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RETURN TO MAIN MENU
IM10083
®
POWER WAVE R350
October, 2010
11745
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Summary of Contents for Lincoln Electric POWER WAVE R350
- Page 1 RETURN TO MAIN MENU IM10083 ® POWER WAVE R350 October, 2010 11745 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
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Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
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... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - POWER WAVE® R350 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% 40% rating 208/230/380-415/460/575 K3022-1 50/60 Hz 100% rating INPUT VOLTAGE/PHASE/ FREQUENCY 200-208/1/50/60 230/1/50/60* 200-208/3/50/60 230/3/50/60 350 Amps 31.5 Volts 380-415/3/50/60 460/3/50/60 575/3/50/60 * On 230 Volt / 1 phase inputs the max. - Page 9 PROCESS GMAW GMAW-Pulse FCAW GTAW-DC MODEL HEIGHT K3022-1 20.40 in ( 518 mm) OPERATING TEMPERATURE RANGE Environmentally Hardened: -4°F to 104°F (-20C to 40C) IP23 155º(F) Insulation Class Weight does not include input cord. Thermal tests have been performed at ambient tem- perature.
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Page 10: Safety Precautions
National Electrical Code, all local codes and the information in this manual. MACHINE GROUNDING The frame of the welder must be grounded. A ground terminal marked with a ground symbol is located next to the input power connection block. -
Page 11: Input Connection
Using input wire sizes, fuses or cir- cuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents. INPUT VOLTAGE SELECTION The POWER WAVE®... -
Page 12: Connection Diagram
CONNECTION DIAGRAM GMAW (MIG) WELDING An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.2 for the connection details. REGULATOR FLOWMETER GAS HOSE PF10-M WIRE FEEDER INSTALLATION FIGURE A.2 MIG PROCESS ARCLINK CABLE K1543-[XX] TO POSITIVE (+) STUD POWER WAVE®... -
Page 13: Recommended Work Cable Sizes
RECOMMENDED WORK CABLE SIZES FOR ARC WELDING Connect the electrode and work cables between the appropriate output studs of the POWER WAVE R350 per the following guidelines: • Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source. -
Page 14: Cable Inductance And Its Effects On Welding
Sense Lead Kits (K940-xx) are available for this pur- pose. The POWER WAVE R350 has the ability to automati- cally sense when remote sense leads are connected. With this feature there are no requirements for setting- up the machine to use remote sense leads. - Page 15 "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.
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Page 16: Voltage Sensing Considerations For Multiple Arc Systems
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 strong- ly recommended. - Page 17 A-10 • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path. (See Figure 8.A) POWER SOURCE INSTALLATION...
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Page 18: Control Cable Connections
The wire feeder connection on the POWER WAVE R350 is located in the upper- right corner of the case back. The K2709 series exter- nal dress cable is recommended for severe duty appli- cations such as hard automation or for robot arms not equipped with an internal control cable. -
Page 19: 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. •... -
Page 20: Product Description
PRODUCT DESCRIPTION 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. -
Page 21: Design Features
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. -
Page 22: Case Back Controls
FIGURE B.2 OPERATION 5. ETHERNET CONNECTOR (RJ-45): Used for ArcLink® XT communication. Also used for diag- nostics and reprogramming the Power Wave R350. 6. WIRE FEEDER RECEPTACLE (14-PIN): For con- nection to the Auto Drive 4R100/4R220 and PF10R series wire feeders. -
Page 23: Common Welding Procedures
The serviceability of a product or structure utiliz- ing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are... - Page 24 GTAW (TIG) WELDING The welding current can be set through a PF10M or PF25M wire feeder. The TIG mode features continuous control from 5 to 350 amps with the use of an optional foot amptrol (K870). The POWER WAVE® R350 can be run in either a Touch Start TIG mode or Scratch start TIG mode.
- Page 25 OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the POWER WAVE® R350 will automatically recalculate the waveform parameters to maintain similar arc properties. The POWER WAVE® R350 utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding.
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Page 26: Accessories
FACTORY INSTALLED None Available FIELD INSTALLED OPTIONS GENERAL OPTIONS DeviceNet Kit Mounts inside the back of the Power Wave R350. Allows Devicenet objects to communicate with the Power Wave R350. Order K2827-1 Work Voltage Sense Lead Kit Required to accurately monitor voltage at the arc. -
Page 27: Maintenance
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Turn the input power to the welding power • Only qualified personnel should install, use or ------------------------------------------------------------------------ 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. -
Page 28: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 29 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS There are two status lights that display error codes. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the sys- tem, check the power source status light for error sequences as noted below.
- Page 30 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”...
- Page 31 Absolute maximum motor current level has been exceeded. This is a short term average to protect drive circuitry. The Shutdown inputs on the Power Wave R350 have been dis- abled. The presence of these errors indicates the Feed Head Control PCB may contain the wrong operating software.
- Page 32 2. Reduce output current, duty cycle, or both. 3. Contact your local authorized Lincoln Electric Field Service facility for technical assistance. 1. Make sure input supply discon- nect has been turned ON. Check input fuses. Make certain that the Power Switch (SW1) on the power source is in the “ON”...
- Page 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Thermal LED is ON Thermal LED is ON “Real Time Clock” no longer func- tioning General degradation of weld perfor- mance 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.
- Page 34 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of the weld. Machine output shuts down during a weld. Machine wonʼt produce full output. Excessively long and erratic arc. 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.
- Page 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Cannot Connect Connection Drops while welding 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. TROUBLESHOOTING POSSIBLE CAUSE...
- Page 36 DIAGRAMS POWER WAVE® R350...
- Page 37 DIMENSION PRINT 27.44 22.25 13.87 18.81 6.00 18.31 POWER WAVE® R350...
- Page 38 NOTES POWER WAVE® R350...
- Page 39 NOTES POWER WAVE® R350...
- Page 40 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 41 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 42 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...