible with the current range of Power Feed and Auto
Drive systems including future versions of ArcLink
feeders.
B-3
B-3
OPERATION
DESIGN FEATURES
Loaded with Standard Features
Multiple process DC output range: 5 - 350 Amps.
200 600 VAC, 1 for 208 and 230, 3 phase for all
voltages, 50-60Hz input power.
New and Improved Line Voltage Compensation
holds the output constant over wide input voltage
fluctuations.
Utilizes next generation microprocessor control,
based on the ArcLink platform.
State of the art power electronics technology yields
superior welding capability.
Electronic over current protection.
Input over voltage protection.
F.A.N. (fan as needed). Cooling fan runs when the
output is energized and for 5 minutes after the output has been turned off.
Thermostatically protected for safety and reliability.
Ethernet connectivity via RJ-45 connector.
Panel mounted Status, FeedHead Status, and
Thermal LED indicators facilitate quick and easy
troubleshooting.
Potted PC boards for enhanced ruggedness/reliability.
115V/15A duplex receptacle supports rigorous
demands of heavy duty fume extraction and water
cooling equipment.
Enclosure reinforced with heavy duty aluminum
extrusions for mechanical toughness.
Waveform Control Technology for good weld
appearance and low spatter, even when welding
nickel alloys.
Sync Tandem installed.
Auto Drive 4R9100, 4R200 and PF-10R feeders
supported via standard 14 pin MS style connector.
Cam Lock type connectors.
Lead
21
67E
Function
Work Voltage Sense
Electrode Voltage Sense
WARNING
The Power Wave R350 ON/OFF switch is NOT
intended as a Service Disconnect for this
equipment.
-----------------------------------------------------------------------8. OPTIONAL VOLTS/AMPS DISPLAY
FIGURE B.1
B-4
B-4
OPERATION
FIGURE B.2
B-5
OPERATION
B-5
B-6
OPERATION
B-6
PULSE WELDING
Pulse welding procedures are set by controlling an
overall arc length variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be
predicted when all the pulsing waveform parameters
are known. Using a preset voltage becomes impractical and instead the arc length is set by adjusting
trim.
Trim adjusts the arc length and ranges from 0.50 to
1.50 with a nominal value of 1.00. Trim values greater
than 1.00 increase the arc length, while values less
than 1.00 decrease the arc length. (See figure B.3)
The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be
adjusted to preference. When the wire feed speed
changes, the Power Wave automatically adjusts the
voltage level correspondingly to maintain similar arc
characteristics throughout the WFS range.
Non Synergic CV
In non-synergic modes, the WFS control behaves
more like a conventional CV power source where
WFS and voltage are independent adjustments.
Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any
changes made to the WFS.
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
B-7
OPERATION
FIGURE B.4
B-7
C-1
ACCESSORIES
FACTORY INSTALLED
None Available
C-1
TIG OPTIONS
GENERAL OPTIONS
DeviceNet Kit
Mounts inside the back of the Power Wave R350. Allows
Devicenet objects to communicate with the Power Wave
R350.
Order K2827-1
I/O Kit
Mounts inside the back of the Power Wave R350.
Allows external access to Feeder Control inputs.
Order K3123-1
Work Voltage Sense Lead Kit
Required to accurately monitor voltage at the arc.
Order K940-XX Series
Order K1811-XX Series
Deluxe Adjustable Gas Regulator & Hose Kit
Accommodates CO2, Argon, or Argon-blend gas cylinders.
Includes a cylinder pressure gauge, dual scale flow gauge
and 4.3 ft. (1.3 m) gas hose.
Order K586-1
Work and Wire Feeder 2/0 Weld Cable Package
Includes Cam-Lock connectors, work clamps, 15 ft. (4.5 m)
work cable and 10 ft. (3.0 m) electrode cable. Rated 350
amps, 60% duty cycle.
Order K1803-2
Cam-Lock cable plug for 2/0 (50mm2)cable. Order K2946-1
Coaxial Welding Cable
Optimum weld cables for minimizing cable inductance and
optimizing welding performance.
AWG 1/0 Coaxial Cables:
Order K1796-25 for 25 feet (7.6 m) cable length.
