RETURN TO MAIN MENU IM956-A POWER WAVE C300 ® For use with machines having Code Numbers: May, 2013 11479 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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 sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
SAFETY vi Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Public Supply System Welding equipment should be connected to the public supply system according to the manufacturer’s recommendations.
vii Thank You vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications ...............................................................................................A-1, A-2 Safety Precautions ...............................................................................................................A-3 Location, Lifting .......................................................
ix ix TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ...............................................................................................................D-1 Routine Maintenance ...........................................................................................................D-1 Periodic Maintenance..........................................................................
A-1 A-1 INSTALLATION ® TECHNICAL SPECIFICATIONS - POWER WAVE C300 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle 40% rating K2675-1 100% rating Input Amperes Idle Power Power Factor @ (1 Phase in parenRated Output thesis) 30/28/16/14/11 208/230/400*/460/575 (53/48/29/25/20) 300 Watts Max. .
A-2 A-2 INSTALLATION GEARING - WIRE FEED SPEED RANGE-WIRE SIZE WFS RANGE GEARING Normal Speed (factory setting) 50 – 700 ipm (1.3 – 17.8 m/min) GMAW GMAW GMAW MILD STEEL WIRE SIZES ALUMINUM WIRE SIZES STAINLESS WIRE SIZES WIRE SIZES .025 – .045" (0.6 – 1.1mm) .030 – 3/64" .035 – .045" (0.8 – 1.2mm) (0.9 – 1.1mm) .035 – .045" (0.9 – 1.1mm) FCAW WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (Uo) 40 - 300 40 – 70 VDC avg., 100 VDC peak 5 – 300 5 – 280 24 VDC avg.
A-3 A-3 INSTALLATION SAFETY PRECAUTIONS Read LIFTING tion. Both handles should be used when lifting POWER WAVE® C300. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the POWER WAVE® C300 with accessories attached to it. this entire installation section before you start installa- WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation.
A-4 A-4 INSTALLATION INPUT CONNECTION WARNING WARNING Only a qualified electrician should connect the input leads to the POWER WAVE® C300. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect access door of the machine. Failure to do so may result in bodily injury or death.
A-5 INSTALLATION A-5 RECOMMENDED WORK CABLE SIZES FOR ARC WELDING SEMI-AUTOMATIC WELDING POLARITY A 15 ft. work cable is provided with the POWER WAVE® C300. This cable is appropriately sized for all of the POWER WAVE® C300ʼs welding procedures. If the work cable needs to be replaced a similar quality of cable should be used as excessive voltage drops caused by undersized welding cables can result in unsatisfactory welding performance.
A-6 A-6 INSTALLATION CABLE CONNECTIONS There are three circular connectors in the wire spool compartment on the POWER WAVE® C300. (See 4-pin, 6-pin and 7-pin---Figure A.2---Table A.1) TABLE A.1 Function FIGURE A.2 4 2 3 1 4-pin trigger connector for pushonly guns. C D B E A F C D B G E 6-pin connector for remote control or foot/hand amptrol.
A-7 INSTALLATION SHIELDING GAS CONNECTION WARNING CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits. • BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL. • Shut off shielding gas supply when not in use. • See American National Standard Z-49.
A-8 INSTALLATION LOADING SPOOLS OF WIRE WARNING • Keep hands, hair, clothing and tools away from rotating equipment. • Do not wear gloves when threading wire or changing wire spool. • Only qualified personnel should install, use or service this equipment. -----------------------------------------------------------------------Loading 10 to 15 lb. (4.5 – 6.8kg) Spools. A K468 spindle adapter is required for 8" (203.2mm) spools. 1.
A-9 A-9 INSTALLATION WIRE DRIVE CONFIGURATION (See Figure A.4) Changing the Gun Receiver Bushing 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.
A-10 A-10 INSTALLATION GUN USED The Magnum 300 is the recommended gun for the POWER WAVE® C300. Refer to the Magnum 300ʼs operators manual for installation instructions. FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1. Turn the Reel or spool until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end and straighten the first 6" (150 mm). Cut off the first 1" (25 mm).