Order K1796-50 for 50 feet (15.2 m) cable length.
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length.
AWG #1 Coaxial Cables:
Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length.
MIG OPTIONS
Work and Feeder Welding Cables
350 amps, 60% duty cycle with Cam-Lock connectors and
Ground Clamp.
Order K1803-2
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
Do not operate with covers
removed.
Turn off power source before
installing or servicing.
Do not touch electrically hot
parts.
Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.
Only qualified personnel should install, use or
service this equipment.
------------------------------------------------------------------------
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing
out the machine, using a low-pressure air stream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.
PERIODIC MAINTENANCE
Calibration of the POWER WAVE R350 is critical to
its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory
weld performance. To ensure optimal performance,
the calibration of output Voltage and Current should
be checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the factory. Generally the machine calibration will not need
adjustment. However, if the weld performance
changes, or the yearly calibration check reveals a
problem, use the calibration section of the
Diagnostics Utility to make the appropriate adjustments.
The calibration procedure itself requires the use of a
grid, and certified actual meters for voltage and current. The accuracy of the calibration will be directly
affected by the accuracy of the measuring equipment
you use. The Diagnostics Utility includes detailed
instructions, and is available on the Service
Navigator CD or at www.powerwavesoftware.com.
D-1
E-1
TROUBLESHOOTING
E-1
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
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM!(SYMPTOM).
Look under the column labeled PROBLEM (SYMPTOMS). This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
WARNING
ELECTRIC SHOCK can kill.
Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.
Do not touch electrically live parts.
When inching with the gun trigger, electrode and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
Welding power source must be connected to system ground per the National Electrical Code or any
applicable local codes.
Only qualified personnel should perform maintenance work.
-----------------------------------------------------------------------------------------------------------------------------------------------------Observe all additional Safety Guidelines detailed throughout this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-2
E-2
TROUBLESHOOTING
TABLE E.1
Light
Condition
Meaning
Main control board status light
Steady Green
System OK. Power source is operational, and is communicating normally with all
healthy peripheral equipment connected to its ArcLink network.
Not applicable.
Blinking Green
Not applicable.
Not applicable.
Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are present. Read the error code(s)
before the machine is turned off.
Not applicable.
Not applicable.
Not applicable.
Blinking Red
Not applicable.
Not applicable.
System OK
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-3
TROUBLESHOOTING
E-3
Error Code #
Indication
Thermal error
The long term average secondary (weld) current limit has been
exceeded. NOTE: The long term average secondary current limit is
325 amps.
Indicates communication link between main control board and chopper has errors. If cycling the input power on the machine does not
clear the error, contact the Service Department.
Review error code from input board status light or status beeper.
Most likely caused by an over power condition which caused an
under voltage on the primary bus. If cycling the input power on the
machine does not clear the error, contact the Service Department.
Other
Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the Power
Source Control Board. If cycling the input power on the machine
does not clear the error, contact the Service Department.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-4
TROUBLESHOOTING
E-4
Error Code #
331
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
337
Pre-charge timeout
346
Other
Error Code #
81
Motor Overload
82
Motor Overcurrent
83
Shutdown #1
84
Shutdown #2
The Shutdown inputs on the Power Wave R350 have been disabled. The presence of these errors indicates the Feed Head
Control PCB may contain the wrong operating software.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
1. Make sure input supply disconnect has been turned ON. Check
input fuses. Make certain that the
Power Switch (SW1) on the
power source is in the ON position.
2. 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 wont weld, cant get any 1. Input voltage is too low or too high.
output.
2. Thermal Error.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Thermal LED is ON
Thermal LED is ON
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Improper
fan operation
Basic
Machine
Problems (Continued)
1. Improper fan operation.
2. Cabling problems.
3. Loss of, or improper Shielding 3. Verify gas flow and type are corGas.
rect.
4. Verify weld mode is correct for 4.Select the correct weld mode for
process.
the application.
5. Machine calibration.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-7
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
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
3. Machine calibration.
2. Loss of, or improper Shielding 2. Verify gas flow and type are correct
Gas
3. Machine calibration.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
E-8
E-8
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Ethernet
Cannot Connect
1. Physical connection.
2. IP address information.
3. Ethernet Speed
1. Cable Location
1. Verify Network cable is not located next to current carrying conductors. This would include input
power cables and welding output
cables.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE R350
B/W
52A
52B
51A
51B
+40VDC D
0 VDC E
GRN
893
892
891
DNET CAN_H
DNET CAN_L 5
351D
353D
351C
353C
1
2
3
4
J50
J55
357
354
352
349
51
52
67
54
53
51C
52C
67C
54C
53C
G6682
CONTROL BOARD
B41
B38
BASE
GND1 VERTICAL PANEL
GND2 CASEBACK
GND3 CASEFRONT
317
317A
318
318A
HEAT
SINK
B37
B39
B40
B53
TOROID
B6
OPTIONAL
DEVICENET
B29
B30
B28
348
347
346
345
344
343
342
341
3A
1A
B31
2A
B32
3 STAGE INVERTER
G4770-1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
J42
321
324
326
328
322
12
11
10
9
8
7
6
5
4
3
2
1
J43
INPUT
CHOKE
OUTPUT
CHOKE
351
338
337
336
335
334
333
332
331
A6
A5
A4
A3
A2
353
355
66
350
65A
8
7
6
5
4
3
2
1
BL6
BL5
BL4
BL3
BL2
BL1
B52
J45
10
9
8
7
6
5
4
3
2
1
CAPACITOR NOT
PRESENT ON
EARLIER MODELS
J3
1
2
3
4
5
6
7
8
9
10
206A
207
511A
16
12
11
10
9
8
7
6
5
4
3
2
1
316
315
337
333
332
336
307
308
306
305
313
314
311
303
301
854
855
856
5
6
52
358
356
51
J23
J26
G6758
J27
1B
16
67D
6
5
4
3
2
1
1W
P85-A
67C
INPUT CONTROL
BOARD
NOT USED
1
2
3
4
5
6
7
8
L15732
8512
511A
15
512A
14
13
8511
11
12
8510
10
858
859
8
9
+15VDC
J47
J46
P112
8
7
6
5
4
3
2
1
361
359
52C
363
67C
360
51C
362
54C
364
66
1
2
3
4
65
J85-A
853
857
852
851
1W STATUS LED
STATUS LED
1B
512A
13
15
14
12
11
10
6
5
4
3
2
1
309
53C
52C
67C
67D
51C
54C
6
5
4
3
2
1
53D
52D
67F
51D
54D
321
322
216
211
213
212
+15VDC - GROUP #2
2 STEP / 4 STEP
DUAL PROCEDURE
TRIGGER
+15VDC - GROUP #1
4
3
2
1
LEM
LOCATED ON
CASE BACK
11 SHUTDOWN 2 INPUT
12 NOT USED
8 GAS PURGE
9 +15VDC - GROUP #3
10 SHUTDOWN 1 INPUT
CURRENT
TRANSDUCER
P114/J16
67E
8512
8511
8510
858
859
857
856
855
854
853
852
851
I/O
CONNECTOR
(OPTIONAL)
67G
J10A1,
J10B1,
J811,
J2
SHEILDED
TWISTED
PAIR
AC
J84
J85
S2
S4
373
372
371
370
J83
G6752
FEEDHEAD PCB
202
206
J82
J51
4
3
2
1
S5
J87
J81
T2
903B
M20305-1
901B
WORK
3A
2A
THERMAL LED
T3
S6
1A
J3, J4,
J45, J61
J86
J86
1
2
3
4
5
6
7
8
9
10
J1
J2
H
G6536-3PRINT
M19540-2
VOLTAGE SENSE
SELECT PCB
16
10
J6, J7,
J41, J85
J87
T1
CONTROL BD STATUS
RED/GREEN LED
L3
L2
L1
12
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICA
FEEDHEAD STATUS
WHITE LED
AC