A-11 A-11 INSTALLATION TIG WELDING SMAW WELDING (Figure A.7) Tig uses Electrode Negative Polarity so for this application, connect the Tig torch to the negative (-) output stud and connect the work clamp to the positive (+) output stud. The TIG torch gas connection should be connected to the POWER WAVE® C300ʼs internal gas supply connection. If required a foot amptrol can be connected to the remote control receptacle. Most SMAW welding procedures use Electrode Positive welding.
B-1 B-1 OPERATION SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL WARNING WARNING OR CAUTION • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases. • Do not touch electrically live part or electrode with skin or wet clothing.
B-2 B-2 OPERATION PROCESS LIMITATIONS PRODUCT DESCRIPTION The Power Wave® C300 is a high performance multiprocess machine with GMAW, FCAW, SMAW, DC TIG, and pulse capability. It will offer a premier welding performance solution for specific areas such as aluminum, stainless, nickel where size and weight are an issue. The Power Wave® C300 will provide the following: • Power - 300A @ 40%, 275A @ 60%, 250A @ 100%. • Multi Input Voltage with no reconnect - 200-600V, 50-60 Hz input.
B-3 OPERATION DESIGN FEATURES Loaded with Standard Features • Multiple process DC output range: 5 - 300 Amps. • 200 – 600 VAC, 1/3 phase, 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.
B-4 B-4 OPERATION CASE FRONT CONTROLS (Code 11479) FIGURE B.1 1 2 3 4 10 5 11 6 12 7 13 8 14 15 9 All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 9. ON/OFF SWITCH- Controls power to the Power Wave® C300. 1. LEFT DISPLAY- Shows wire feed speed or amperage, 10. RIGHT DISPLAY- Shows voltage or trim. 2. LEFT KNOB- Adjusts value in left display. 11. THERMAL LIGHT- Indicates when machine has thermal fault. 12.
B-5 OPERATION CASE BACK CONTROLS (Code 11479) FIGURE B.2 1 2 3 1. ETHERNET CONNECTOR 2. POWER CORD 3.
B-6 B-6 OPERATION INTERNAL CONTROLS (Code 11479) FIGURE B.3 2 1 3 4 5 6 7 8 9 10 11 12 1. SPINDLE BRAKE 7. NEGATIVE STUD 2. WIRE DRIVE PRESSURE ARM 8. GAS CONNECTION 3. THUMB SCREW, FOR SECURING THE WELDING GUN 9. POSITIVE STUD 4. GUN BUSHING 10. COLD INCH / GAS PURGE SWITCH 5. SOCKET HEAD CAP SCREW FOR SECURING THE GUN BUSHING 11. 6-PIN CONNECTOR FOR REMOTE CONTROL OPTIONS 6. 4-PIN TRIGGER RECEPTACLE 12.
B-7 OPERATION MAKING A WELD WITH WAVEFORM TECHNOLOGY POWER SOURCES WARNING MAKING A WELD The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
B-8 B-8 OPERATION CASE FRONT CONTROLS USED WIRE FEED SPEED (WFS) VOLTS TRIM AMPS + LESS AMPS + MORE AMPS OUTPUT OFF OUTPUT ON SETUP IR PORT WELD MODE START OPTIONS UltimArc™ Control END OPTIONS DUAL PROCEDURE/ MEMORY PANEL OPERATION POWER WAVE® C300
B-9 B-9 OPERATION SMAW (STICK) WELDING SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder controls Amperage, Output Control and Arc Force during SMAW welding. During SMAW welding the wire drive remains idle.
B-10 B-10 OPERATION NON-SYNERGIC GMAW AND FCAW WELDING In non-synergic modes, the WFS control is similar to 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. UltimArc™Control, adjusts the apparent inductance of the wave shape. The UltimArc™Control adjustment is similar to the “pinch” function in that it is inversely proportional to inductance.
B-11 B-11 OPERATION GMAW (MIG) SYNERGIC WELDING Synergic CV programs feature an ideal voltage best suited for most procedures. Use this voltage as a starting point and adjust if needed for personal preferences. For each wire feed speed, a corresponding voltage is preprogrammed into the machine. The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference.