21
67E
S3
J12, J23,
J25, J42
GENERAL INFORMATION
2
1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
GRN
BLK/GRN
RED
BLK/RED
51A
52A
67A
54A
53A
51B
52B
67B
54B
53B
554
553
1
2
3
4
5
6
7
8
9
10
351
351B
351A
353B
353
353A
NOT USED
3J54
1J54
3J55
1J55
3J56
1J56
S4
DEVICENET
CONNECTOR
(OPTIONAL)
J15
(ASSEMBLY G6571)
115 VAC
INVERTER PCB
33A
DIAGRAMS
894
BLK/RED
S5
SYNC/TANDEM
CONNECTOR
DIFF_2 LOW
RED
BLK/GRN
DIFF_1 LOW
DIFF_2 HIGH E
FAN
FAN
FAN
GND-B
DIFF_1 HIGH C
.0047 uF
67A
67B
ELECTRODE
C
SENSE
S3 ARCLINK
RECEPTACLE
54A
54B
53A
53B
67G
ARCLINK +
ARCLINK -
B/R
B/G
522
847
521
541
539
65A
65
S6 ROBOTIC
INTERFACE
RECEPTACLE
10A
CB2
ETHERNET
CABLE
(Neutral Bonded)
ETHERNET
CONNECTOR
RJ 45
TYPE
32A
GND5
32
115V
RECEPTACLE
34
33
J4
33A
21
10A
67
202
CB1
358
356
361
362
364
J9
6
5
4
3
2
1
J2
416
363
553
J62
1
2
3
4
J8
33
32
350
1
2
3
4
5
6
7
8
9
10
1 415
2 416
3 GND4
4 417
5 418
6
206
417
216
32A
GND5
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
892
893
J63
54
53
1
2
3
4
J11
406
J12
J61
409
213
212
211
317
317A
318
318A
401
B5
408
554
360
404
7
2
6
1
359
403
402
J7
418
415
372
373
355
410
J6
891
894
1
2
3
4
5
6
J13
345
346
341
357
349
352
343
344
348
347
354
342
1
2
3
4
5
6
7
8
9
10
11
12
407
414
413
412
411
409
410
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
4
3
2
1
J5
200 OHM
100 W
371
370
311
J24
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
316
315
314
313
B
W
360
511
512
404
J28
J41
303
2
1
309
308
307
306
305
R
W
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
8
7
6
5
4
301
847
G
B/G
B/W
B/R
408
407
406
404
403
402
401
2
1
338
335
541
539
J25
6
5
4
512
324
880
886
522
521
6
5
4
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
2
1
511
67G
326
334
331
250 OHM 25 W
J29
52D
51D
54D
53D
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
2
1
2
1
328
67F
250 OHM 25 W
xxxxxxx
xxxxxxx
4
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
F-1
F-1
DIMENSION PRINT
F-2
27.44
F-2
22.25
13.87
18.81
6.00
18.31
Contents
ii
PART NUMBER
DESCRIPTION
QTY
AR
P-664-B.2
MISCELLANEOUS ITEMS
AR
P-664-C
AR
P-664-D
AR
P-664-E
AR
P-664-F
AR
P-664-G
AR
P-664-H
ROOF ASSEMBLY
AR
P-664-A
P-664-A.jpg
Miscellaneous Items
PART NUMBER
DESCRIPTION
QTY
9SG6094
9SM19969-13
KEY
Miscellaneous Items
No Image
DESCRIPTION
QTY
9SG6519-3
9SG6513-3
CASE FRONT
9SM22487-1
LED HARNESS
9SS23740-2
9ST13657-4FA
YELLOW LED
9ST13657-7H24
LED-T-1 3/4BI-COLORRED/GREEN
9SS23093-1
3A
9SS23094-1
RETAINING O RING
4A
9SM20305-1
4B
9SS28402
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SL13263-1
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SL13263-2
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
7A
9SS20030-1
LINE SWITCH
7B
9SS25384-1
9ST9695-1
LOCKWASHER
9SCF000084
#10-32X.625HHCS
9SS18491-3
M.O.V. ASBLY
15A
9SS16656-4
15B
9SS9225-99