B-12 OPERATION B-12 STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDING Trim adjusts the arc length and ranges from 0.50 to When pulse welding, the power source primarily regu1.50 with a nominal value of 1.00. Increasing the trim lates the arc current, not the arc voltage. During a value increases the arc length. Decreasing the trim pulsing cycle, arc current is regulated from a low value decreases the arc length. background level to a high peak level and then back down to the low background level.
B-13 B-13 OPERATION STEEL AND STAINLESS GMAW-P (PULSED MIG) WELDING BASIC OPERATION WFS AMPS 220 1.06 + + Less Deposition More Deposition VOLTS TRIM Longer Arc Shorter Arc CONTROL OPTIONS START OPTIONS DESCRIPTION EFFECT Postflow Time Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire. WELD MODE ELECTRODE AND GAS Steel(Crisp) Steel(Soft) Stainless Stainless Stainless Ar(Mix) Ar(Mix) Ar/ CO2 Ar/ CO2 Ar/He/CO 2 WIRE SIZE 0.030 0.035 0.045 0.
B-14 B-14 OPERATION ALUMINUM SYNERGIC GMAW-P (PULSED MIG)AND GMAW-PP (PULSE ON PULSE) WELDING The Power Wave® C300 can produce top quality aluminum welds with excellent appearance, little spatter and good bead shape. Push-pull guns are available for consistent feeding when welding a long distance away from the wire feeder. PULSE-ON-PULSE WELDING The Power Wave® system offers both traditional pulse and Pulse-on-Pulse™. Pulse-on-Pulse (GMAW-PP) is an exclusive waveform for aluminum welding.
B-15 B-15 OPERATION ALUMINUM GMAW-P (PULSED MIG) AND GMAW-PP (PULSE ON PULSE) WELDING BASIC OPERATION WFS AMPS 220 1.06 + + Less Deposition More Deposition Shorter Arc VOLTS TRIM Longer Arc CONTROL OPTIONS EFFECT START OPTIONS DESCRIPTION Postflow Time RUN-IN WFS: WELD MODES ELECTRODE AND GAS ALUMINUM 4043 ALUMINUM 4043 ALUMINUM 5356 ALUMINUM 5356 Ar Ar Ar Ar . WIRE SIZE 0.
B-16 B-16 OPERATION GTAW (TIG) WELDING The Power Wave® C300 is excellent for Touch Start TIG welding. BASIC OPERATION Maximum Amperage WFS AMPS 220 OFF + + VOLTS TRIM OUTPUT OFF OUTPUT ON CONTROL OPTIONS WELD MODE MODE TOUCH START 3 START OPTIONS No Arc starting Options are active for Touch Start TIG 3 SETUP IR PORT TOUCH START TIG WELD MODE UltimArc™ Control UltimArc™ Control No UltimArc™ Control are active for Touch Start TIG.
B-17 B-17 OPERATION DUAL PROCEDURE/MEMORY PANEL OPERATION The Dual Procedure/Memory Panel performs three functions: • Weld procedure selection • Memory save and recall • Limits setting There are two procedure memories (A and B) and eight user memories (1-8). Procedure Memory vs. User Memory Procedure memory is used while welding. Changes to the weld procedure (WFS, voltage, arc control, etc.) immediately change the contents inside the selected procedure memory.
B-18 B-18 OPERATION LIMITS Set Limits: Press 5 seconds Limits allow the welder to adjust the welding procedure only within a defined range. Each user memory may have a different set of limits. For example, memory 1 can be set to limit the WFS to 200 through 300 in/min, and memory 2 can be set to limit the WFS to 275 through 310 in/min, while memory 3 may not have any WFS limits. Parameters are always constrained by machine limits.
B-19 B-19 OPERATION If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application or Palm O.S. application is required to change the passcode. Memory Value Low Limit High Limit 200 The memory value must always be less than or equal to the high limit, and greater than or equal to the low limit. After setting limits, press the memory button with the flashing LED. The MSP4 will ask to save or discard the limit changes just made.