16A
9SG6758-1
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
18
9SG6967
NAMEPLATE
19
9ST3960
FLANGE NUT
21
9ST10397-23
PLUG BUTTON
9SG6864
9SS9262-184
WASHER
9SS9225-100
9SS9225-99
26A
9SS9262-80
PLAIN WASHER
26B
9SE106A-15
LOCKWASHER
26C
9SCF000021
1/2-13X1.00HHCS
5A
6A
PART NUMBER
22A
DESCRIPTION
QTY
9SS18657
9SS8025-118
28A
9SL15069
COVER PLATE
28B
9SS9225-99
28C
9SG6529
UI TRIM
9SS23740-1
9ST13657-7H24
LED-T-1 3/4BI-COLORRED/GREEN
27A
PART NUMBER
P-664-C.jpg
DESCRIPTION
QTY
9SL15067-1
BASE
9SS9225-99
9SM21251-2
BASE EXTRUSION
3A
9SL15091
BRACKET
3B
9SS9225-99
9ST9695-1
LOCKWASHER
4A
9SCF000013
1/4-20X.625HHCS
4B
9SS28070
9SE106A-2
LOCKWASHER
5A
9SM21489-1
INPUT CHOKE
5B
9SM21468
5C
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
10A
9SL13138
CORNER CAP
10B
9SS9262-182
PLAIN WASHER
10C
9SS9225-100
12A
9SM21469-3
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SG6037-1
13A
9ST13359-29
THERMOSTAT
13B
9SM21469-2
9SS9225-100
9SE106A-1
LOCKWASHER
9SS9262-27
PLAIN WASHER
14
9SM15045-100
ACOUSTICAL FOAM
15
9ST13260-4
16A
9SCF000010
#10-24HN
16B
9SE106A-1
LOCKWASHER
13
PART NUMBER
KEY
P-664-D.jpg
PART NUMBER
DESCRIPTION
QTY
9SG6589-3
9SG6511
CENTER PANEL
2A
9SL15732-1
40 V DC BUS BD ASBLY
2B
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
3A
9SS28105
MYLAR INSULATION
3B
9SS20763-3
TERMINAL BLOCK
3C
9SCF000193
#8-32X1.25RHS
4A
9SS28735-5
4B
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9ST12380-1
BUSHING
9SS18858-11
SUPPRESSOR ASBLY
9SG6967
NAMEPLATE
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SS9225-99
9SG6571-2
9SS19300-7
SUPPORTPCBSNAP-IN0.63
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
11A
11C
10
P-664-E.jpg
11
QTY
9SL13270-3
9SM21471-3
9ST11827-3
CARRIAGE BOLT
9SS28371
CHOKE INSULATOR
9SS25781-2
SPACER WASHER
9SS26801-2
6A
9SM21472-3
6B
9SS18504-10
CURRENT TRANSDUCER
9SCF000033
#8-32X.50RHS
9SS9262-3
PLAIN WASHER
9ST4291-A
LOCKWASHER
7A
9ST14605
INSULATOR
7B
9SS9262-98
PLAIN WASHER
7C
9SE106A-2
LOCKWASHER
7D
9SCF000017
1/4-20HN
14A
9SS22168
9SCF000015
1/4-20X1.00HHCS
14C
9SS9262-98
PLAIN WASHER
14D
9SE106A-2
LOCKWASHER
14E
9SCF000017
1/4-20HN
15A
9SM22372
BUS BAR
15B
9SCF000015
1/4-20X1.00HHCS
15C
9SS9262-98
PLAIN WASHER
15D
9SE106A-2
LOCKWASHER
15E
9SCF000017
1/4-20HN
16A
9SCF000015
1/4-20X1.00HHCS
16B
9SS9262-98
PLAIN WASHER
16C
9SE106A-2
LOCKWASHER
16D
9SCF000017
1/4-20HN
17A
9SS10404-137
RESISTOR-WW100W2005%
17B
9ST4479-A
INSULATING WASHER
17C
9SS9262-27
PLAIN WASHER
9ST9695-1
LOCKWASHER
9SCF000191
#10-24X7.50RHS
17E
12
PART NUMBER
KEY
PART NUMBER
QTY
4
9SS9225-99
DESCRIPTION
13
P-664-F.jpg
14
DESCRIPTION
QTY
9SG6523-3
1A
9SL15066
FAN BRACKET
1B
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
2A
9SM22149
FAN ASBLY
2B
9SCF000408
#8-32X2.00HHMS
12
9SS9262-3
PLAIN WASHER
12
9ST4291-A
LOCKWASHER
12
9SG6510-3
REAR PANEL
6A
9SS19999
6B
9ST14370-3
CONDUIT LOCKNUT
7A
9SM19969-9
7B
9SS25438-9
ADAPTER PLATE
7C
9SM19969-4
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SL15109
FAN HARNESS
10A
9ST12287-20
CIRCUIT BREAKER-10A250VAC
10B
9SS22061-3
SEALING BOOT
11A
9SS25438-3
COVER PLATE
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SS28546
COVER PLATE
9SS9225-99
9SM21927-1
13A
9SS12021-79
13B
9SS25438-2
9SS8025-96
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SS17062-9
15A
9SL15108
15B
9SS9225-99
9SS9225-99
9SG6602
RECEPTACLE ASSEMBLY
9ST9695-1
LOCKWASHER
9SCF000010
#10-24HN
9SS28056-3
RATING PLATE
12A
PART NUMBER
14
20A
21
15
PART NUMBER
DESCRIPTION
QTY
22A
9SL15123
AIR BAFFLE
22B
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9SG6967
NAMEPLATE
9SM22519
9SS12021-73
9SS8025-118
26
9SS17062-10
27
9SS17062-11
9SG6539
28A
9SS12021-72
28B
9SS25438-4
ADAPTER PLATE
9SS8025-96
23
25A
16
P-664-G.jpg
17
Roof Assembly
DESCRIPTION
QTY
9SM22129-5
ROOF ASSEMBLY
1A
9SL12763-1
ROOF
1B
9SG6967
NAMEPLATE
1C
9SL8064-1
9SS9225-99
9SM22375
2A
9SL15068-1
2B
9SM21251-1
TOP EXTRUSION
9SS9225-99
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
3A
9SL15070
3B
9SS9225-100
5A
9SL13138
CORNER CAP
5B
9SS9262-182
PLAIN WASHER
12
5C
9SS9225-100
12
6A
9SG6525-3
HANDLE
6B
9SCF000410
1/4-20x.75HHCS-FULL-GR2-4554
9SE106A-27
LOCK WASHER
9SM22191-1
7A
9SL13232-3
7B
9SS27368-4
DECAL LE LOGO
7C
9SS27468
POWERWAVE LOGO
9SM22192-1
8A
9SL13232-2
8B
9SS27368-4
DECAL LE LOGO
8C
9SS27468
POWERWAVE LOGO
8D
9SS28039-2
9SS9262-182
PLAIN WASHER
9SS9225-100
9SS9225-99
9SM22119
10A
9SM22120
10B
9SS28626-5
FEEDHEAD PC BD ASBLY
9ST9187-13
#10-24HLN-1817/1-NYLON INSERT
9C
18
PART NUMBER
KEY
Roof Assembly
KEY
10D
10H
DESCRIPTION
QTY
9ST13637-6
DIODE-BRIDGE35A400VF-W1-PH
9SS9262-27
PLAIN WASHER
9SE106A-1
LOCKWASHER
9SCF000010
#10-24HN
9SM19540-3
9SS9225-99
9SG6536-3
WIRING DIAGRAM
11
PART NUMBER
19
P-664-H.jpg
20
Roof Assembly
WARNING
AVISO DE
PRECAuCION
Spanish
French
German
ATTENTION
WARNuNG
Portuguese
ATENO
Japanese
inflammable.
cuerpo.
votre corps.
perschutz!
dos.
corpo.
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
guards off.
piracin.
l Mantenga la cabeza fuera de los
humos. Utilice ventilacin o
aspiracin para gases.
l Gardez la tte lcart des fumes.
l Utilisez un ventilateur ou un aspira-
tien.
Schweibrauch!
l Sorgen Sie fr gute Be- und
Entlftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaa.
l Use ventilao e exhausto para
guardas quitadas.
oder Innenschutzverkleidung in
Betrieb setzen!
servio.
l No toque as partes eltricas nuas.
moventes.
ou guardas removidas.
WARNING
AVISO DE
PRECAuCION
Spanish
French
ATTENTION
German
WARNuNG
Portuguese
ATENO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRTICAS DE SEGURANA DO EMPREGADOR.