B-20 2-STEP 4-STEPOPERATION OPERATION TRIGGER The 2-Step - 4-Step switch changes the function of the gun trigger. 2-Step trigger operation switches the welding output ON-OFF in direct response to the trigger. 4-Step trigger operation provides 'trigger interlock' capability and gives the ability to control the amount of time spent in the arc start and arc crater steps. Press the push button on the case front to toggle between 2-Step and 4-Step operation.
B-21 B-21 OPERATION EXAMPLE 1 - 2 STEP TRIGGER: Simple operation The simplest trigger operation occurs with a 2 Step trigger and the Start, Crater and Burnback functions all set to OFF. (See Figure B.11) For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled. RUN-IN: After preflow time expires, the power source regulates to the welding output and wire is advanced towards the work piece at the Run-In WFS. If an arc is not established within 1.
B-22 B-22 OPERATION EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start and Arc End. Tailoring the arc start and arc end is a common method for reducing spatter and improving weld quality. This can be accomplished with the Start and Burnback functions set to a desired values and Crater set to OFF. (See Figure B.12) UPSLOPE: Once the wire touches the work and an arc is established, both the machine output and the wire feed speed ramp to the weld settings throughout the start time.
B-23 B-23 OPERATION EXAMPLE 3 - 2 STEP TRIGGER: Customized Arc Start, Crater and Arc End. Sometimes it is advantageous to set specific arc start, crater and arc ending parameters for the ideal weld. Many times when welding aluminum crater control is necessary to make a good weld. This is done by setting Start, Crater and Burnback functions to desired values. (See Figure B.13) For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled.
B-24 B-24 OPERATION EXAMPLE 4 – 4 STEP TRIGGER: Trigger Interlock The 4 step trigger can be configured as a trigger interlock. Trigger interlock adds to the welderʼs comfort when making long welds by allowing the trigger to be released after an initial trigger pull. Welding stops when the trigger is pulled a second time and then released, or if the arc is interrupted. (See Figure B.14) For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled.
B-25 B-25 OPERATION EXAMPLE 5 - 4 STEP TRIGGER: Manual control of Start and Crater times with Burnback ON. The 4 step trigger sequence gives the most flexibility when the Start, Crater and Burnback functions are active. This is a popular choice when welding aluminum because extra heat may be needed during Start and less heat desired during crater. With 4 step trigger, the welder chooses the amount of time to weld at the Start, Weld and Crater settings by using the gun trigger.
B-26 OPERATION COLD FEED/GAS PURGE SWITCH Cold Feed and Gas Purge are combined into a single spring centered toggle switch. COLD FEED GAS PURGE To activate Cold Feeding, hold the switch in the FORWARD position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the WFS knob. Cold feeding, or "cold inching" the electrode is useful for threading the electrode through the gun.
B-27 B-27 OPERATION SETUP MENU FEATURES The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters that generally only need to be set at installation. The parameters are grouped as shown in the following table. PARAMETER DEFINITION P.1 through P.99 P.101 through P.199 P.501 through P.599 Unsecured Parameters (always adjustable) Diagnostic Parameters (always read only) Secured Parameters (only accessible through a p.c.
B-28 OPERATION B-28 USER DEFINED PARAMETERS Parameter Definition Exit Setup Menu P.0 This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press the left Mode Select button to exit the setup menu. P.1 Wire Feed Speed Units P.1 selects which units wire feed speed will be displayed in. English = in/minute wire feed speed units (default). Metric = m/minute wire feed speed units. P.2 Arc Display Mode P.
B-29 OPERATION B-29 USER DEFINED PARAMETERS Parameter P.5 Definition Procedure Change Method Selects how remote procedure selection (A/B) will be made. The selected procedure can be changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods can be used to remotely change the selected procedure: • Use an external switch wired to the procedure select input. • Quickly releasing and re-pulling the gun trigger.
B-30 OPERATION B-30 USER DEFINED PARAMETERS Parameter P.7 Definition Gun Offset Adjustment Range: -30 to 30 (default = 0) Adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only be performed when other possible corrections do not solve any push-pull feeding problems. An rpm meter is required to perform the pull gun motor offset calibration. To perform the calibration procedure do the following: • Release the pressure arm on both the pull and push wire drives.
B-31 OPERATION B-31 USER DEFINED PARAMETERS Parameter P.16 Definition Push-Pull Gun Knob Behavior Determines how the potentiometer on the Push/Pull torch will behave. • Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the push-pull gun (default). The left front panel knob is only used to adjust Start and Crater wire feed speed. • Gun Pot Disabled = The wire feed speed is always controlled by the left front panel knob.
B-32 OPERATION B-32 USER DEFINED PARAMETERS Parameter P.103 Definition View Software Version Information Used for viewing the firmware versions for each board in the system. Press the right MSP Button to enter the option. Rotate Set knob to select the desired board to read. Press the right button again to read the firmware version. Press the left button to back out to select another board. Rotate the SET knob to select another board, or press the left button to exit this option. P.
B-33 OPERATION B-33 USER DEFINED PARAMETERS Parameter P.503 Definition Memory Button Disable Disables the specified memory button(s). When a memory is disabled, welding procedures cannot be restored from or saved to that memory. If an attempt is made to save or restore a disabled memory, a message will be displayed on the Mode Select Panel indicating the memory number is disabled. In multi-head systems, this parameter disables the same memory buttons on both feed heads.
B-34 OPERATION B-34 USER DEFINED PARAMETERS Parameter P.507 Definition UI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parameters. Presently, this option does not exist in any setup menu. P.509 UI Master Lockout Locks all user interface controls, preventing the operator from making any changes. This parameter can only be accessed using Power Wave Manager.
C-1 ACCESSORIES OPTIONS / ACCESSORIES K1783-4 STICK OPTIONS K875 ACCESSORY KIT - 150 Amp K1783-7 For stick welding. Includes 20 ft. (6.1m) #6 electrode cable with lug, 15 ft. (4.6m) #6 work cable with lugs, headshield, filter plate, work clamp, electrode holder and sample pack of mild steel electrode. PTA-26 TIG Torch (25 ft 7.6m) 2 CABLES PTA-26V TIG Torch (12.5 ft 3.8m) 2 CABLES K1783-9 PTA-26V TIG Torch (25 ft 7.
C-2 ACCESSORIES WIRE FEEDER OPTIONS C-2 K2519-1 CONTROL CABLE EXTENSION K1703-1 ALUMINUM FEEDING KIT Extend your spool gun reach with a 25 ft. (7.5 m) control cable extension. Features a 7-pin female MS-type connector on the spool gun end and a 7-pin male MS-type connector on the power source end. Conversion kit for welding with 3/64″ (1.2mm) aluminum wire. Includes tension spring, drive rolls, contact tips (qty. 2), non-metallic wire guides and cable liner.
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.
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.
E-2 E-2 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Not all of the Power Wave® C300 errors will be displayed on the user interface. There are three status lights that contain error sequences that may not show up on the user interface. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.
E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE® The following is a partial list of possible error codes for the POWER WAVE® C300. For a complete listing consult the Service Manual for this machine. MAIN CONTROL BOARD ( “STATUS” LIGHT) 36 Error Code # Indication Thermal error Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation.
E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual INPUT CONTROL BOARD Indication Error Code # 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.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED 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 cycle, or both. ing output levels in excess of machine rating. 3. Major physical or electrical dam- 3.
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. 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.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of 1. Burnback Time 1. Reduce burnback time and/or the weld. work point. Machine output shuts down during a 1. Secondary current limit has been 1. Adjust procedure or reduce load weld. exceeded, and the machine shuts to lower current draw from the down to protect itself. machine.
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. 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 inserted into the bulk head connector. 1b.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2 DIMENSION PRINT POWER WAVE® C300 F-2
NOTES POWER WAVE® C300
Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Keep flammable materials away. Wear eye, ear and body protection. Mantenga el material combustible Protéjase los ojos, los oídos y el electrode with skin or wet clothing. Insulate yourself from work and ground. No toque las partes o los electrodos bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra.
Keep your head out of fumes. Use ventilation or exhaust to Turn power off before servicing. Do not operate with panel open or guards off. remove fumes from breathing zone. Los humos fuera de la zona de res- piración. Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. Gardez la tête à l’écart des fumées. Utilisez un ventilateur ou un aspira- Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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